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Komatsu Bulldozer D31-, D32-, D37-, D39- Series Operation Maintenance Manual

Complete Operation Maintenance Manuals for Komatsu Bulldozer D31-, D32-, D37-, D39– Series, with all the service information to maintain & operatre.

PRODUCT DETAILS:
Total Pages: 4,512 pages
File Format: PDF
Language: English

CEAM000700 – Bulldozer D32E,P-1, D38E,P-1, D39E,P-1 Operation & Maintenance Manual.pdf
CEAM002700 – Bulldozer D32E,P-1, D38E,P-1, D39E,P-1 Operation & Maintenance Manual.pdf
CEAM004300 – Crawler Tractor D32E,P-1A, D38E,P-1A, D39E,P-1A (plus) Operation & Maintenance Manual.pdf
EEAM023900 – Bulldozer D31EX,PX-21, D37EX,PX-21, D39EX,PX-21 Operation & Maintenance Manual.pdf
EEAM024300 – Bulldozer D31EX,PX-21, D37EX,PX-21, D39EX,PX-21 Operation & Maintenance Manual.pdf
PEN00220-00 – Bulldozer D31E,P,PL,PLL-20 & D31P-20A & D37E-5 & D37P-5A Operation & Maintenance Manual.pdf
SEAM015400 – Bulldozer D31E,P,PL,PLL-20, D37EX,PX-21, D31P-20A, D37E-5, D37P-5A Operation & Maintenance Manual.pdf
SEAM040200 – Bulldozer D39EX-21, D39PX-21 Operation & Maintenance Manual.pdf
SEAM040203T – Bulldozer GALEO D39EX-21, D39PX-21 Operation & Maintenance Manual.pdf
SEAM044001T – Bulldozer GALEO D31EX-21, D31PX-21, D37EX-21, D37PX-21 Operation & Maintenance Manual.pdf
SEAM044002T – Bulldozer GALEO D31EX-21, D31PX-21, D37EX-21, D37PX-21 Operation & Maintenance Manual.pdf
SEAM01142001 – Bulldozer D31E,P,PL,PLL-20, D31P-20A, D37E-5, D37P-5A Operation & Maintenance Manual.pdf
SEAM01142004 – Bulldozer D31E,P,PL,PLL-20, D31P-20A, D37E-5, D37P-5A Operation & Maintenance Manual.pdf
TEN00109-01 – Bulldozer D31EX-21, D31PX-21, D37EX-21, D37PX-21, D39EX-21, D39PX-21 Operation & Maintenance Manual.pdf
TEN00268-04 – Bulldozer D39EX-22, D39PX-22 Operation & Maintenance Manual (SN3001&up).pdf
TEN00290-04 – Bulldozer D31EX-22, D31PX-22, D37EX-22, D37PX-22 Operation & Maintenance Manual (SN60001&up).pdf
TEN00469-00 – Bulldozer D39EX-22, D39PX-22 Operation & Maintenance Manual (SN3440&up).pdf
TEN00470-00 – Bulldozer D31EX-22, D31PX-22, D37EX-22, D37PX-22 Operation & Maintenance Manual (SN60541&up).pdf
TEN00525-03 – Bulldozer D31EX-22, D31PX-22, D37EX-22, D37PX-22 Operation & Maintenance Manual (SN60730&up).pdf
TEN00606-02 – Bulldozer D37EX-23, D37PX-23, D39EX-23, D39PX-23 Operation & Maintenance Manual (SN80001&up).pdf

TABLE OF CONTENTS
FOREWORD … 1-2
SAFETY INFORMATION.. 1-3
NOISE… 1-5
VIBRATION… 1-5
INTRODUCTION… 1-6
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE … 1-6
NECESSARY INFORMATION … 1-7
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE.. 1-7
ENGINE SERIAL NO. PLATE… 1-7
POSITION OF SERVICE METER .. 1-8
TABLE OF ENTER SERIAL NO. AND DISTRIBUTORN.. 1-8
MACHINE SERIAL PLATE. .. 1-9
SAFETY
SAFETY .. 2-2
SAFETY LABELS… 2-4
POSITIONS OF SAFETY PICTOGRAMS .. 2-4
SAFETY LABELS … 2-5
GENERAL PRECAUTIONS … 2-10
PRECAUTIONS FOR OPERATION … 2-19
STARTING ENGINE … 2-19
OPERATION … 2-21
TRANSPORTATION… 2-24
BATTERY … 2-25
TOWING … 2-27
PRECAUTIONS FOR MAINTENANCE .. 2-28
OPERATION
GENERAL VIEW .. 3-2
GENERAL VIEW OF MACHINE … 3-2
GENERAL VIEW OF CONTROLS AND GAUGES… 3-3
EXPLANATION OF COMPONENTS.. 3-5
FRONT PANEL… 3-5
CHECK MONITOR SYSTEM .. 3-6
EMERGENCY CAUTION ITEMS .. 3-7
CAUTION CAUTION ITEMS … 3-9
METER GROUP .. 3-11
LAMPS… 3-20
METHOD OF USING MAINTENANCE MODE.. 3-21
SWITCHES … 3-30
CONTROL LEVERS AND PEDALS … 3-35
FUSE .. 3-41
ELECTRIC POWER TAKE-OUT ADAPTER .. 3-42
DOOR – OPEN LOCK … 3-43
SASH GLASS INTERMEDIATE LOCK… 3-43
CAP, COVER WITH LOCK… 3-44
METHOD OF OPENING AND CLOSING CAP WITH LOCK .. 3-44
METHOD OF OPENING AND CLOSING COVER WITH LOCK … 3-45
DOOR POCKET … 3-45
ASHTRAY … 3-46
LUNCHBOX HOLDER BELT .. 3-46
CUP HOLDER .. 3-46
TOOL BOX.. 3-47
GREASE PUMP HOLDER.. 3-47
CAR STEREO, HANDLING .. 3-48
EXPLANATION OF COMPONENTS… 3-48
METOD OF OPERATION.. 3-53
PRECAUTION WHEN USING… 3-55
AIR CONDITIONER, HANDLING … 3-56
EXPLANATION OF PARTS… 3-56
PREVENTION METHOD OF ENTRY OF DUST… 3-58
PRECAUTION WHEN USING AIR CONDITIONER.. 3-58
INSPECTION DURING OFF-SEASON … 3-58
PROCEDURE FOR REPLACING RECEIVER .. 3-59
CLEANING AIR FILTER .. 3-59
ACCUMULATOR, HANDLING.. 3-60
METHOD OF RELEASING PRESSURE IN OPERATING CIRCUIT ON MACHINE EQUIPPED WITH
ACCUMULATOR … 3-60
OPERATION… 3-61
CHECK BEFORE STARTING ENGINE, ADJUST.. 3-61
WALK-AROUND CHECK .. 3-61
CHECK BEFORE STARTING … 3-63
CONTENTS
ADJUSTMENT… 3-72
OPERATION AND CHECK BEFORE STARTING ENGINE.. 3-75
STARTING ENGINE … 3-77
NORMAL STARTING .. 3-77
STARTING IN COLD WEATHER .. 3-79
OPERATIONS AND CHECKS AFTER STARTING ENGINE … 3-81
BREAKING IN THE NEW MACHINE .. 3-81
WARMING UP OPERATIONS .. 3-81
STARTING IN COLD WEATHER .. 3-82
STOPPING ENGINE… 3-84
MACHINE OPERATION … 3-85
MOVING MACHINE… 3-85
STOPPING MACHINE… 3-88
SHIFTING GEARS.. 3-89
SHIFTING BETWEEN FORWARD AND REVERSE .. 3-90
STEERING MACHINE .. 3-91
NORMAL TURNING .. 3-91
TURNING WHILE DESCENDING A SLOPE… 3-92
PRECAUTIONS FOR OPERATION … 3-93
PAY ATTENTION TO GAUGES .. 3-93
PERMISSIBLE WATER DEPTH.. 3-93
METHOD OF USING BRAKES … 3-93
PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS.. 3-93
PRECAUTIONS ON SLOPES … 3-94
IT IS PROHIBITED TO KEEP THE DOOR OPEN DURING OPERATIONS… 3-94
IT IS PROHIBITED TO MODIFY THE CAB GLASS IN ANY WAY THAT WILL OBSTRUCT THE VIEW 3-94
PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB STAY … 3-94
WORK POSSIBLE USING BULLDOZER … 3-95
DOZING … 3-95
SMOOTHING… 3-95
CUTTING INTO HARD OR FROZEN GROUND OR DITCHING .. 3-96
FELLING TREES, REMOVING STUMPS … 3-96
SIDE-CUTTING OPERATIONS… 3-96
PARKING MACHINE .. 3-97
CHECK AFTER FINISHING WORK … 3-98
BEFORE STARTING ENGINE .. 3-98
AFTER STARTING ENGINE … 3-98
LOCKING.. 3-99
TIPS FOR LONGER UNDERCARRIAGE LIFE .. 3-100
OPERATION METHOD … 3-100
INSPECTION AND ADJUSTMENT … 3-100
INSPECTION AND REPAIR .. 3-101
TRANSPORTATION… 3-103
TRANSPORTATION MEANS … 3-103
PRECAUTIONS WHEN REMOVING WORK EQUIPMENT… 3-103
REMOVING CAB .. 3-103
LOADING, UNLOADING WORK .. 3-104
LIFTING MACHINE… 3-108
COLD WEATHER OPERATION .. 3-109
PRECAUTIONS FOR LOW TEMPERATURE .. 3-109
AFTER COMPLETION OF WORK … 3-111
AFTER COLD WEATHER .. 3-111
LONG-TERM STORAGE.. 3-112
BEFORE STORAGE… 3-112
DURING STORAGE … 3-112
AFTER STORAGE.. 3-112
TROUBLESHOOTING.. 3-113
AFTER RUNNING OUT OF FUEL.. 3-113
MACHINE TOWING METHOD … 3-113
WHEN IT IS POSSIBLE TO START ENGINE… 3-114
WHEN ENGINE DOES NOT START .. 3-115
IF BATTERY IS DISCHARGED.. 3-120
REMOVE AND INSTALL BATTERY … 3-121
PRECAUTIONS FOR BATTERY CHARGING .. 3-121
STARTING ENGINE WITH BOOSTER CABLE .. 3-122
WHEN ENGINE DOES NOT STOP.. 3-124
OTHER TROUBLE … 3-125
ELECTRICAL SYSTEM… 3-125
MONITOR PANEL … 3-126
CHASSIS … 3-127
ENGINE … 3-128

CEAM000700 – Bulldozer D32E,P-1, D38E,P-1, D39E,P-1 Operation & Maintenance Manual…………….3
1. FOREWORD …………….6
2. SAFETY INFORMATION …………….7
3. INTRODUCTION …………….8
 3.1 INTENDED USE …………….8
 3.2 FEATURES …………….8
 3.3 BREAKING IN THE MACHINE …………….8
4. LOCATION OF PLATES. TABLE TO ENTER P.I.N. AND DISTRIBUTOR …………….9
 4.1 P.I.N. PLATE LOCATION …………….9
 4.2 ENGINE SERIAL NO. PLATE LOCATION …………….9
 4.3 TABLE TO ENTER NUMBERS AND DISTRIBUTOR …………….9
5. CONTENTS …………….10
SAFETY …………….14
 6. GENERAL PRECAUTIONS …………….15
 7. PRECAUTIONS DURING OPERATION …………….19
 7.1 BEFORE STARTING ENGINE …………….19
 7.2 OPERATING MACHINE …………….21
 7.3 TRANSPORTATION …………….24
 7.4 BATTERY …………….26
 7.5 TOWING …………….27
 8. PRECAUTIONS FOR MAINTENANCE …………….28
 8.1 BEFORE CARRYING OUT MAINTENANCE …………….28
 8.2 DURING MAINTENANCE …………….30
 9. POSITIONS FOR ATTACHING SAFETY LABELS …………….33
OPERATION …………….36
 10. GENERAL VIEW …………….37
 10.1 GENERAL VIEW OF MACHINE …………….37
 10.2 GENERAL VIEW OF CONTROLS AND GAUGES …………….38
 10.3 UNIVERSAL SYMBOLS …………….39
 11. EXPLANATION OF COMPONENTS …………….40
 11.1 GENERAL …………….40
 11.2 GAUGES AND WARNING LIGHTS …………….40
 11.3 SWITCHES …………….44
 11.4 SUSPENSION SEAT, SEAT BELT …………….47
 11.5 CONTROL LEVERS AND PEDALS …………….48
 12. OPERATION …………….54
 12.1 CHECKS BEFORE STARTING ENGINES …………….54
 12.2 STARTING ENGINE …………….66
 12.3 OPERATIONS AND CHECKS AFTER ENGINE STARTS …………….70
 12.4 MOVING MACHINE …………….72
 12.5 SHIFTING GEAR …………….75
 12.6 SHIFTING BETWEEN FORWARD AND REVERSE …………….76
 12.7 STEERING MACHINE …………….78
 12.8 STOPPING MACHINE …………….80
 12.9 PRECAUTIONS FOR OPERATION …………….82
 12.10 WORK POSSIBLE USING BULLDOZER …………….83
 12.11 PARKING MACHINE …………….84
 12.12 CHECK AFTER FINISHING WORK …………….86
 12.13 STOPPING ENGINE …………….87
 12.14 CHECK AFTER STOPPING ENGINE …………….90
 12.15 LOCKING …………….90
 12.16 TIPS FOR LONGER UNDERCARRIAGE LIFE …………….91
 13. TRANSPORTATION…………….94
 13.1 LOADING, UNLOADING WORK …………….94
 13.2 PRECAUTIONS FOR LOADING …………….94
 13.3 PRECAUTIONS FOR TRANSPORTATION …………….94
 14. COLD WEATHER OPERATION …………….95
 14.1 PRECAUTIONS FOR LOW TEMPERATURE …………….95
 14.2 AFTER COMPLETION OF WORK …………….96
 14.3 AFTER COLD WEATHER …………….97
 15. LONG TERM STORAGE (MORE THAN ONE MONTH) …………….98
 15.1 BEFORE STORAGE …………….98
 15.2 DURING STORAGE …………….98
 15.3 AFTER STORAGE …………….98
 16. TROUBLESHOOTING …………….99
 16.1 AFTER RUNNING OUT OF FUEL …………….99
 16.2 IF BATTERY IS DISCHARGED …………….99
 16.3 OTHER TROUBLE …………….101
 16.4 METHODS OF TOWING MACHINE …………….103
MAINTENANCE…………….104
 17. GUIDES TO MAINTENANCE …………….105
 18. OUTLINES OF SERVICE …………….107
 18.1 OUTLINE OF OIL, FUEL, COOLANT …………….107
 18.2 RELATING TO ELECTRICAL SYSTEM …………….109
 19. WEAR PARTS LIST …………….110
 20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE …………….111
 20.1 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANT …………….111
 20.2 COOLING SYSTEM …………….113
 20.3 FUEL SYSTEM …………….116
 21. STANDARD TIGHTENING TORQUES …………….117
 21.1 INTRODUCTION OF NECESSARY TOOLS …………….117
 21.2 BOLT IDENTIFICATION CHART …………….118
 21.3 HYDRAULIC TUBES AND FITTINGS …………….121
 21.4 HOSE CLAMPS …………….121
 21.5 SPLIT FLANGE CONNECTIONS …………….121
 22. PERIODIC REPLACEMENT OF CRITICAL PARTS …………….122
 23. MAINTENANCE SCHEDULE CHART …………….125
 23.1 MAINTENANCE SCHEDULE CHART …………….125
 24. SERVICE PROCEDURE …………….128
 24.1 INITIAL 10 HOURS SERVICE …………….128
 24.2 INITIAL 50 HOURS SERVICE …………….129
 24.3 EVERY 10 HOURS SERVICE (CHECK BEFORE STARTING) …………….133
 24.4 EVERY 50 HOURS SERVICE …………….138
 24.5 EVERY 100 HOURS SERVICE …………….139
 24.6 EVERY 250 HOURS SERVICE …………….140
 24.7 EVERY 500 HOURS SERVICE …………….144
 24.8 EVERY 1000 HOURS SERVICE …………….145
 24.9 EVERY 2000 HOURS SERVICE …………….150
 24.10 PERIODIC …………….153
 24.11 WHEN REQUIRED…………….159
 24.12 SEASONAL PREPARATION…………….169
 24.13 TURBOCHARGER: D38E-1, D38P-1, D39E-1 AND D39P-1 …………….171
SPECIFICATIONS…………….174
 25. SPECIFICATIONS …………….175
 25.1 D32E-1, D32P-1 SPECIFICATIONS …………….175
 25.2 D38E-1, D38P-1 SPECIFICATIONS …………….176
 25.3 D39E-1, D39P-1 SPECIFICATIONS …………….177
 25.4 D32E-1 DIMENSIONS …………….178
 25.5 D32P-1 DIMENSIONS …………….179
 25.6 D38E-1 DIMENSIONS …………….180
 25.7 D38P-1 DIMENSIONS …………….181
 25.8 D39E-1 DIMENSIONS …………….182
 25.9 D39P-1 DIMENSIONS …………….183
OPTIONS, ATTACHMENTS …………….184
 26. GENERAL PRECAUTIONS …………….185
 26.1 PRECAUTIONS RELATED TO SAFETY …………….185
CEAM002700 – Bulldozer D32E,P-1, D38E,P-1, D39E,P-1 Operation & Maintenance Manual…………….187
INTRODUCTION …………….191
 1. FORWARD …………….192
 2. SAFETY INFORMATION …………….193
 3. INTRODUCTION …………….194
 3.1 INTENDED USE …………….194
 3.2 FEATURES …………….194
 3.3 BREAKING IN THE MACHINE …………….194
 4. LOCATION OF PLATES, TABLE TO ENTER P.I.N. AND DISTRIBUTOR …………….195
 4.1 P.I.N. PLATE LOCATION …………….195
 4.2 ENGINE SERIAL NO. PLATE LOCATION …………….195
 4.3 TABLE TO ENTER NUMBERS AND DISTRIBUTOR …………….195
 5. TABLE OF CONTENTS …………….196
SAFETY …………….201
 6. GENERAL PRECAUTIONS …………….202
 7. PRECAUTIONS DURING OPERATION …………….207
 7.1 BEFORE STARTING ENGINE …………….207
 7.2 OPERATING MACHINE …………….209
 7.3 TRANSPORTATION…………….212
 7.4 BATTERY …………….214
 7.5 TOWING …………….215
 8. PRECAUTIONS FOR MAINTENANCE …………….216
 8.1 BEFORE CARRYING OUT MAINTENANCE …………….216
 8.2 DURING MAINTENANCE …………….218
 9. POSITION FOR ATTACHING SAFETY LABELS…………….221
OPERATION …………….223
 10. GENERAL VIEW…………….224
 10.1 GENERAL VIEW OF MACHINES …………….224
 10.2 GENERAL VIEW OF CONTROLS AND GAUGES …………….225
 10.3 UNIVERSAL SYMBOLS …………….226
 11. EXPLANATIONS OF COMPONENTS …………….227
 11.1 GENERAL …………….227
 11.2 GAUGES AND WARNING LIGHTS …………….227
 11.2.1 HOURMETER …………….228
 11.2.2 TRANSMISSION OIL FILTER WARNING LIGHT …………….228
 11.2.3 ENGINE COOLANT TEMPERATURE GAUGE …………….228
 11.2.4 ENGINE OIL PRESSURE GAUGE …………….229
 11.2.5 ILLUMINATION LAMP …………….229
 11.2.6 VOLTMETER …………….229
 11.2.7 DRIVE TRAIN OIL TEMPERATURE GAUGE …………….229
 11.2.8 HYDRAULIC OIL FILTER LIGHT …………….230
 11.2.9 AIR CLEANER SERVICE LIGHT …………….230
 11.2.10 FUEL GAUGE …………….230
 11.2.11 GEAR RANGE INDICATOR …………….230
 11.2.12 TRANSMISSION PRESSURE WARNING LIGHT …………….230
 11.3 SWITCHES …………….231
 11.3.1 START KEY SWITCH …………….231
 11.3.2 WORK LIGHT SWITCH …………….232
 11.3.3 HORN SWITCH …………….232
 11.3.4 ETHER START SWITCH …………….232
 11.3.5 ELECTRICAL SYSTEM MASTER SWITCH …………….232
 11.3.6 CAB SWITCHES …………….233
 11.4 SEAT, SEAT BELT AND ARM RESTS …………….235
 11.4.1 SEAT WITH ADJUSTABLE SEAT BELT …………….235
 11.4.2 SEAT WITH RETRACTABLE SEAT BELT …………….235
 11.4.3 SEAT BELT …………….235
 11.4.4 ARM RESTS…………….236
 11.5 CONTROL LEVERS AND PEDALS …………….237
 11.5.1 FUEL CONTROL LEVER …………….237
 11.5.2 TRANSMISSION STEERING LEVER …………….237
 11.5.3 SAFETY LOCK LEVER…………….238
 11.5.4 LEFT PEDAL SECONDARY BRAKE…………….238
 11.5.5 BRAKE AND DECELERATOR PEDAL …………….239
 11.5.6 BRAKE PEDAL LOCK …………….239
 11.5.7 BLADE CONTROL LEVER…………….239
 11.5.8 RIPPER CONTROL LEVER…………….242
 11.5.9 CAB CONTROLS…………….243
 12. OPERATION…………….244
 12.1 CHECKS BEFORE STARTING ENGINE …………….244
 12.1.1 WALK AROUND CHECK …………….244
 12.1.2 CHECK BEFORE STARTING …………….245
 12.1.3 OPERATIONS AND CHECKS BEFORE STARTING ENGINE …………….250
 12.2 STARTING ENGINE …………….252
 12.2.1 NORMAL STARTING …………….252
 12.2.2 COLD WEATHER STARTING …………….254
 12.3 OPERATIONS AND CHECKS AFTER ENGINE STARTS …………….256
 12.4 MOVING MACHINE …………….258
 12.5 SHIFTING GEAR …………….260
 12.6 SHIFTING BETWEEN FORWARD AND REVERSE …………….261
 12.7 STEERING MACHINE …………….263
 12.7.1 NORMAL TURNING…………….263
 12.7.2 TURNING WHILE DESCENDING A SLOPE…………….264
 12.8 STOPPING MACHINE …………….265
 12.9 PRECAUTIONS FOR OPERATION …………….266
 12.9.1 METHOD FOR USING STEERING CLUTCH…………….266
 12.9.2 PERMISSIBLE WATER DEPTH…………….266
 12.9.3 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS…………….267
 12.9.4 PRECAUTIONS ON SLOPES…………….267
 12.10 WORK POSSIBLE USING BULLDOZER …………….267
 12.10.1 DOZING …………….267
 12.10.2 SMOOTHING…………….267
 12.10.3 CUTTING INTO HARD/ FROZEN GROUND OR DITCH ING …………….268
 12.11 PARKING MACHINE …………….269
 12.12 CHECK AFTER FINISHING WORK…………….270
 12.13 STOPPING ENGINE …………….271
 12.14 CHECK AFTER STOPPING ENGINE …………….272
 12.15 LOCKING …………….273
 12.15.1 ROPS CANOPY …………….273
 12.15.2 ROPS CAB …………….273
 12.16 TIPS FOR LONGER UNDERCARRIAGE LIFE …………….274
 12.16.1 OPERATION METHOD …………….274
 12.16.2 INSPECTION AND ADJUSTMENT …………….275
 12.16.3 INSPECTION AND REPAIR …………….275
 13. TRANSPORTATION…………….277
 13.1 LOADING, UNLOADING WORK …………….277
 13.2 PRECAUTIONS FOR LOADING …………….277
 13.3 PRECAUTIONS FOR TRANSPORTATION …………….278
 14. COLD WEATHER OPERATIONS …………….279
 14.1 PRECAUTIONS FOR LOW TEMPERATURE …………….279
 14.1.1 FUEL AND LUBRICANTS …………….279
 14.1.2 COOLANT…………….279
 14.1.3 BATTERY …………….279
 14.2 AFTER COMPLETION OF WORK …………….280
 14.3 AFTER COLD WEATHER …………….280
 15. LONG TERM STORAGE (MORE THAN ONE MONTH)…………….281
 15.1 BEFORE STORAGE …………….281
 15.2 DURING STORAGE …………….281
 15.3 AFTER STORAGE …………….281
 16. TROUBLESHOOTING…………….282
 16.1 AFTER RUNNING OUT OF FUEL …………….282
 16.2 IF BATTERY IS DISCHARGED …………….282
 16.2.1 STARTING ENGINE WITH BOOSTER CABLE …………….282
 16.3 OTHER TROUBLE …………….284
 16.3.1 ELECTRICAL SYSTEM …………….284
 16.3.2 CHASSIS…………….284
 16.3.3 ENGINE…………….285
 16.4 METHODS OF TOWING MACHINE…………….286
MAINTENANCE …………….287
 17. GUIDES TO MAINTENANCE …………….288
 18. OUTLINES OF SERVICE …………….290
 18.1 OUTLINE OF OIL, FUEL, COOLANT …………….290
 18.1.1 OIL …………….290
 18.1.2 FUEL …………….290
 18.1.3 COOLANT …………….291
 18.1.4 GREASE …………….291
 18.1.5 STORING OIL AND FUEL …………….291
 18.1.6 FILTERS…………….291
 18.2 RELATING TO ELECTRICAL SYSTEM …………….292
 19. WEAR PARTS LIST…………….293
 20. USE OF FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE …………….294
 20.1 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANT …………….294
 20.1.1 D32E-1, D32P-1, D38E-1 OR D38P-1…………….294
 20.1.2 D39E-1 OR D39P-1 …………….295
 20.1.3 ABBREVIATIONS …………….296
 20.2 COOLING SYSTEM …………….297
 20.2.1 GENERAL …………….297
 20.2.2 WATER …………….297
 20.2.3 ANTIFREEZE…………….298
 20.2.4 INHIBITORS/CONDITIONERS …………….299
 20.3 FUEL SYSTEM …………….300
 20.3.1 GENERAL …………….300
 20.3.2 DIESEL FUEL SPECIFICATIONS …………….300
 21. STANDARD TIGHTENING TORQUES …………….301
 21.1 INTRODUCTION OF NECESSARY TOOLS …………….301
 21.2 BOLT IDENTIFICATION CHART …………….302
 21.2.1 GRADE 5 AND 8 NON-PHOSPHATE COATED HARDWARE …………….303
 21.2.2 GRADE 8 PHOSPHATE COATED HARDWARE …………….304
 21.2.3 STANDARD METRIC FASTENERS …………….304
 21.3 HYDRAULIC TUBES AND FITTINGS …………….305
 21.4 HOSE CLAMPS …………….305
 21.5 SPLIT FLANGE CONNECTIONS…………….305
 22. PERIODIC REPLACEMENT OF CRITICAL PARTS …………….306
 23. MAINTENANCE SCHEDULE CHART …………….309
 24. SERVICE PROCEDURE …………….312
 24.1 INITIAL 10 HOURS SERVICE …………….312
 24.1.1 BLADE CUTTING EDGE HARDWARE …………….312
 24.1.2 TRACK SHOE BOLT TORQUE …………….312
 24.2 INITIAL 50 HOURS SERVICE…………….313
 24.2.1 REPLACING DRIVE TRAIN PRESSURE FILTER…………….313
 24.2.2 SERVICING THE DRIVE TRAIN SUCTION STRAINER…………….314
 24.2.3 TRACK TENSION AND ADJUSTMENT …………….315
 24.3 EVERY 10 HOURS SERVICE (CHECK BEFORE STARTING) …………….317
 24.3.1 CHECK RADIATOR COOLANT LEVEL …………….317
 24.3.2 CHECK ENGINE CRANKCASE OIL LEVEL …………….317
 24.3.3 CHECK EQUIPMENT SYSTEM HYDRAULIC OIL LEVEL …………….318
 24.3.4 FILL FUEL TANK …………….318
 24.3.5 DRAIN FUEL FILTER WATER SEPARATOR …………….319
 24.3.6 OPEN FUEL SHUT OFF VALVE …………….319
 24.3.7 CLEAN PRE-CLEANER HOOD …………….319
 24.3.8 CHECK BRAKE PEDAL TRAVEL …………….320
 24.3.9 PERFORM GROUND LEVEL INSPECTION …………….320
 24.4 EVERY 50 HOURS SERVICE …………….322
 24.4.1 CHECK OIL LEVEL IN DRIVE TRAIN …………….322
 24.4.2 LUBRICATION …………….322
 24.5 EVERY 100 HOURS …………….323
 24.5.1 BLADE CUTTING EDGE HARDWARE …………….323
 24.6 EVERY 250 HOURS SERVICE …………….324
 24.6.1 REPLACE ENGINE OIL FILTER …………….324
 24.6.2 CHANGE ENGINE CRANKCASE OIL …………….325
 24.6.3 CHECKING FINAL DRIVE OIL LEVEL …………….325
 24.6.4 REPLACE FUEL FILTER WATER SEPARATOR …………….326
 24.6.5 CHECK ENGINE DRIVE BELT FOR WEAR …………….327
 24.6.6 CHECK OPERATION OF THE DECELERATOR …………….327
 24.6.7 REVERSE REVERSIBLE FAN BLADES …………….327
 24.7 EVERY 500 HOURS SERVICE …………….328
 24.7.1 CHECK HOSE CLAMP TORQUE …………….328
 24.7.2 CHECK ROPS MOUNTING BOLT NUT TORQUE …………….328
 24.7.3 CHECK TRACK SHOE BOLT TORQUE …………….328
 24.7.4 INSPECT MOUNTED EQUIPMENT …………….328
 24.7.5 RADIATOR LEAKS …………….328
 24.7.6 OUTSIDE OF RADIATOR CORE …………….328
 24.8 EVERY 1000 HOURS SERVICE …………….329
 24.8.1 SERVICE THE DRIVE TRAIN SUCTION STRAINER …………….329
 24.8.2 CHANGING DRIVE TRAIN SYSTEM OIL…………….330
 24.8.3 DRAIN, FLUSH AND REFILL FINAL DRIVE OIL…………….330
 24.8.4 REPLACE DRIVE TRAIN SYSTEM BREATHER…………….330
 24.8.5 REPLACING DRIVE TRAIN PRESSURE FILTER …………….331
 24.8.6 REPLACE HYDRAULIC SYSTEM RETURN FILTER …………….332
 24.8.7 CLEAN NEUTRAL VALVE INLET STRAINER …………….333
 24.8.8 LUBRICATE VALVE CAM PLATE …………….333
 24.8.9 CHECK TORQUE OF SPROCKET MOUNTING BOLTS …………….333
 24.9 EVERY 2000 HOURS SERVICE …………….334
 24.9.1 DRAIN, FLUSH AND REFILL COOLING SYSTEM …………….334
 24.9.2 CLEAN HYDRAULIC SUCTION STRAINER …………….335
 24.9.3 CLEAN HYDRAULIC RESERVOIR RELIEF VALVE …………….335
 24.9.4 CHANGE HYDRAULIC SYSTEM FLUID …………….336
 24.10 PERIODIC …………….337
 24.10.1 CLEAN AIR CLEANER ELEMENTS …………….337
 24.10.2 CLEAN FUEL TANK STRAINER …………….341
 24.10.3 DRAIN FUEL TANK SEDIMENT BOWL …………….341
 24.10.4 REPLACE IN-LINE FUEL STRAINER …………….342
 24.10.5 LUBRICATE …………….342
 24.10.6 SEAT BELT …………….343
 24.11 WHEN REQUIRED …………….344
 24.11.1 FAN BELT …………….344
 24.11.2 ELECTRICAL SYSTEM…………….344
 24.11.3 ETHER START…………….349
 24.11.4 VENTING THE FUEL SYSTEM …………….351
 24.11.5 ANGLING FRAME TO BLADE …………….351
 24.11.6 REVERSE AND REPLACE THE END BITS AND CUTTING EDGES …………….352
 24.11.7 TRACK TENSION AND ADJUSTMENT …………….353
 24.11.8 ADJUST FRONT IDLER CLEARANCE…………….355
 24.11.9 CLEAN OR REPLACE CAB FRESH AIR FILTER…………….355
 24.11.10 GREASE CAB DOOR HINGES …………….355
 24.11.11 WIPER WASHER FLUID LEVEL …………….356
 24.12 SEASONAL PREPARATION …………….357
 24.12.1 GENERAL …………….357
 24.12.2 OUTSIDE SOURCE OF HEAT …………….357
 24.12.3 LUBRICATION …………….357
 24.12.4 FUEL SYSTEM…………….357
 24.12.5 COOLING SYSTEM …………….357
 24.12.6 ELECTRICAL SYSTEM…………….358
 24.13 TURBOCHARGER: D38E-1, D38P-1, D39E-1 AND D39P-1 …………….359
 24.13.1 PRECAUTIONS…………….359
 24.13.2 PRIMING…………….360
SPECIFICATIONS …………….361
 25. SPECIFICATIONS …………….362
 25.1 D32E-1, D32P-1 SPECIFICATIONS …………….362
 25.2 D38E-1, D38P-1 SPECIFICATIONS …………….363
 25.3 D39E-1, D39P-1 SPECIFICATIONS …………….364
 25.4 D32E-1 DIMENSIONS …………….365
 25.5 D32P-1 DIMENSIONS …………….366
 25.6 D38E-1 DIMENSIONS …………….367
 25.7 D38P-1 DIMENSIONS …………….368
 25.8 D39E-1 DIMENSIONS …………….369
 25.9 D39P-1 DIMENSIONS …………….370
OPTIONS, ATTACHMENTS …………….371
 26. PRECAUTIONS RELATED TO SAFETY …………….372
CEAM004300 – Crawler Tractor D32E,P-1A, D38E,P-1A, D39E,P-1A (plus) Operation & Maintenance Manual…………….375
COVER…………….375
INTRODUCTION…………….380
 FORWARD…………….381
 SAFETY INFORMATION…………….381
 INTRODUCTION…………….382
 INTENDED USE…………….382
 FEATURES…………….382
 BREAKING IN THE MACHINE…………….382
 LOCATION OF PLATES, TABLE TO ENTER P.I.N. AND DISTRIBUTION…………….383
 P.I.N. PLATE LOCATION…………….383
 ENGINE SERIAL NO. PLATE LOCATION…………….383
 TABLE OF CONTENTS…………….384
 TABLE OF CONTENTS…………….384
SAFETY…………….390
 WARNING LABELS…………….391
 GENERAL PRECAUTIONS…………….395
 SAFETY RULES…………….395
 SAFETY FEATURES…………….395
 UNATHORIZED MODIFICATION…………….395
 CLOTHING AND PERSONAL PROTECTIVE ITEMS…………….395
 ALWAYS APPLY LOCK WHEN LEAVING OPERATIORS SEAT…………….395
 MOUNTING AND DISMOUNTING…………….396
 FIRE PREVENTION FOR FUEL AND OIL…………….396
 CRUSHING OR CUTTING PREVENTION…………….396
 PRECAUTIONS WHEN HANDLING AT HIGH TEMPERATURES…………….396
 ASBESTOS DUST HAZARD PREVENTION…………….397
 FIRE EXTINGUISHER AND FIRST AID KIT…………….397
 PRECAUTIONS FOR ATTACHMENTS…………….397
 PRECAUTIONS FOR ROPS CANOPY OR CAB…………….397
 PRECAUTIONS DURING OPERATION…………….398
 BEFORE STARTING ENGINE…………….398
 SAFETY AT WORK SITE…………….398
 FIRE PREVENTION…………….398
 IN OPERATORS COMPARTMENT…………….398
 VENTILATION FOR ENCLOSED AREAS…………….398
 PRECAUTIONS FOR MIRROR AND LIGHTS…………….398
 OPERATING MACHINE…………….399
 WHEN STARTING ENGINE…………….399
 PRECAUTIONS WHEN MOVING FORWARD OR BACKWARD…………….399
 VISIBILITY…………….399
 TRAVELING ON SLOPES…………….399
 OPERATE CAREFULLY ON SNOW…………….400
 WORKING ON LOOSE GROUND…………….400
 PARKING THE MACHINE…………….400
 TRANSPORTATION…………….401
 LOADING AND UNLOADING…………….401
 SHIPPING…………….401
 PRECAUTIONS WHEN FIXING ROPE AND RAISING MACHINE…………….402
 BATTERY…………….403
 BATTERY HAZARD PREVENTION…………….403
 STARTING WITH BOOSTER CABLES…………….403
 TOWING…………….404
 PRECAUTIONS FOR MAINTENANCE…………….405
 BEFORE CARRYING OUT MAINTENANCE…………….405
 WARNING TAG…………….405
 PROPER TOOLS…………….405
 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE…………….405
 RULES TO FOLLOW WHEN ADDING FUEL OR OIL…………….405
 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…………….406
 RADIATOR COOLANT LEVEL …………….406
 USE OF LIGHTING…………….406
 DURING MAINTENANCE…………….407
 PERSONNEL…………….407
 ATTACHMENTS…………….407
 WORK UNDER THE MACHINE…………….407
 KEEP THE MACHINE CLEAN…………….407
 HANDLING HIGH PRESSURE HOSES…………….407
 PRECAUTION WITH BATTERY…………….407
 PRECAUTION WITH HIGH PRESSURE OIL…………….408
 PRECAUTION WHEN CARRYING OUT MAINTENANCE AT HIGH TEMPERATURE OR PRESSURE…………….408
 PRECAUTION WHEN USING HIGH PRESSURE GREASE TO ADJUST TRACK TENSION…………….408
 ROTATING FAN AND BELT…………….408
 WASTE MATERIALS…………….408
 OPERATION…………….410
 GENERAL VIEW…………….411
 GENERAL VIEW OF MACHINE…………….411
 GENERAL VIEW OF CONTROLS AND GAUGES…………….412
 UNIVERSAL SYMBOLS…………….413
 EXPLANATIONS OF COMPONENTS…………….414
 GENERAL…………….414
 GAUGES AND WARNING LIGHTS…………….414
 HOURMETER…………….415
 TRANSMISSION OIL FILTER WARNING LIGHT…………….415
 ENGINE COOLANT TEMPERATURE GAUGE…………….415
 ENGINE OIL PRESSURE GAUGE…………….416
 ILLUMINATION LAMP…………….416
 VOLTMETER…………….416
 DRIVE TRAIN OIL TEMPERATURE GAUGE…………….416
 HYDRAULIC OIL FILTER LIGHT…………….417
 AIR CLEANER SERVICE LIGHT…………….417
 FUEL GAUGE…………….417
 GEAR RANGE INDICATOR…………….417
 TRANSMISSION PRESSURE WARNING LIGHT…………….417
 SWITCHES…………….418
 START KEY SWITCH…………….418
 WORK LIGHT SWITCH…………….419
 HORN SWITCH…………….419
 ETHER START SWITCH…………….419
 ELECTRIAL SYSTEM MASTER SWITCH…………….419
 CAB SWITCHES…………….420
 SEAT, SEAT BELT AND ARM RESTS…………….422
 SEAT…………….422
 SEAT BELT…………….422
 ARM REST…………….422
 CONTROL LEVERS AND PEDALS…………….423
 FUEL CONTROL LEVER…………….423
 TRANSMISSION STEERING LEVER…………….423
 SAFETY LOCK LEVER…………….424
 LEFT PEDAL SECONDARY BRAKE…………….425
 BRAKE AND DECELERATOR PEDAL…………….425
 BRAKE PEDAL LOCK…………….425
 BLADE CONTROL LEVER…………….426
 RIPPER CONTROL LEVER…………….428
 CAB CONTROLS…………….429
 LOCKING FUEL CAP…………….430
 OPENING…………….430
 CLOSING…………….430
 OPERATION…………….431
 CHECKS BEFORE STARTING ENGINE…………….431
 WALK AROUND CHECK…………….431
 CHECK BEFORE STARTING…………….432
 OPERATIONS AND CHECKS BEFORE STARTING ENGINE…………….437
 STARTING ENGINE…………….439
 NORMAL STARTING…………….439
 COLD WEATHER STARTING…………….441
 OPERATIONS AND CHECKS AFTER ENGINE STARTS…………….443
 MOVING MACHINE…………….445
 SHIFTING GEAR…………….447
 SHIFTING BETWEEN FORWARD AND REVERSE…………….448
 STEERING MACHINE…………….449
 NORMAL STARTING…………….449
 TURNING WHILE DESCENDING A SLOPE…………….450
 STOPPING MACHINE…………….451
 PRECAUTIONS FOR OPERATION…………….453
 METHOD FOR USING STEERING CLUTCH…………….453
 PERMISSIBLE WATER DEPTH…………….453
 WHEN TRAVELING UP OR DOWN HILLS…………….453
 ON SLOPES…………….453
 WORK POSSIBLE USING BULLDOZER…………….454
 DOZING…………….454
 SMOOTHING…………….454
 CUTTING INTO HARD/FROZEN GROUND OR DITCHING…………….454
 PARKING MACHINE…………….455
 CHECK AFTER FINISHING WORK…………….457
 STOPPING ENGINE…………….458
 CHECKS AFTER STOPPING ENGINE…………….460
 LOCKING…………….461
 ROPS CANOPY…………….461
 ROPS CAB…………….461
 TIPS FOR LONGER UNDERCARRIAGE LIFE…………….463
 OPERATION METHOD…………….463
 INSPECTION AND ADJUSTMENT…………….464
 INSPECTION AND REPAIR…………….464
 TRANSPORTATION…………….466
 LOADING, UNLOADING WORK…………….466
 PRECAUTIONS FOR LOADING…………….466
 PRECAUTIONS FOR TRANSPORTATION…………….467
 COLD WEATHER OPERATIONS…………….468
 PRECAUTIONS FOR LOW TEMPERATURE…………….468
 FUEL AND LUBRICANTS…………….468
 COOLANT…………….468
 BATTERY…………….468
 AFTER COMPLETION OF WORK…………….469
 AFTER COLD WEATHER…………….469
 LONG TERM STORAGE…………….470
 BEFORE STORAGE…………….470
 DURING STORAGE…………….470
 ATER STORAGE…………….470
 TROUBLESHOOTING…………….471
 AFTER RUNNING OUT OF FUEL…………….471
 IF BATTERY IS DISCHARGED …………….471
 STARTING ENGINE WITH BOOSTER CABLE…………….471
 OTHER TROUBLE…………….473
 ELECTRICAL SYSTEM…………….473
 CHASSIS…………….473
 ENGINE…………….474
 METHODS OF TOWING MACHINE…………….475
MAINTENANCE…………….476
 GUIDES TO MAINTENANCE…………….477
 OUTLINES OF SERVICE…………….479
 OUTLINE OF OIL, FUEL, COOLANT…………….479
 OIL …………….479
 FUEL…………….479
 COOLANT…………….480
 GREASE…………….480
 STORING OIL AND FUEL…………….480
 FILTERS…………….480
 RELATING TO ELECTRICAL SYSTEM…………….480
 WEAR PARTS LIST…………….481
 USE OF FUEL, COOLANT AND LUBRICANTS…………….482
 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS…………….482
 D32E-1, D32P-1, D38E-1 OR D38P-1…………….482
 D39E-1 OR D39P-1…………….483
 ABBREVIATIONS…………….483
 ENGINE OIL SPECIFICATIONS…………….484
 NORMAL OPERATION …………….484
 ARCTIC OPERATION…………….484
 DRIVE TRAIN OIL SPECIFICATIONS…………….485
 TRACK FRONT IDLER, TRACK ROLLER, TOP IDLER OIL SPECIFICATIONS…………….485
 EQUIPMENT SYSTEM OIL SPECIFICATIONS…………….485
 FINAL DRIVE OIL SPECIFICATIONS…………….485
 COOLING SYSTEM…………….486
 GENERAL…………….486
 WATER…………….486
 ANTIFREEZE…………….486
 INHIBITORS / CONDITIONERS…………….487
 FUEL SYSTEM…………….489
 GENERAL…………….489
 DIESEL FUEL SPECIFICATIONS…………….489
 STANDARD TIGHTENING TORQUES…………….490
 INTRODUCTION OF NECESSARY TOOLS…………….490
 BOLT IDENTIFICATION CHART…………….491
 GRADE 5 AND 8 NON-PHOSPHATE COATED HARDWARE…………….492
 GRADE 8 PHOSPHATE COATED HARDWARE…………….493
 STANDARD METRIC FASTENERS …………….493
 HYDRAULIC TUBES AND FITTINGS…………….494
 HOSE CLAMPS…………….494
 SPLIT FLANGE CONNECTIONS…………….494
 PERIODIC REPLACEMENT OF CRITICAL PARTS…………….495
 MAINTENANCE SCHEDULE CHART…………….498
 SERVICE PROCEDURE…………….501
 INITIAL 10 HOURS SERVICE…………….501
 BLADE CUTTING EDGE HARDWARE…………….501
 TRACK SHOE BOLT TORQUE…………….501
 EVERY 50 HOURS SERVICE…………….502
 REPLACING DRIVE TRAIN PRESSURE FILTER…………….502
 SERVICING THE DRIVE TRAIN PRESSURE FILTER…………….503
 TRACK TENSION AND ADJUSTMENT…………….504
 EVERY 10 HOURS SERVICE…………….506
 CHECK RADIATOR COOLANT LEVEL…………….506
 CHECK ENGINE CRANKCASE OIL LEVEL…………….506
 CHECK EQUIPMENT SYSTEM HYDRAULIC OIL LEVEL…………….507
 FILL FUEL TANK…………….507
 DRAIN FUEL FILTER WATER SEPARATOR…………….508
 OPEN FUEL SHUT OFF VALVE…………….508
 CLEAN PRE-CLEANER HOOD…………….508
 CHECK BRAKE PEDAL TRAVEL…………….509
 PERFORM GROUND LEVEL INSPECTION…………….509
 EVERY 50 HOURS SERVICE…………….511
 CHECK OIL LEVEL IN DRIVE TRAIN…………….511
 LUBRICATION…………….511
 EVERY 100 HOURS…………….512
 BLADE CUTTING EDGE HARDWARE…………….512
 EVERY 250 HOURS SERVICE…………….513
 REPLACE ENGINE OIL FILTER…………….513
 CHANGE ENGINE CRANKCASE OIL …………….513
 CHECKING FINAL DRIVE OIL LEVEL…………….514
 REPLACE FUEL FILTER WATER SEPARATOR…………….515
 CHECK ENGINE DRIVE BELT FOR WEAR…………….516
 CHECK OPERATION OF THE DECELERATOR…………….516
 REVERSE REVERSIBLE FAN BLADES…………….516
 EVERY 500 HOURS SERVICE…………….517
 CHECK ROPS MOUNTING BOT NUT TORQUE…………….517
 CHECK TRACK SHOE BOLT NUT TORQUE…………….517
 INSPECT MOUNTED EQUIPMENT…………….517
 RADIATOR LEAKS…………….517
 OUTSIDE OF RADIATOR CORE…………….517
 EVERY 1000 HOURS SERVICE…………….518
 SERVICE THE DRIVE TRAIN SUCTION STRAINER…………….518
 CHANGING DRIVE TRAIN SYSTEM OIL…………….519
 DRAIN, FLUSH AND REFILL FINAL DRIVE OIL…………….519
 REPLACE DRIVE TRAIN SYSTEM BREATHER…………….520
 REPLACING DRIVE TRAIN PRESSURE FILTER…………….520
 REPLACE HYDRAULIC SYSTEM RETURN FILTER…………….521
 CLEAN NEUTRAL VALVE INLET STRAINER…………….522
 LUBRICATE VALVE CAM PLATE…………….523
 CHECK TORQUE OF SPROCKET MOUNTING BOLTS…………….523
 LUBRICATION…………….523
 EVERY 2000 HOURS SERVICE…………….525
 DRAIN, FLUSH AND REFILL COOLING SYSTEM…………….525
 CLEAN HYDRAULIC SUCTION STRAINER…………….526
 CLEAN HYDRAULIC RESERVOIR RELIEF VALVE…………….526
 CHANGE HYDRAULIC SYSTEM FLUID…………….527
 PERIODIC…………….528
 CLEAN AIR CLEANER ELEMENTS…………….528
 CLEAN FUEL TANK STRAINER…………….532
 DRAIN FUEL TANK SEDIMENT BOWL…………….532
 REPLACE IN LINE FUEL STRAINER…………….532
 SEAT BELT…………….533
 CHECK HOSE CLAMP TORQUE…………….533
 WHEN REQUIRED…………….534
 FAN BELT…………….534
 ELECTRICAL SYSTEM…………….534
 ETHER START…………….539
 VENTING THE FUEL SYSTEM…………….541
 ANGLING FRAME TO BLADE…………….541
 REVERSE OR REPLACE END BITS AND CUTTING EDGES…………….542
 TRACK TENSION AND ADJUSTMENT…………….543
 ADJUST FRONT IDLER CLEARANCE…………….545
 CLEAN OR REPLACE CAB FRESH AIR FILTER…………….545
 GREASE CAB DOOR HINGES…………….545
 WIPER WASHER FLUID LEVEL…………….546
 SEASONAL PREPARATION…………….547
 GENERAL…………….547
 OUTSIDE SOURCE OF HEAT…………….547
 LUBRICATION…………….547
 FUEL SYSTEM…………….547
 COOLING SYSTEM…………….547
 ELECTRICAL SYSTEM…………….548
 TURBOCHARGER: D38E/P-1 AND D39E/P-1…………….549
 PRECAUTIONS…………….549
 PRIMING…………….550
SPECIFICATIONS…………….552
 SPECIFICATIONS…………….553
 D32E-1,D32P-1 SPECIFICATIONS…………….553
 D38E-1, D38P-1 SPECIFICATIONS…………….554
 D39E-1, D39P-1 SPECIFICATIONS…………….555
 D32E-1 DIMENSIONS…………….556
 D32P-1 DIMENSIONS…………….557
 D38E-1 DIMENSIONS…………….558
 D38P-1 DIMENSIONS…………….559
 D39E-1 DIMENSIONS…………….560
 D39P-1 DIMENSIONS…………….561
OPTIONS, ATTACHMENTS…………….562
 PRECAUTIONS RELATED TO SAFETY…………….563
EEAM023900 – Bulldozer D31EX,PX-21, D37EX,PX-21, D39EX,PX-21 Operation & Maintenance Manual…………….565
FOREWORD…………….567
 FOREWORD…………….568
 SAFETY INFORMATION…………….569
 NOISE…………….571
 VIBRATION…………….571
 INTRODUCTION…………….572
 FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE…………….572
 NECESSARY INFORMATION…………….573
 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…………….573
 ENGINE SERIAL NO. PLATE…………….573
 POSITION OF SERVICE METER…………….574
 TABLE OF ENTER SERIAL NO. AND DISTRIBUTORN…………….574
 MACHINE SERIAL PLATE……………..575
 FOREWORD…………….576
 SAFETY…………….576
 OPERATION…………….577
 MAINTENANCE…………….580
 SPECIFICATIONS…………….581
 ATTACHMENTS, OPTIONS…………….582
 INDEX…………….582
 COLOPHON…………….582
SAFETY…………….583
 SAFETY…………….584
 SAFETY LABELS…………….586
 POSITIONS OF SAFETY PICTOGRAMS…………….586
 SAFETY LABELS…………….587
 GENERAL PRECAUTIONS…………….592
 PRECAUTIONS FOR OPERATION…………….601
 STARTING ENGINE…………….601
 OPERATION…………….603
 TRANSPORTATION…………….606
 BATTERY…………….607
 TOWING…………….609
 PRECAUTIONS FOR MAINTENANCE…………….610
OPERATION…………….617
 GENERAL VIEW…………….618
 GENERAL VIEW OF MACHINE…………….618
 GENERAL VIEW OF CONTROLS AND GAUGES…………….619
 EXPLANATION OF COMPONENTS…………….621
 FRONT PANEL…………….621
 CHECK MONITOR SYSTEM…………….622
 EMERGENCY CAUTION ITEMS…………….623
 CAUTION CAUTION ITEMS…………….625
 METER GROUP…………….627
 LAMPS…………….636
 METHOD OF USING MAINTENANCE MODE…………….637
 SWITCHES…………….646
 CONTROL LEVERS AND PEDALS…………….651
 FUSE…………….657
 ELECTRIC POWER TAKE-OUT ADAPTER…………….658
 DOOR – OPEN LOCK…………….659
 SASH GLASS INTERMEDIATE LOCK…………….659
 CAP, COVER WITH LOCK…………….660
 METHOD OF OPENING AND CLOSING CAP WITH LOCK…………….660
 METHOD OF OPENING AND CLOSING COVER WITH LOCK…………….661
 DOOR POCKET…………….661
 ASHTRAY…………….662
 LUNCHBOX HOLDER BELT…………….662
 CUP HOLDER…………….662
 TOOL BOX…………….663
 GREASE PUMP HOLDER…………….663
 CAR STEREO, HANDLING…………….664
 EXPLANATION OF COMPONENTS…………….664
 METOD OF OPERATION…………….669
 PRECAUTION WHEN USING…………….671
 AIR CONDITIONER, HANDLING…………….672
 EXPLANATION OF PARTS…………….672
 PREVENTION METHOD OF ENTRY OF DUST…………….674
 PRECAUTION WHEN USING AIR CONDITIONER…………….674
 INSPECTION DURING OFF-SEASON…………….674
 PROCEDURE FOR REPLACING RECEIVER…………….675
 CLEANING AIR FILTER…………….675
 ACCUMULATOR, HANDLING…………….676
 METHOD OF RELEASING PRESSURE IN OPERATING CIRCUIT ON MACHINE EQUIPPED WITH ACCUMULATOR…………….676
 OPERATION…………….677
 CHECK BEFORE STARTING ENGINE, ADJUST…………….677
 WALK-AROUND CHECK…………….677
 CHECK BEFORE STARTING…………….679
 ADJUSTMENT…………….688
 OPERATION AND CHECK BEFORE STARTING ENGINE…………….691
 STARTING ENGINE…………….693
 NORMAL STARTING…………….693
 STARTING IN COLD WEATHER…………….695
 OPERATIONS AND CHECKS AFTER STARTING ENGINE…………….697
 BREAKING IN THE NEW MACHINE…………….697
 WARMING UP OPERATIONS…………….697
 STARTING IN COLD WEATHER…………….698
 STOPPING ENGINE…………….700
 MACHINE OPERATION…………….701
 MOVING MACHINE…………….701
 STOPPING MACHINE…………….704
 SHIFTING GEARS…………….705
 SHIFTING BETWEEN FORWARD AND REVERSE…………….706
 STEERING MACHINE…………….707
 NORMAL TURNING…………….707
 TURNING WHILE DESCENDING A SLOPE…………….708
 PRECAUTIONS FOR OPERATION…………….709
 PAY ATTENTION TO GAUGES…………….709
 PERMISSIBLE WATER DEPTH…………….709
 METHOD OF USING BRAKES…………….709
 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS…………….709
 PRECAUTIONS ON SLOPES…………….710
 IT IS PROHIBITED TO KEEP THE DOOR OPEN DURING OPERATIONS…………….710
 IT IS PROHIBITED TO MODIFY THE CAB GLASS IN ANY WAY THAT WILL OBSTRUCT THE VIEW…………….710
 PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB STAY…………….710
 WORK POSSIBLE USING BULLDOZER…………….711
 DOZING…………….711
 SMOOTHING…………….711
 CUTTING INTO HARD OR FROZEN GROUND OR DITCHING…………….712
 FELLING TREES, REMOVING STUMPS…………….712
 SIDE-CUTTING OPERATIONS…………….712
 PARKING MACHINE…………….713
 CHECK AFTER FINISHING WORK…………….714
 BEFORE STARTING ENGINE…………….714
 AFTER STARTING ENGINE…………….714
 LOCKING…………….715
 TIPS FOR LONGER UNDERCARRIAGE LIFE…………….716
 OPERATION METHOD…………….716
 INSPECTION AND ADJUSTMENT…………….716
 INSPECTION AND REPAIR…………….717
 TRANSPORTATION…………….719
 TRANSPORTATION MEANS…………….719
 PRECAUTIONS WHEN REMOVING WORK EQUIPMENT…………….719
 REMOVING CAB…………….719
 LOADING, UNLOADING WORK…………….720
 LIFTING MACHINE…………….724
 COLD WEATHER OPERATION…………….725
 PRECAUTIONS FOR LOW TEMPERATURE…………….725
 AFTER COMPLETION OF WORK…………….727
 AFTER COLD WEATHER…………….727
 LONG-TERM STORAGE…………….728
 BEFORE STORAGE…………….728
 DURING STORAGE…………….728
 AFTER STORAGE…………….728
 TROUBLESHOOTING…………….729
 AFTER RUNNING OUT OF FUEL…………….729
 MACHINE TOWING METHOD…………….729
 WHEN IT IS POSSIBLE TO START ENGINE…………….730
 WHEN ENGINE DOES NOT START…………….731
 IF BATTERY IS DISCHARGED…………….736
 REMOVE AND INSTALL BATTERY…………….737
 PRECAUTIONS FOR BATTERY CHARGING…………….737
 STARTING ENGINE WITH BOOSTER CABLE…………….738
 WHEN ENGINE DOES NOT STOP…………….740
 OTHER TROUBLE…………….741
 ELECTRICAL SYSTEM…………….741
 MONITOR PANEL…………….742
 CHASSIS…………….743
 ENGINE…………….744
MAINTENANCE…………….745
 GUIDE TO MAINTENANCE…………….746
 OUTLINE OF SERVICE…………….749
 OUTLINE OF OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…………….749
 OIL…………….749
 FUEL…………….749
 COOLANT…………….750
 GREASE…………….750
 CARRYING OUT KOWA (Komatsu Oil Wear Analysis)…………….750
 STORING OIL AND FUEL…………….751
 FILTERS…………….751
 RELATING TO ELECTRIC SYSTEM…………….752
 WEAR PARTS LIST…………….753
 WEAR PARTS LIST…………….753
 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…………….755
 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS…………….755
 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…………….759
 TORQUE LIST…………….759
 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…………….760
 SAFETY CRITICAL PARTS…………….760
 MAINTENANCE SCHEDULE CHART…………….761
 MAINTENANCE SCHEDULE CHART…………….761
 WHEN REQUIRED…………….761
 CHECK BEFORE STARTING…………….761
 EVERY 50 HOURS SERVICE…………….761
 EVERY 250 HOURS SERVICE…………….761
 EVERY 500 HOURS SERVICE…………….761
 EVERY 1000 HOURS SERVICE…………….761
 EVERY 2000 HOURS SERVICE…………….762
 EVERY 4000 HOURS SERVICE…………….762
 SERVICE PROCEDURE…………….763
 WHEN REQUIRED…………….763
 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…………….763
 CLEAN INSIDE OF COOLING SYSTEM…………….767
 CHECK TRACK SHOE TENSION, ADJUST…………….769
 CHECK AND TIGHTEN TRACK SHOE BOLTS…………….771
 CHECK ELECTRICAL INTAKE AIR HEATER…………….771
 REVERSE AND REPLACE END BITS AND CUTTING EDGES…………….772
 CHECK IDLER OIL LEVEL, ADD OIL…………….773
 ADJUST IDLER CLEARANCE…………….773
 ADJUST PLAY IN CENTER BALL…………….774
 GREASE DOOR HINGE…………….774
 CHECK DOOR LOCK STRIKER…………….775
 CHECK, ADJUST AIR CONDITIONER…………….775
 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…………….777
 REPLACE WIPER BLADE…………….777
 PROCEDURE FOR BLEEDING AIR IN HYDRAULIC SYSTEM…………….778
 PROCEDURE FOR RELEASING INTERNAL PRESSURE OF HYDRAULIC SYSTEM…………….779
 CHECK BEFORE STARTING…………….780
 EVERY 50 HOURS SERVICE…………….781
 DRAIN WATER, SEDIMENT FROM FUEL TANK…………….781
 EVERY 250 HOURS SERVICE…………….782
 LUBRICATING…………….782
 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…………….784
 CHECK LEVEL OF BATTERY ELECTROLYTE…………….785
 CHECK BRAKE PERFORMANCE…………….787
 CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)…………….788
 EVERY 500 HOURS SERVICE…………….789
 REPLACE FUEL FILTER CARTRIDGE…………….789
 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…………….792
 REPLACE CORROSION RESISTOR CARTRIDGE…………….793
 CLEAN, CHECK RADIATOR FINS AND OIL COOLER FINS…………….794
 EVERY 1000 HOURS SERVICE…………….795
 CHANGE OIL IN FINAL DRIVE CASE…………….795
 CHECK FAN BELT TENSION, ADJUST…………….795
 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…………….795
 CHECK PLAY OF TURBOCHARGER ROTOR…………….796
 CHECK FOR LOOSE ROPS MOUNT BOLTS…………….796
 EVERY 2000 HOURS SERVICE…………….797
 CHANGE OIL IN HYDRAULIC TANK, REPLACE OIL FILTER CARTRIDGE AND CLEAN SUCTION STRAINER…………….797
 CLEAN, CHECK TURBOCHARGER…………….799
 CHECK VIBRATION DAMPER…………….799
 CHECK ALTERNATOR, STARTING MOTOR…………….799
 CHECK ENGINE VALVE CLEARANCE, ADJUST…………….799
 EVERY 4000 HOURS SERVICE…………….800
 CHECK WATER PUMP…………….800
SPECIFICATIONS…………….801
 SPECIFICATIONS…………….802
ATTACHMENTS, OPTIONS…………….805
 GENERAL PRECAUTIONS…………….806
 PRECAUTIONS RELATED TO SAFETY…………….806
 HANDLING HYDRAULIC RIPPER…………….807
 GENERAL VIEW…………….807
 EXPLANATION OF COMPONENTS…………….808
 OPERATION…………….809
 CHECK BEFORE STARTING ENGINE, ADJUST…………….809
 PRECAUTIONS WHEN OPERATING…………….809
 ADUSTING POSTURE OF WORK EQUIPMENT…………….809
 TROUBLESHOOTING…………….810
 OTHER TROUBLE…………….810
 MAINTENANCE…………….810
 EVERY 250 HOURS SERVICE…………….810
 DELUXE SEAT…………….811
 HEADREST…………….813
 EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT…………….814
INDEX…………….815
 <A>…………….817
 <C>…………….817
 <D>…………….817
 <E>…………….817
 <F>…………….817
 <G>…………….817
 <H>…………….817
 …………….817
 <L>…………….817
 <M>…………….817
 <N>…………….817
 <O>…………….817
 …………….817
 <R>…………….818
 <S>…………….818
 <T>…………….818
 …………….818
 <W>…………….818
COLOPHON…………….819
EEAM024300 – Bulldozer D31EX,PX-21, D37EX,PX-21, D39EX,PX-21 Operation & Maintenance Manual…………….821
FOREWORD…………….823
 FOREWORD…………….824
 SAFETY INFORMATION…………….825
 Noise emission levels (D37EX, D37PX)…………….827
 Vibration levels (D37EX, D37PX)…………….827
 Guide to Reduce Vibration Levels on Machine…………….828
 INTRODUCTION…………….830
 FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE…………….830
 NECESSARY INFORMATION…………….831
 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…………….831
 ENGINE SERIAL NO. PLATE…………….831
 POSITION OF SERVICE METER…………….832
 TABLE OF ENTER SERIAL NO. AND DISTRIBUTORN…………….832
 MACHINE SERIAL PLATE……………..833
 FOREWORD…………….834
 SAFETY…………….834
 OPERATION…………….835
 MAINTENANCE…………….837
 SPECIFICATIONS…………….839
 ATTACHMENTS, OPTIONS…………….839
 INDEX…………….840
 COLOPHON…………….840
SAFETY…………….841
 SAFETY…………….842
 SAFETY LABELS…………….844
 POSITIONS OF SAFETY PICTOGRAMS…………….844
 SAFETY LABELS…………….845
 GENERAL PRECAUTIONS…………….850
 PRECAUTIONS FOR OPERATION…………….859
 STARTING ENGINE…………….859
 OPERATION…………….861
 TRANSPORTATION…………….864
 BATTERY…………….865
 TOWING…………….867
 PRECAUTIONS FOR MAINTENANCE…………….868
OPERATION…………….875
 GENERAL VIEW…………….876
 GENERAL VIEW OF MACHINE…………….876
 GENERAL VIEW OF CONTROLS AND GAUGES…………….877
 EXPLANATION OF COMPONENTS…………….879
 FRONT PANEL…………….879
 CHECK MONITOR SYSTEM…………….880
 EMERGENCY CAUTION ITEMS…………….881
 CAUTION CAUTION ITEMS…………….883
 METER GROUP…………….885
 LAMPS…………….894
 METHOD OF USING MAINTENANCE MODE…………….895
 SWITCHES…………….904
 CONTROL LEVERS AND PEDALS…………….909
 FUSE…………….915
 ELECTRIC POWER TAKE-OUT ADAPTER…………….916
 DOOR – OPEN LOCK…………….917
 SASH GLASS INTERMEDIATE LOCK…………….917
 CAP, COVER WITH LOCK…………….918
 METHOD OF OPENING AND CLOSING CAP WITH LOCK…………….918
 METHOD OF OPENING AND CLOSING COVER WITH LOCK…………….919
 DOOR POCKET…………….919
 ASHTRAY…………….920
 LUNCHBOX HOLDER BELT…………….920
 CUP HOLDER…………….920
 TOOL BOX…………….921
 GREASE PUMP HOLDER…………….921
 CAR STEREO, HANDLING…………….922
 EXPLANATION OF COMPONENTS…………….922
 METOD OF OPERATION…………….927
 PRECAUTION WHEN USING…………….929
 AIR CONDITIONER, HANDLING…………….930
 EXPLANATION OF PARTS…………….930
 PREVENTION METHOD OF ENTRY OF DUST…………….932
 PRECAUTION WHEN USING AIR CONDITIONER…………….932
 INSPECTION DURING OFF-SEASON…………….932
 PROCEDURE FOR REPLACING RECEIVER…………….933
 CLEANING AIR FILTER…………….933
 ACCUMULATOR, HANDLING…………….934
 METHOD OF RELEASING PRESSURE IN OPERATING CIRCUIT ON MACHINE EQUIPPED WITH ACCUMULATOR…………….934
 OPERATION…………….935
 CHECK BEFORE STARTING ENGINE, ADJUST…………….935
 WALK-AROUND CHECK…………….935
 CHECK BEFORE STARTING…………….937
 ADJUSTMENT…………….946
 OPERATION AND CHECK BEFORE STARTING ENGINE…………….949
 STARTING ENGINE…………….951
 NORMAL STARTING…………….951
 STARTING IN COLD WEATHER…………….953
 OPERATIONS AND CHECKS AFTER STARTING ENGINE…………….955
 BREAKING IN THE NEW MACHINE…………….955
 WARMING UP OPERATIONS…………….955
 STARTING IN COLD WEATHER…………….956
 STOPPING ENGINE…………….958
 MACHINE OPERATION…………….959
 MOVING MACHINE…………….959
 STOPPING MACHINE…………….962
 SHIFTING GEARS…………….963
 SHIFTING BETWEEN FORWARD AND REVERSE…………….964
 STEERING MACHINE…………….965
 NORMAL TURNING…………….965
 TURNING WHILE DESCENDING A SLOPE…………….966
 PRECAUTIONS FOR OPERATION…………….967
 PAY ATTENTION TO GAUGES…………….967
 PERMISSIBLE WATER DEPTH…………….967
 METHOD OF USING BRAKES…………….967
 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS…………….967
 PRECAUTIONS ON SLOPES…………….968
 IT IS PROHIBITED TO KEEP THE DOOR OPEN DURING OPERATIONS…………….968
 IT IS PROHIBITED TO MODIFY THE CAB GLASS IN ANY WAY THAT WILL OBSTRUCT THE VIEW…………….968
 PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB STAY…………….968
 WORK POSSIBLE USING BULLDOZER…………….969
 DOZING…………….969
 SMOOTHING…………….969
 CUTTING INTO HARD OR FROZEN GROUND OR DITCHING…………….970
 FELLING TREES, REMOVING STUMPS…………….970
 SIDE-CUTTING OPERATIONS…………….970
 PARKING MACHINE…………….971
 CHECK AFTER FINISHING WORK…………….972
 BEFORE STARTING ENGINE…………….972
 AFTER STARTING ENGINE…………….972
 LOCKING…………….973
 TIPS FOR LONGER UNDERCARRIAGE LIFE…………….974
 OPERATION METHOD…………….974
 INSPECTION AND ADJUSTMENT…………….974
 INSPECTION AND REPAIR…………….975
 TRANSPORTATION…………….977
 TRANSPORTATION MEANS…………….977
 PRECAUTIONS WHEN REMOVING WORK EQUIPMENT…………….977
 REMOVING CAB…………….977
 LOADING, UNLOADING WORK…………….978
 LIFTING MACHINE…………….982
 COLD WEATHER OPERATION…………….983
 PRECAUTIONS FOR LOW TEMPERATURE…………….983
 AFTER COMPLETION OF WORK…………….985
 AFTER COLD WEATHER…………….985
 LONG-TERM STORAGE…………….986
 BEFORE STORAGE…………….986
 DURING STORAGE…………….986
 AFTER STORAGE…………….986
 TROUBLESHOOTING…………….987
 AFTER RUNNING OUT OF FUEL…………….987
 MACHINE TOWING METHOD…………….987
 WHEN IT IS POSSIBLE TO START ENGINE…………….988
 WHEN ENGINE DOES NOT START…………….989
 IF BATTERY IS DISCHARGED…………….994
 REMOVE AND INSTALL BATTERY…………….995
 PRECAUTIONS FOR BATTERY CHARGING…………….995
 STARTING ENGINE WITH BOOSTER CABLE…………….996
 WHEN ENGINE DOES NOT STOP…………….998
 OTHER TROUBLE…………….999
 ELECTRICAL SYSTEM…………….999
 MONITOR PANEL…………….1000
 CHASSIS…………….1001
 ENGINE…………….1002
MAINTENANCE…………….1003
 GUIDE TO MAINTENANCE…………….1004
 OUTLINE OF SERVICE…………….1007
 OUTLINE OF OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…………….1007
 OIL…………….1007
 FUEL…………….1007
 COOLANT…………….1008
 GREASE…………….1008
 CARRYING OUT KOWA (Komatsu Oil Wear Analysis)…………….1008
 STORING OIL AND FUEL…………….1009
 FILTERS…………….1009
 RELATING TO ELECTRIC SYSTEM…………….1010
 WEAR PARTS LIST…………….1011
 WEAR PARTS LIST…………….1011
 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…………….1013
 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS…………….1013
 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…………….1017
 TORQUE LIST…………….1017
 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…………….1018
 SAFETY CRITICAL PARTS…………….1018
 MAINTENANCE SCHEDULE CHART…………….1019
 MAINTENANCE SCHEDULE CHART…………….1019
 WHEN REQUIRED…………….1019
 CHECK BEFORE STARTING…………….1019
 EVERY 50 HOURS SERVICE…………….1019
 EVERY 250 HOURS SERVICE…………….1019
 EVERY 500 HOURS SERVICE…………….1019
 EVERY 1000 HOURS SERVICE…………….1019
 EVERY 2000 HOURS SERVICE…………….1020
 EVERY 4000 HOURS SERVICE…………….1020
 SERVICE PROCEDURE…………….1021
 WHEN REQUIRED…………….1021
 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…………….1021
 CLEAN INSIDE OF COOLING SYSTEM…………….1025
 CHECK TRACK SHOE TENSION, ADJUST…………….1027
 CHECK AND TIGHTEN TRACK SHOE BOLTS…………….1029
 CHECK ELECTRICAL INTAKE AIR HEATER…………….1029
 REVERSE AND REPLACE END BITS AND CUTTING EDGES…………….1030
 CHECK IDLER OIL LEVEL, ADD OIL…………….1031
 ADJUST IDLER CLEARANCE…………….1031
 ADJUST PLAY IN CENTER BALL…………….1032
 GREASE DOOR HINGE…………….1032
 CHECK DOOR LOCK STRIKER…………….1033
 CHECK, ADJUST AIR CONDITIONER…………….1033
 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…………….1035
 REPLACE WIPER BLADE…………….1035
 PROCEDURE FOR BLEEDING AIR IN HYDRAULIC SYSTEM…………….1036
 PROCEDURE FOR RELEASING INTERNAL PRESSURE OF HYDRAULIC SYSTEM…………….1037
 CHECK BEFORE STARTING…………….1038
 EVERY 50 HOURS SERVICE…………….1039
 DRAIN WATER, SEDIMENT FROM FUEL TANK…………….1039
 EVERY 250 HOURS SERVICE…………….1040
 LUBRICATING…………….1040
 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…………….1042
 CHECK LEVEL OF BATTERY ELECTROLYTE…………….1043
 CHECK BRAKE PERFORMANCE…………….1045
 CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)…………….1046
 EVERY 500 HOURS SERVICE…………….1047
 REPLACE FUEL FILTER CARTRIDGE…………….1047
 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…………….1050
 REPLACE CORROSION RESISTOR CARTRIDGE…………….1051
 CLEAN, CHECK RADIATOR FINS AND OIL COOLER FINS…………….1052
 EVERY 1000 HOURS SERVICE…………….1053
 CHANGE OIL IN FINAL DRIVE CASE…………….1053
 CHECK FAN BELT TENSION, ADJUST…………….1053
 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…………….1053
 CHECK PLAY OF TURBOCHARGER ROTOR…………….1054
 CHECK FOR LOOSE ROPS MOUNT BOLTS…………….1054
 EVERY 2000 HOURS SERVICE…………….1055
 CHANGE OIL IN HYDRAULIC TANK, REPLACE OIL FILTER CARTRIDGE AND CLEAN SUCTION STRAINER…………….1055
 CLEAN, CHECK TURBOCHARGER…………….1057
 CHECK VIBRATION DAMPER…………….1057
 CHECK ALTERNATOR, STARTING MOTOR…………….1057
 CHECK ENGINE VALVE CLEARANCE, ADJUST…………….1057
 EVERY 4000 HOURS SERVICE…………….1058
 CHECK WATER PUMP…………….1058
SPECIFICATIONS…………….1059
 SPECIFICATIONS…………….1060
ATTACHMENTS, OPTIONS…………….1063
 GENERAL PRECAUTIONS…………….1064
 PRECAUTIONS RELATED TO SAFETY…………….1064
 HANDLING HYDRAULIC RIPPER…………….1065
 GENERAL VIEW…………….1065
 EXPLANATION OF COMPONENTS…………….1066
 OPERATION…………….1067
 CHECK BEFORE STARTING ENGINE, ADJUST…………….1067
 PRECAUTIONS WHEN OPERATING…………….1067
 ADUSTING POSTURE OF WORK EQUIPMENT…………….1067
 TROUBLESHOOTING…………….1068
 OTHER TROUBLE…………….1068
 MAINTENANCE…………….1068
 EVERY 250 HOURS SERVICE…………….1068
 DELUXE SEAT…………….1069
 HEADREST…………….1071
 EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT…………….1072
INDEX…………….1073
 <A>…………….1075
 <C>…………….1075
 <D>…………….1075
 <E>…………….1075
 <F>…………….1075
 <G>…………….1075
 <H>…………….1075
 …………….1075
 <L>…………….1075
 <M>…………….1075
 <N>…………….1075
 <O>…………….1075
 …………….1075
 <R>…………….1076
 <S>…………….1076
 <T>…………….1076
 …………….1076
 <W>…………….1076
COLOPHON…………….1077
PEN00220-00 – Bulldozer D31E,P,PL,PLL-20 & D31P-20A & D37E-5 & D37P-5A Operation & Maintenance Manual…………….1079
COVER…………….1079
1. FOREWORD…………….1080
2. SAFETY INFORMATION…………….1081
3. INTRODUCTION…………….1082
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…………….1083
5. CONTENTS…………….1084
SAFETY…………….1088
 6. GENERAL PRECAUTIONS…………….1089
 7. PRECAUTIONS DURING OPERATION…………….1094
 7.1 BEFORE STARTING ENGINE…………….1094
 7.2 AFTER STARTING ENGINE…………….1096
 7.3 TRANSPORTATION…………….1102
 7.4 BATTERY…………….1103
 7.5 TOWING…………….1105
 8. PRECAUTIONS FOR MAINTENANCE…………….1106
 8.1 BEFORE CARRYING OUT MAINTENANCE…………….1106
 8.2 DURING MAINTENANCE…………….1111
 9. POSITION FOR ATTACHING SAFETY LABELS…………….1116
OPERATION…………….1120
 10. GENERAL VIEW…………….1121
 10.1 GENERAL VIEW OF MACHINE…………….1121
 10.2 GENERAL VIEW OF CONTROLS AND GAUGES…………….1122
 11. EXPLANATION OF COMPONENTS…………….1123
 11.1 METER AND LAMPS…………….1123
 11.2 SWITCHES…………….1125
 11.3 CONTROL LEVERS, PEDALS…………….1127
 11.4 FUSE BOX…………….1132
 11.5 LOCATION OF FIRE EXTINGUISHER…………….1132
 11.6 ELECTRIC POWER TAKE-OUT ADAPTER…………….1133
 11.7 MANUAL POCKET…………….1133
 12. OPERATION…………….1134
 12.1 CHECK BEFORE STARTING ENGINE…………….1134
 12.2 STARTING ENGINE…………….1145
 12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…………….1148
 12.4 MOVING MACHINE…………….1149
 12.5 SHIFTING GEAR…………….1150
 12.6 SHIFTING BETWEEN FORWARD AND REVERSE…………….1151
 12.7 STEERING MACHINE…………….1152
 12.8 STOPPING MACHINE…………….1155
 12.9 PRECAUTIONS FOR OPERATION…………….1156
 12.10 WORK POSSIBLE USING BULLDOZER…………….1157
 12.11 PARKING MACHINE…………….1158
 12.12 CHECK AFTER FINISHING WORK…………….1159
 12.13 STOPPING ENGINE…………….1160
 12.14 CHECK AFTER STOPPING ENGINE…………….1161
 12.15 LOCKING…………….1161
 12.16 TIPS FOR LONGER UNDERCARRIAGE LIFE…………….1162
 13. TRANSPORTATION…………….1165
 13.1 LOADING, UNLOADING WORK…………….1165
 13.2 PRECAUTIONS FOR LOADING…………….1166
 13.3 LIFTING MACHINE…………….1167
 13.4 PRECAUTIONS FOR TRANSPORTATION…………….1169
 14. COLD WEATHER OPERATION…………….1170
 14.1 PRECAUTIONS FOR LOW TEMPERATURE…………….1170
 14.2 AFTER COMPLETION OF WORK…………….1172
 14.3 AFTER COLD WEATHER…………….1172
 15. LONG-TERM STORAGE (MORE THAN ONE MONTH)…………….1173
 15.1 BEFORE STORAGE…………….1173
 15.2 DURING STORAGE…………….1173
 15.3 AFTER STORAGE…………….1173
 16. TROUBLESHOOTING…………….1174
 16.1 AFTER RUNNING OUT OF FUEL…………….1174
 16.2 IF BATTERY IS DISCHARGED…………….1174
 16.3 OTHER TROUBLE…………….1178
MAINTENANCE…………….1182
 17. GUIDES TO MAINTENANCE…………….1183
 18. OUTLINES OF SERVICE…………….1185
 18.1 OUTLINE OF OIL, FUEL, COOLANT…………….1185
 18.2 RELATING TO ELECTRIC SYSTEM…………….1187
 19. WEAR PARTS LIST…………….1188
 20.USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…………….1189
 21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…………….1193
 21.1 INTRODUCTION OF NECESSARY TOOLS…………….1193
 21.2 TORQUE LIST…………….1194
 22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…………….1195
 23. MAINTENANCE SCHEDULE CHART…………….1197
 24. SERVICE PROCEDURE…………….1200
 24.1 INITIAL 250 HOURS SERVICE…………….1200
 24.2 WHEN REQUIRED…………….1201
 24.3 CHECK BEFORE STARTING…………….1215
 24.4 EVERY 50 HOURS SERVICE…………….1221
 24.5 EVERY 250 HOURS SERVICE…………….1222
 24.6 EVERY 500 HOURS SERVICE…………….1228
 24.7 EVERY 1000 HOURS SERVICE…………….1232
 24.8 EVERY 2000 HOURS SERVICE…………….1239
 24.9 EVERY 4000 HOURS SERVICE…………….1240
SPECIFICATIONS…………….1242
 25. SPECIFICATIONS…………….1243
OPTIONS, ATTACHMENTS…………….1250
 26. GENERAL PRECAUTIONS…………….1251
 26.1 PRECAUTIONS RELATED TO SAFETY…………….1251
 27. USING SEAT BELT…………….1252
 27.1 SEAT VELT (FOR FIXED TYPE)…………….1252
 27.2 SEAT BELT (FOR SUSPENSION TYPE)…………….1253
 28. HANDLING SUSPENSION SEAT…………….1254
 29. HANDLING DECELERATOR PEDAL…………….1255
SEAM01142001 – Bulldozer D31E,P,PL,PLL-20, D31P-20A, D37E-5, D37P-5A Operation & Maintenance Manual…………….1258
1. FOREWORD …………….1260
2. SAFETY INFORMATION …………….1261
3. INTRODUCTION …………….1262
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR …………….1263
5. CONTENTS …………….1264
SAFETY …………….1266
 6. GENERAL PRECAUTIONS …………….1267
 7. PRECAUTIONS DURING OPERATION …………….1272
 7.1 BEFORE STARTING ENGINE …………….1272
 7.2 OPERATING MACHINE …………….1274
 7.3 TRANSPORTATION …………….1278
 7.4 BATTERY …………….1279
 7.5 TOWING …………….1280
 8. PRECAUTIONS FOR MAINTENANCE …………….1281
 9. POSITION FOR STICKING SAFETY LABELS …………….1286
OPERATION …………….1288
 10. GENERAL VIEW …………….1289
 10.1 GENERAL VIEW OF MACHINE …………….1289
 10.2 GENERAL VIEW OF CONTROLS AND GAUGES …………….1290
 11. EXPLANATION OF COMPONENTS …………….1291
 11.1 METERS AND LAMPS …………….1291
 11.2 SWITCHES …………….1293
 11.3 CONTROL LEVERS AND PEDALS …………….1295
 11.4 FUSE BOX …………….1300
 12. OPERATION …………….1301
 12.1 CHECKS BEFORE STARTING ENGINE …………….1301
 12.2 STARTING ENGINE …………….1311
 12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE …………….1314
 12.4 MOVING MACHINE OFF …………….1315
 12.5 SHIFTING GEAR …………….1316
 12.6 SHIFTING BETWEEN FORWARD AND REVERSE …………….1317
 12.7 STEERING MACHINE …………….1318
 12.8 STOPPING MACHINE …………….1320
 12.9 PRECAUTIONS FOR OPERATION …………….1321
 12.10 WORK POSSIBLE USING BULLDOZER …………….1322
 12.11 PARKING MACHINE …………….1323
 12.12 CHECK AFTER FINISHING WORK …………….1324
 12.13 STOPPING ENGINE …………….1325
 12.14 CHECK AFTER STOPPING ENGINE …………….1326
 12.15 LOCKING …………….1326
 12.16 TIPS FOR LONGER UNDERCARRIAGE LIFE …………….1327
 13. TRANSPORTATION …………….1330
 13.1 LOADING, UNLOADING WORK …………….1330
 13.2 PRECAUTIONS FOR LOADING …………….1331
 13.3 PRECAUTIONS FOR TRANSPORTATION …………….1332
 14. COLD WEATHER OPERATION …………….1333
 14.1 PRECAUTIONS FOR LOW TEMPERATURE …………….1333
 14.2 CAUTIONS AFTER COMPLETION OF WORK …………….1334
 14.3 AFTER COLD WEATHER …………….1335
 15. LONG-TERM STORAGE …………….1336
 15.1 BEFORE STORAGE …………….1336
 15.2 DURING STORAGE …………….1336
 15.3 AFTER STORAGE …………….1337
 16. TROUBLESHOOTING …………….1338
 16.1 AFTER RUNNING OUT OF FUEL …………….1338
 16.2 IF BATTERY IS DISCHARGED …………….1339
 16.3 OTHER TROUBLE …………….1343
MAINTENANCE …………….1346
 17. GUIDES TO MAINTENANCE …………….1347
 18. OUTLINES OF SERVICE …………….1350
 18.1 RELATING TO ENGINE …………….1351
 18.2 RELATING TO HYDRAULIC SYSTEM …………….1353
 18.3 RELATING TO ELECTRIC SYSTEM …………….1354
 18.4 RELATING TO LUBRICATION …………….1355
 19. WEAR PARTS LIST …………….1356
 20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE …………….1357
 21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS …………….1361
 21.1 INTRODUCTION OF NECESSARY TOOLS …………….1361
 21.2 TORQUE LIST …………….1362
 22. PERIODICAL REPLACEMENT OF CRITICAL PARTS …………….1363
 23. MAINTENANCE SCHEDULE CHART …………….1365
 24. SERVICE PROCEDURE…………….1368
 24.1 INITIAL 250 HOURS SERVICE …………….1368
 24.2 WHEN REQUIRED …………….1369
 24.3 CHECK BEFORE STARTING …………….1384
 24.4 EVERY 50 HOURS SERVICE …………….1389
 24.5 EVERY 250 HOURS SERVICE …………….1390
 24.6 EVERY 500 HOURS SERVICE …………….1395
 24.7 EVERY 1000 HOURS SERVICE …………….1400
 24.8 EVERY 2000 HOURS SERVICE …………….1408
 24.9 EVERY 4000 HOURS SERVICE …………….1409
SPECIFICATIONS …………….1410
 25. SPECIFICATIONS …………….1411
OPTIONS, ATTACHMENTS …………….1418
 26. USING SEAT BELT …………….1419
 26.1 SEAT BELT (For fixed type) …………….1419
 26.2 SEAT BELT (For suspension type)…………….1421
 27. HANDLING SUSPENSION SEAT …………….1423
 28. HANDLING DECELERATOR PEDAL …………….1424
 29. GENERAL PRECAUTIONS …………….1425
 29.1 PRECAUTIONS RELATED TO SAFETY …………….1425
SEAM01142004 – Bulldozer D31E,P,PL,PLL-20, D31P-20A, D37E-5, D37P-5A Operation & Maintenance Manual…………….1427
1. FOREWORD …………….1428
2. SAFETY INFORMATION …………….1429
3. INTRODUCTION …………….1430
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR …………….1431
5. CONTENTS …………….1432
SAFETY …………….1436
 6. GENERAL PRECAUTIONS …………….1437
 7. PRECAUTIONS DURING OPERATION …………….1442
 7.1 BEFORE STARTING ENGINE …………….1442
 7.2 OPERATING MACHINE …………….1444
 7.3 TRANSPORTATION …………….1447
 7.4 BATTERY …………….1448
 7.5 TOWING …………….1450
 8. PRECAUTIONS FOR MAINTENANCE …………….1451
 8.1 BEFORE CARRYING OUT MAINTENANCE …………….1451
 8.2 DURING MAINTENANCE …………….1453
 9. POSITION FOR ATTACHING SAFETY LABELS AND STORAGE OF OPERATION & MAINTENANCE MANUAL …………….1458
 9.1 PLACE FOR STORING MANUAL …………….1461
OPERATION…………….1462
 10. GENERAL VIEW …………….1463
 10.1 GENERAL VIEW OF MACHINE …………….1463
 10.2 GENERAL VIEW OF CONTROLS AND GAUGES …………….1464
 11. EXPLANATION OF COMPONENTS …………….1465
 11.1 METERS AND LAMPS …………….1465
 11.2 SWITCHES …………….1467
 11.3 CONTROL LEVERS AND PEDALS …………….1469
 11.4 FUSE BOX …………….1474
 11.5 LOCATION OF FIRE EXTINGUISHER …………….1474
 12. OPERATION …………….1475
 12.1 CHECKS BEFORE STARTING ENGINE …………….1475
 12.2 STARTING ENGINE …………….1485
 12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE …………….1488
 12.4 MOVING MACHINE …………….1489
 12.5 SHIFTING GEAR …………….1490
 12.6 SHIFTING BETWEEN FORWARD AND REVERSE …………….1491
 12.7 STEERING MACHINE …………….1492
 12.8 STOPPING MACHINE …………….1495
 12.9 PRECAUTIONS FOR OPERATION …………….1496
 12.10 WORK POSSIBLE USING BULLDOZER …………….1497
 12.11 PARKING MACHINE …………….1498
 12.12 CHECK AFTER FINISHING WORK …………….1499
 12.13 STOPPING ENGINE …………….1500
 12.14 CHECK AFTER STOPPING ENGINE …………….1501
 12.15 LOCKING …………….1501
 12.16 TIPS FOR LONGER UNDERCARRIAGE LIFE …………….1502
 13. TRANSPORTATION …………….1505
 13.1 LOADING, UNLOADING WORK …………….1505
 13.2 LIFTING MACHINE …………….1506
 13.3 PRECAUTIONS FOR LOADING AND SECURING MAClilNE …………….1509
 13.4 PRECAUTIONS FOR TRANSPORTATION …………….1509
 14. COLD WEATHER OPERATION …………….1510
 14.1 PRECAUTIONS FOR LOW TEMPERATURE …………….1510
 14.2 AFTER COMPLETION OF WORK …………….1511
 14.3 AFTER COLD WEATHER …………….1512
 15. LONG-TERM STORAGE (MORE THAN ONE MONTH) …………….1513
 15.1 BEFORE STORAGE …………….1513
 15.2 DURING STORAGE …………….1513
 15.3 AFTER STORAGE …………….1514
 16. TROUBLESHOOTING …………….1515
 16.1 AFTER RUNNING OUT OF FUEL …………….1515
 16.2 IF BATTERY IS DISCHARGED …………….1516
 16.3 OTHER TROUBLE …………….1520
MAINTENANCE…………….1524
 17. GUIDES TO MAINTENANCE …………….1525
 18. OUTLINES OF SERVICE …………….1528
 18.1 OUTLINE OF OIL, FUEL, COOLANT …………….1528
 18.2 RELATING TO ELECTRIC SYSTEM …………….1531
 19. WEAR PARTS LIST …………….1532
 20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE …………….1533
 21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS …………….1537
 21.1 INTRODUCTION OF NECESSARY TOOLS …………….1537
 21.2 TORQUE LIST …………….1538
 22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS …………….1539
 23. MAINTENANCE SCHEDULE CHART …………….1541
 24. SERVICE PROCEDURE …………….1544
 24.1 INITIAL 250 HOURS SERVICE …………….1544
 24.2 WHEN REQUIRED …………….1545
 24.3 CHECK BEFORE STARTING …………….1560
 24.4 EVERY 50 HOURS SERVICE …………….1565
 24.5 EVERY 250 HOURS SERVICE …………….1566
 24.6 EVERY 500 HOURS SERVICE …………….1571
 24.7 EVERY 1000 HOURS SERVICE …………….1576
 24.8 EVERY 2000 HOURS SERVICE …………….1584
 24.9 EVERY 4000 HOURS SERVICE …………….1585
SPECIFICATIONS …………….1586
 25. SPECIFICATIONS…………….1587
OPTIONS, ATTACHMENTS…………….1594
 26. GENERAL PRECAUTIONS …………….1595
 26.1 PRECAUTIONS RELATED TO SAFETY …………….1595
 27. USING SEAT BELT …………….1597
 27.1 SEAT BELT (For fixed type) …………….1597
 27.2 SEAT BELT (For suspension type)…………….1598
 28. HANDLING SUSPENSION SEAT …………….1600
 29. HANDLING DECELERATOR PEDAL …………….1601
SEAM015400 – Bulldozer D31E,P,PL,PLL-20, D37EX,PX-21, D31P-20A, D37E-5, D37P-5A Operation & Maintenance Manual…………….1603
1. FOREWORD …………….1604
2. SAFETY INFORMATION …………….1605
3. INTRODUCTION …………….1606
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR …………….1607
5. CONTENTS …………….1608
SAFETY …………….1612
 6. GENERAL PRECAUTIONS …………….1613
 7. PRECAUTIONS DURING OPERATION…………….1618
 7.1 BEFORE STARTING ENGINE…………….1618
 7.2 AFTER STARTING ENGINE …………….1620
 7.3 TRANSPORTATION …………….1626
 7.4 BATTERY …………….1627
 7.5 TOWING…………….1629
 8. PRECAUTIONS FOR MAINTENANCE …………….1630
 8.1 BEFORE CARRYING OUT MAINTENANCE …………….1630
 8.2 DURING MAINTENANCE…………….1635
 9. POSITION FOR ATTACHING SAFETY LABELS …………….1640
OPERATION …………….1642
 10. GENERAL VIEW …………….1643
 10.1 GENERAL VIEW OF MACHINE …………….1643
 10.2 GENERAL VIEW OF CONTROLS AND GAUGES …………….1644
 11. EXPLANATION OF COMPONENTS …………….1645
 11.1 METERS AND LAMPS …………….1645
 11.2 SWITCHES …………….1647
 11.3 CONTROL LEVERS AND PEDALS …………….1649
 11.4 FUSE BOX …………….1654
 11.5 LOCATION OF FIRE EXTINGUISHER …………….1654
 11.6 ELECTRIC POWER TAKE-OUT ADAPTER …………….1655
 11.7 MANUAL POCKET …………….1655
 12. OPERATION …………….1656
 12.1 CHECK BEFORE STARTING ENGINE …………….1656
 12.2 STARTING ENGINE …………….1667
 12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE …………….1670
 12.4 MOVING MACHINE …………….1671
 12.5 SHIFTING GEAR …………….1672
 12.6 SHIFTING BETWEEN FORWARD AND …………….1673
 12.7 STEERING MACHINE…………….1674
 12.8 STOPPING MACHINE …………….1677
 12.9 PRECAUTIONS FOR OPERATION …………….1678
 12.10 WORK POSSIBLE USING BULLDOZER …………….1679
 12.11 PARKING MACHINE …………….1680
 12.12 CHECK AFTER FINISHING WORK …………….1681
 12.13 STOPPING ENGINE …………….1682
 12.14 CHECK AFTER STOPPING ENGINE …………….1683
 12.15 LOCKING …………….1683
 12.16 TIPS FOR LONGER UNDERCARRIAGE LIFE …………….1684
 13. TRANSPORTATION …………….1687
 13.1 LOADING, UNLOADING WORK …………….1687
 13.2 PRECAUTIONS FOR LOADING …………….1688
 13.3 LIFTING MACHINE …………….1689
 13.4 PRECAUTIONS FOR TRANSPORTATION …………….1691
 14. COLD WEATHER OPERATION …………….1692
 14.1 PRECAUTIONS FOR LOW TEMPERATURE …………….1692
 14.2 AFTER COMPLETION OF WORK …………….1694
 14.3 AFTER COLD WEATHER …………….1694
 15. LONG-TERM STORAGE (MORE THAN ONE MONTH) …………….1695
 15.1 BEFORE STORAGE …………….1695
 15.2 DURING STORAGE …………….1695
 15.3 AFTER STORAGE …………….1695
 16. TROUBLESHOOTING …………….1696
 16.1 AFTER RUNNING OUT OF FUEL …………….1696
 16.2 IF BATTERY IS DISCHARGED …………….1696
 16.3 OTHER TROUBLE …………….1700
MAINTENANCE …………….1704
 17. GUIDES TO MAINTENANCE …………….1705
 18. OUTLINES OF SERVICE …………….1707
 18.1 OUTLINE OF OIL, FUEL, COOLANT …………….1707
 18.2 RELATING TO ELECTRIC SYSTEM …………….1709
 19. WEAR PARTS LIST …………….1710
 20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE …………….1711
 21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…………….1715
 21.1 INTRODUCTION OF NECESSARY TOOLS …………….1715
 21.2 TORQUE LIST …………….1716
 22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS …………….1717
 23. MAINTENANCE SCHEDULE CHART …………….1719
 24. SERVICE PROCEDURE …………….1722
 24.1 INITIAL 250 HOURS SERVICE …………….1722
 24.2 WHEN REQUIRED …………….1723
 24.3 CHECK BEFORE STARTING …………….1737
 24.4 EVERY 50 HOURS SERVICE …………….1743
 24.5 EVERY 250 HOURS SERVICE …………….1744
 24.6 EVERY 500 HOURS SERVICE …………….1750
 24.7 EVERY 1000 HOURS SERVICE …………….1754
 24.8 EVERY 2000 HOURS SERVICE …………….1761
 24.9 EVERY 4000 HOURS SERVICE …………….1762
SPECIFICATIONS …………….1764
 25. SPECIFICATIONS …………….1765
OPTIONS, ATTACHMENTS …………….1772
 26. GENERAL PRECAUTIONS…………….1773
 26.1 PRECAUTIONS RELATED TO SAFETY …………….1773
 27. USING SEAT BELT …………….1774
 27.1 SEAT BELT (For fixed type) …………….1774
 27.2 SEAT BELT (For suspension type) …………….1775
 28. HANDLING SUSPENSION SEAT …………….1776
 29. HANDLING DECELERATOR PEDAL …………….1777
SEAM040200 – Bulldozer D39EX-21, D39PX-21 Operation & Maintenance Manual…………….1779
COVER…………….1779
FOREWORD…………….1780
 FOREWORD…………….1781
 SAFETY INFORMATION…………….1784
 INTRODUCTION…………….1786
 FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE…………….1786
 NECESSARY INFORMATION…………….1787
 MACHINE SERIAL NO. PLATE AND POSITION…………….1787
 ENGINE SERIAL NO. PLATE AND POSITION…………….1787
 EMISSION CONTROL INFORMAITON LABEL AND POSITION…………….1788
 POSITION OF SERVICE METER…………….1788
 TABLE TO ENTER SERIAL NO. AND DISTRIBUTION…………….1789
 CONTENTS…………….1790
SAFETY…………….1794
 SAFETY…………….1795
 SAFETY LABELS…………….1797
 POSITIONS OF SAFETY PICTOGRAMS…………….1797
 SAFETY LABELS…………….1798
 GENERAL PRECAUTIONS…………….1801
 SAFETY RULES…………….1801
 IF ABNORMALITY ARE FOUND …………….1801
 CLOTHING AND PERSONAL PROTECTIVE ITEMS…………….1801
 FIRE EXTINGUISHER AND FIRST AID KIT…………….1801
 SAFETY FEATURES…………….1801
 KEEP MACHINE CLEAN…………….1802
 INSIDE OPERATOR'S COMPARTMENT…………….1802
 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT…………….1802
 HANDRAILS AND STEPS…………….1803
 MOUNTING AND DISMOUNTING…………….1803
 NO PEOPLE ON ATTACHMENTS…………….1803
 CRUSHING OR CUTTING PREVENTION…………….1803
 PREVENTION OF BURNS…………….1804
 FIRE PREVENTION…………….1804
 ACTION IF FIRE OCCURS…………….1805
 WINDOW WASHER LIQUID…………….1805
 PRECAUTIONS WHEN USING ROPS…………….1805
 PRECAUTIONS FOR ATTACHMENTS…………….1805
 UNAUTHORIZED MODIFICATION…………….1806
 SAFETY AT WORKSITE…………….1806
 WORKING ON LOOSE GROUND…………….1806
 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES…………….1807
 ENSURE GOOD VISIBILITY…………….1807
 VENTILATION FOR ENCLOSED AREA…………….1807
 CHECKING SIGNALMAN'S SIGNALS AND SIGNS…………….1807
 EMERGENCY EXIT FROM OPERATOR'S CAB…………….1808
 BE CAREFUL ABOUT ASBESTOS DUST…………….1808
 PRECAUTIONS FOR OPERATIONS…………….1809
 STARTING ENGINE…………….1809
 CHECKS BEFORE STARTING ENGINE…………….1809
 PRECAUTIONS WHEN STARTING…………….1809
 PRECAUTIONS IN COLD AREAS…………….1810
 OPERATION…………….1811
 CHECKS BEFORE OPERATION…………….1811
 PRECAUTIONS FOR MOVING MACHINE FORWARD OR IN REVERSE…………….1811
 PRECAUTIONS WHEN TRAVELING…………….1812
 TRAVELING ON SLOPES…………….1812
 OPERATE CAREFULLY ON SNOW…………….1813
 PARKING MACHINE…………….1814
 TRANSPORTATION…………….1815
 LOADING AND UNLOADING…………….1815
 SHIPPING…………….1815
 BATTERY…………….1816
 BATTERY HAZARD PREVENTION…………….1816
 STARTING WITH BOOSTER CABLE…………….1817
 TOWING…………….1818
 WHEN TOWING…………….1818
 PRECAUTIONS FOR MAINTENANCE…………….1819
 WARNING TAG…………….1819
 KEEP WORK PLACE CLEAN AND TIDY…………….1819
 APPOINT LEADER WHN WORKING WITH OTHERS…………….1819
 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE…………….1819
 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…………….1820
 PROPER TOOLS…………….1821
 NO UNAUTHORIZED PERSONNEDL INTO AREA…………….1821
 ATTACHMENTS…………….1821
 WORK UNDER THE MACINE…………….1821
 NOISE…………….1821
 PRECAUTIONS WHEN USING HAMMER…………….1822
 REPAIR WELDING…………….1822
 REMOVING BATTERY TERMINAL…………….1822
 PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…………….1822
 DO NOT DISASSEMBLE RECOIL SPRING…………….1822
 PRECAUTION WITH HIGH-PRESSURE OIL…………….1823
 HANDLING HIGH-PRESSURE HOSES…………….1823
 WASTE MATERIAL…………….1823
 MAINTENANCE FOR AIR CONDITIONER…………….1823
 COMPRESSED AIR…………….1824
 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…………….1824
OPERATION…………….1826
 GENERAL VIEW…………….1827
 GENERAL VIEW OF MACHINE…………….1827
 GENERAL VIEW OF CONTROLS AND GAUGES…………….1828
 EXPLANATION OF COMPONENTS…………….1829
 MONITOR PANEL…………….1829
 SWITCHES…………….1832
 CONTROL LEVERS AND PEDALS…………….1836
 FUSE…………….1842
 ELECTRIC POWER TAKE-OUT ADAPTER…………….1843
 DOOR-OPEN LOCK…………….1844
 SASH GLASS INTERMEDIATE LOCK…………….1844
 CAP, COVER WITH LOCK…………….1845
 DOOR POCKET…………….1846
 ASHTRAY…………….1847
 LUNCHBOX HOLDER BELT…………….1847
 CUP HOLDER…………….1847
 TOOL BOX…………….1848
 GREASE PUMP HOLDER…………….1848
 CAR STEREO, HANDLING…………….1849
 AIR CONDITIONER, HANDLING…………….1854
 OPERATION…………….1859
 CHECK BEFORE STARTING ENGINE, ADJUST…………….1859
 STARTING ENGINE…………….1876
 OPERATIONS AND CHECKS AFTER STARTING ENGINE…………….1879
 STOPPING ENGINE…………….1881
 CHECK AFTER STOPPING ENGINE…………….1881
 MACHINE OPERATION…………….1882
 STOPPING MACHINE…………….1884
 SHIFTING GEAR…………….1886
 SHIFTING BETWEEN FORWARD AND REVERSE…………….1887
 STEERING MACHINE…………….1888
 PRECAUTIONS FOR OPERATION…………….1890
 WORK POSSIBLE USING BULLDOZER…………….1892
 PARKING MACHINE…………….1894
 CHECK AFTER FINISHING WORK…………….1896
 LOCKING…………….1896
 TIPS FOR LONGER UNDERCARRIAGE LIFE…………….1897
 TRANSPORATION…………….1900
 TRANSPORATION MEANS…………….1900
 REMOVING CAB…………….1900
 PRECAUTIONS WHEN REMOVING WORK EQUIPMENT…………….1900
 LOADING, UNLOADING WORK…………….1901
 LIFTING MACHINE…………….1905
 COLD WEATHER OPERATION…………….1906
 PRECAUTIONS FOR LOW TEMPERATURE…………….1906
 AFTER COMPLETION OF WORK…………….1908
 AFTER COLD WEATHER…………….1908
 LONG-TERM STORAGE…………….1909
 BEFORE STORAGE…………….1909
 DURING STORAGE…………….1909
 AFTER STORAGE…………….1909
 TROUBLESHOOTING…………….1910
 AFTER RUNNING OUT OF FUEL…………….1910
 MACHINE TOWING METHOD…………….1910
 IF BATTERY IS DISCHARGED…………….1916
 WHEN ENGINE DOES NOT STOP…………….1919
 OTHER TROUBLE…………….1920
MAINTENANCE…………….1924
 GUIDE TO MAINTENANCE…………….1925
 OUTLINE OF SERVICE…………….1928
 OUTLINE OF OIL, FUEL, COOLANT…………….1928
 RELATING TO ELECTRIC SYSTEM…………….1931
 WEAR PARTS LIST…………….1932
 WEAR PARTS LIST…………….1932
 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…………….1933
 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS…………….1933
 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…………….1937
 TROQUE LIST…………….1937
 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…………….1938
 SAFETY CRITICAL PARTS…………….1939
 MAINTENANCE SCHEDULE CHART…………….1940
 MAINTENANCE SCHEDULE CHART…………….1940
 SERVICE PROCEDURE…………….1942
 WHEN REQUIRED…………….1942
 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…………….1942
 CLEAN INSIDE OF COOLING SYSTEM…………….1945
 CHECK TRACK TENSION…………….1947
 CHECK AND TIGHTEN TRACK SHOE BOLTS…………….1949
 CHECK ELECTRICAL INTAKE AIR HEATER…………….1949
 REVERSE AND REPLACE END BITS AND CUTTING EDGES…………….1950
 ADJUST IDLER CLEARANCE…………….1951
 CHECK, ADJUST AIR CONDITIONER…………….1952
 GREASE DOOR HINGE …………….1953
 CHECK DOOR LOCK STRIKER…………….1953
 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…………….1954
 REPLACE WIPER BLADE…………….1955
 CHECK IDLER OIL LEVEL, ADD OIL…………….1956
 ADJUST PLAY IN CENTER BALL…………….1957
 PROCEDURE FOR BLEEDING AIR IN HYDRAULIC SYSTEM…………….1958
 PROCEDURE FOR RELEASING INTERNAL PRESSURE OF HYDRAULIC SYSTEM…………….1959
 CHECK BEFORE STARTING…………….1960
 EVERY 50 HOURS SERVICE…………….1961
 DRAIN WATER, SEDIMENT FROM FUEL TANK…………….1961
 EVERY 250 HOURS SERVICE…………….1962
 LUBRICATING…………….1962
 CHECK OIL LEVEL IN FINAL DRIVE CASE , ADD OIL…………….1963
 CHECK LEVEL OF BATTERY ELECTROLYTE…………….1964
 CHECK BRAKE PERFORMANCE…………….1965
 CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)…………….1966
 EVERY 500 HOURS SERVICE…………….1967
 REPLACE FUEL FILTER CARTRIDGE…………….1967
 CHANGE OIL IN ENGINE OIL PAN, RPLACE ENGINE OIL FILTER CARTRIDGE…………….1970
 REPLACE CORROSION RESISTOR CARTRIDGE…………….1971
 CHECK, CLEAN RADIATOR FINS…………….1971
 EVERY 1000 HOURS SERVICE…………….1972
 CHANGE OIL IN FINAL DRIVE CASE…………….1972
 CHECK FAN BELT TENSION, ADJUST…………….1972
 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…………….1972
 CHECK PLAY OF TURBOCHARGER ROTOR…………….1972
 CHECK FOR LOOSE ROPS MOUNT BOLTS…………….1973
 EVERY 2000 HOURS SERVICE…………….1974
 CHANGE OIL IN HYDRAULIC TANK, REPLACE OIL FILTER CARTRIDGE AND CLEAN SUCTION STRAINER…………….1974
 CLEAN, CHECK TURBOCHARGER…………….1975
 CHECK VIBRATION DAMPER…………….1975
 CHECK ALTERNATOR, STARTING MOTOR…………….1975
 CHECK ENGINE VALVE CLEARANCE, ADJUST…………….1975
 EVERY 4000 HOURS SERVICE…………….1976
 CHECK WATER PUMP…………….1976
SPECIFICATIONS…………….1978
 SPECIFICATIONS…………….1979
ATTACHMENTS, OPTIONS…………….1980
 GENERAL PRECAUTIONS…………….1981
 PRECAUTIONS RELATED TO SAFETY…………….1981
 SUSPENSION SEAT…………….1982
 HEADREST…………….1983
 EQUIPPING FIRE EXTINGUISHER AND FIRST AID KIT…………….1984
INDEX…………….1986
SEAM040203T – Bulldozer GALEO D39EX-21, D39PX-21 Operation & Maintenance Manual…………….1990
COVER…………….1990
FOREWORD…………….1991
 FOREWORD…………….1992
 SAFETY INFORMATION…………….1995
 INTRODUCTION…………….1997
 FRONT/REAR,LEFT/RIGHT DIRECTIONS OF MACHINE…………….1997
 NECESSARY INFORMATION…………….1998
 MACHINE SERIAL NO.PLATE AND POSITION…………….1998
 ENGINE SERIAL NO.PLATE AND POSITION…………….1998
 EMISSION CONTROL INFORMATION LABEL AND POSITION…………….1999
 POSITION OF SERVICE METER…………….1999
 TABLE OF ENTER SERIAL NO.AND DISTRIBUTORN…………….2000
CONTENTS…………….2001
SAFETY…………….2004
 SAFETY…………….2005
 SAFETY LABELS…………….2007
 POSITIONS OF SAFETY PICTOGRAMS…………….2007
 GENERAL PRECAUTIONS…………….2011
 SAFETY RULES…………….2011
 IF ABNORMALITIES ARE FOUND…………….2011
 CLOTHING AND PERSONAL PROTECTIVE ITEMS…………….2011
 FIRE EXTINGUISHER AND FIRST AID KIT…………….2011
 SAFETY FEATURES…………….2011
 KEEP MACHINE CLEAN…………….2012
 INSIDE OPERATOR'S COMPARTMENT…………….2012
 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT…………….2012
 HANDRAILS AND STEPS…………….2013
 MOUNTING AND DISMOUNTING …………….2013
 NO PEOPLE ON ATTACHMENTS…………….2013
 CRUSHING OR CUTTING PREVENTION…………….2013
 PREVENTION OF BURNS…………….2014
 FIRE PREVENTION…………….2014
 ACTION IF FIRE OCCURS…………….2015
 WINDOW WASHER LIQUID…………….2015
 PRECAUTIONS WHEN USING ROPS…………….2015
 PRECAUTIONS FOR ATTACHMENTS…………….2015
 UNAUTHORIZED MODIFICATION…………….2016
 SAFETY AT WORKSITE…………….2016
 WORKING ON LOOSE GROUND…………….2016
 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES…………….2016
 ENSURE GOOD VISIBILITY…………….2018
 VENTILATION FOR ENCLOSED AREAS…………….2018
 CHECKING SIGNALMAN'S SIGNALS AND SIGNS…………….2018
 EMERGENCY EXIT FROM OPERATOR'S CAB…………….2018
 BE CAREFUL ABOUT ASBESTOS DUST…………….2018
 PRECAUTIONS FOR OPERATION…………….2019
 STARTING ENGINE…………….2019
 CHECKS BEFORE STARING ENGINE…………….2019
 PRECAUTIONS WHEN STARTING…………….2019
 PRECAUTIONS IN COLD AREAS…………….2019
 OPERATION…………….2021
 CHECKS BEFORE OPERATION…………….2021
 PRECAUTIONS FOR MOVING MACHINE FORWARD OR IN REVERSE…………….2021
 PRECAUTIONS WHEN TRAVELING…………….2022
 TRAVELING ON SLOPES…………….2022
 OPERATE CAREFULLY ON SNOW…………….2024
 PARKING MACHINE…………….2024
 TRANSPORTATION…………….2025
 LOADING AND UNLOADING…………….2025
 SHIPPING…………….2025
 BATTERY…………….2026
 BATTERY HAZARD PREVENTION…………….2026
 STARTING WITH BOOSTER CABLE…………….2027
 TOWING…………….2028
 WHEN TOWING…………….2028
 PRECAUTIONS FOR MAINTENANCE…………….2029
 WARNING TAG…………….2029
 KEEP WORK PLACE CLEAN AND TIDY…………….2029
 APPOINT LEADER WHEN WORKING WITH OTHERS…………….2029
 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE…………….2029
 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…………….2030
 PROPER TOOLS…………….2031
 NO UNAUTHORIZED PERSONNEL INTO AREA…………….2031
 ATTACHMENTS…………….2031
 WORK UNDER THE MACHINE…………….2031
 NOISE…………….2031
 PRECAUTIONS WHEN USING HAMMER…………….2032
 REPAIR WELDING…………….2032
 REMOVING BATTERY TERMINAL…………….2032
 PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…………….2032
 DO NOT DISASSEMBLE RECOIL SPRING…………….2032
 PRECAUTION WITH HIGH-PRESSURE OIL…………….2033
 HANDLING HIGH-PRESSURE HOSES…………….2033
 WASTE MATERIAL…………….2033
 MAINTENANCE OF AIR CONDITIONER…………….2033
 COMPRESSED AIR…………….2034
 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…………….2034
OPERATION…………….2035
 GENERAL VIEW…………….2036
 GENERAL VIEW OF MACHINE…………….2036
 GENERAL VIEW OF CONTROLS AND GAUGES…………….2037
 EXPLANATION OF COMPONENTS…………….2038
 MONITOR PANEL…………….2038
 SWITCHES…………….2041
 CONTROL LEVERS AND PEDALS…………….2045
 FUSE…………….2051
 ELECTRIC POWER TAKE-OUT ADAPTER…………….2052
 DOOR-OPEN LOCK…………….2053
 SASH GLASS INTERMEDIATE LOCK…………….2053
 CAP,COVER WITH LOCK…………….2054
 DOOR POCKET…………….2055
 ASHTRAY…………….2056
 LUNCHBOX HOLDER BELT…………….2056
 CUP HOLDER…………….2056
 TOOL BOX…………….2057
 GREASE PUMP HOLDER…………….2057
 CAR STEREO,HANDLING…………….2058
 AIR CONDITIONER,HANDLING…………….2066
 OPERATION…………….2070
 CHECK BEFORE STARTING ENGINE,ADJUST…………….2070
 STARTING ENGINE…………….2087
 OPERATIONS AND CHECKS AFTER STARTING ENGINE…………….2090
 STOPPING ENGINE…………….2093
 CHECK AFTER STOPPING ENGINE…………….2093
 MACHINE OPERATION…………….2094
 SHIFTING GEAR…………….2098
 SHIFTING BETWEEN FORWARD AND REVERSE…………….2099
 STEERING MACHINE…………….2100
 PRECAUTIONS FOR OPERATION…………….2103
 WORK POSSIBLE USING BULLDOZER…………….2105
 PARKING MACHINE…………….2107
 CHECK AFTER FINISHING WORK…………….2109
 LOCKING…………….2109
 TIPS FOR LONGER UNDERCARRIAGE LIFE…………….2110
 TRANSPORTATION…………….2113
 TRANSPORTATION MEANS…………….2113
 PRECAUTIONS WHEN REMOVING WORK EQUIPMENT…………….2113
 REMOVING CAB…………….2113
 LOADING,UNLOADING WORK…………….2114
 LIFTING MACHINE…………….2117
 COLD WEATHER OPERATION…………….2118
 PRECAUTIONS FOR LOW TEMPERATURE…………….2118
 AFTER COMPLETION OF WORK…………….2120
 AFTER COLD WEATHER…………….2120
 LONG-TERM STORAGE…………….2121
 BEFORE STORAGE…………….2121
 DURING STORAGE…………….2121
 AFTER STORAGE…………….2121
 TROUBLESHOOTING…………….2122
 AFTER RUNNING OUT OF FUEL…………….2122
 MACHINE TOWING METHOD…………….2122
 IF BATTERY IS DISCHARGED…………….2127
 WHEN ENGINE DOES NOT STOP…………….2131
 OTHER TROUBLE…………….2132
MAINTENANCE…………….2136
 GUIDE TO MAINTENANCE…………….2137
 OUTLINE OF SERVICE…………….2140
 OUTLINE OF OIL,FUEL,COOLANT…………….2140
 RELATING TO ELECTRIC SYSTEM…………….2142
 WEAR PARTS LIST…………….2143
 WEAR PARTS LIST…………….2143
 USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…………….2144
 PROPER SELECTION OF FUEL,COOLANT AND LUBRICANTS…………….2144
 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…………….2148
 TORQUE LIST…………….2148
 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…………….2149
 SAFETY CRITICAL PARTS…………….2150
 MAINTENANCE SCHEDULE CHART…………….2151
 MAINTENANCE SCHEDULE CHART…………….2151
 SERVICE PROCEDURE…………….2153
 WHEN REQUIRED…………….2153
 CHECK,CLEAN AND REPLACE AIR CLEANER ELEMENT…………….2153
 CLEAN INSIDE OF COOLING SYSTEM…………….2156
 CHECK TRACK TENSION…………….2158
 CHECK AND TIGHTEN TRACK SHOE BELT…………….2160
 CHECK ELECTRICAL INTAKE AIR HEATER…………….2160
 REVERSE AND REPLACE END BITS AND CUTTING EDGES…………….2161
 CHECK IDLER OIL LEVEL,ADD OIL…………….2162
 ADJUST IDLER CLEARANCE…………….2163
 ADJUST PLAY IN CENTER BALL…………….2163
 GREASE DOOR HINGE…………….2164
 CHECK DOOR LOCK STRIKER…………….2164
 CHECK,ADJUST AIR CONDITIONER…………….2165
 CHECK WINDOW WASHER FLUID LEVEL,ADD FLUID…………….2166
 REPLACE WIPER BLADE…………….2166
 PROCEDURE FOR BLEEDING AIR IN HYDRAULIC SYSTEM…………….2168
 PROCEDURE FOR RELEASING INTERNAL PRESSURE OF HYDRAULIC SYSTEM…………….2169
 CHECK BEFORE STARTING…………….2170
 EVERY 50 HOURS SERVICE…………….2171
 DRAIN WATER,SEDIMENT FROM FUEL TANK…………….2171
 EVERY 250 HOURS SERVICE…………….2172
 LUBRICATING…………….2172
 CHECK OIL LEVEL IN FINAL DRIVE CASE,ADD OIL…………….2173
 CHECK LEVEL OF BATTRY ELECTROLYTE…………….2174
 CHECK BRAKE PERFORMANCE…………….2176
 CLEAN AIR CONDITIONER AIE FILTER(FRESH/RECIRC FILTER)…………….2177
 EVERY 500 HOURS SERVICE…………….2178
 REPLACE FUEL FILTER CARTRIDGE…………….2178
 CHANGE OIL ENGINE OIL PAN,REPLACE ENGINE OIL FILTER CARTRIDGE…………….2181
 REPLACE CORROSION RESISTER CARTRIDGE…………….2183
 CLEAN,CHECK RADIATOR FINS AND OIL COOLER FINS…………….2183
 EVERY 1000 HOURS SERVICE…………….2185
 CHANGE OIL IN FINAL DRIVE CASE…………….2185
 CHECK FAN BELT TENSION,ADJUST…………….2186
 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…………….2186
 CHECK PLAY OF TURBOCHARGER ROTOR…………….2186
 CHECK FOR LOOSE ROPS MOUNT BOLTS…………….2186
 EVERY 2000 HOURS SERVICE…………….2187
 CHANGE OIL IN HYDRAULIC TANK,REPLACE OIL FILTER CARTRIDGE AND CLEAN SUCTION STRAINER…………….2187
 CLEAN,CHECK TURBOCHARGER…………….2188
 CHECK VIBRATION DAMPER…………….2188
 CHECK ALTERNATOR,STARTING MOTOR…………….2188
 CHECK ENGINE VALVE CLEARANCE,ADJUST…………….2188
 EVERY 4000 HOURS SERVICE…………….2189
 CHECK WATER PUMP…………….2189
SPECIFICATIONS…………….2190
 SPECIFICATIONS…………….2191
ATTACHMENTS,OPTIONS…………….2192
 GENERAL PRECAUTIONS…………….2193
 PRECAUTIONS RELATED TO SAFETY…………….2193
 DELUXE SEAT…………….2194
 HEADREST…………….2195
 EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT…………….2196
INDEX…………….2197
SEAM044001T – Bulldozer GALEO D31EX-21, D31PX-21, D37EX-21, D37PX-21 Operation & Maintenance Manual…………….2200
COVER…………….2200
FOREWORD…………….2201
 FOREWORD…………….2202
 SAFETY INFORMATION…………….2205
 INTRODUCTION…………….2207
 FRONT/REAR,LEFT/RIGHT DIRECTIONS OF MACHINE…………….2207
 NECESSARY INFORMATION…………….2208
 MACHINE SERIAL NO.PLATE AND POSITION…………….2208
 ENGINE SERIAL NO.PLATE AND POSITION…………….2208
 EMISSION CONTROL INFORMATION LABEL AND POSITION…………….2209
 POSITION OF SERVICE METER…………….2209
 TABLE OF ENTER SERIAL NO.AND DISTRIBUTORN…………….2210
CONTENTS…………….2211
SAFETY…………….2214
 SAFETY…………….2215
 SAFETY LABELS…………….2217
 POSITION OF SAFETY PICTOGRAMS…………….2217
 SAFETY LABELS…………….2218
 GENERAL PRECAUTIONS…………….2221
 SAFETY RULES…………….2221
 IF ABNORMALITIES ARE FOUND…………….2221
 CLOTHING AND PERSONAL PROTECTIVE ITEMS…………….2221
 FIRE EXTINGUISHER AND FIRST AID KIT…………….2221
 SAFETY FEATURES…………….2221
 KEEP MACHINE CLEAN…………….2222
 INSIDE OPERATOR'S COMPARTMENT…………….2222
 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT…………….2222
 HANDRAILS AND STEPS…………….2223
 MOUNTING AND DISMOUNTING …………….2224
 NO PEOPLE ON ATTACHMENTS…………….2224
 CRUSHING OR CUTTING PREVENTION…………….2224
 PREVENTION OF BURNS…………….2224
 FIRE PREVENTION…………….2225
 ACTION IF FIRE OCCURS…………….2226
 WINDOW WASHER LIQUID…………….2226
 PRECAUTIONS WHEN USING ROPS…………….2226
 PRECAUTIONS FOR ATTACHMENTS…………….2226
 UNAUTHORIZED MODIFICATION…………….2226
 SAFETY AT WORKSITE…………….2227
 WORKING ON LOOSE GROUND…………….2227
 DO NOT GO CLOSE TO HIGHT-VOLTAGE CABLES…………….2227
 ENSURE GOOD VISIBILITY…………….2228
 VENTILATION FOR ENCLOSED ARESA…………….2228
 CHECKING SIGNALMAN'S SIGNALS AND SIGNS…………….2228
 EMERGENCY EXIT FROM OPERATOR'S CAB…………….2228
 BE CAREFUL ABOUT ASBESTOS DUST…………….2228
 PRECAUTIONS FOR OPERATION…………….2229
 STARTING ENGINE…………….2229
 CHECKS BEFORE STARING ENGINE…………….2229
 PRECAUTIONS WHEN STARTING…………….2229
 PRECAUTIONS IN COLD AREAS…………….2230
 OPERATION…………….2231
 CHECKS BEFORE OPERATION…………….2231
 PRECAUTIONS FOR MOVING MACHINE FORWARD OR IN REVERSE…………….2231
 PRECAUTIONS WHEN TRAVELING…………….2232
 TRAVELING ON SLOPES…………….2232
 OPERATE CAREFULLY ON SNOW…………….2233
 PARKING MACHINE…………….2234
 TRANSPORTATION…………….2235
 LOADING AND UNLOADING…………….2235
 SHIPPING…………….2235
 BATTERY…………….2236
 BATTERY HAZARD PREVENTION…………….2236
 STARTING WITH BOOSTER CABLES…………….2237
 TOWING…………….2238
 WHEN TOWING…………….2238
 PRECAUTIONS FOR MAINTENANCE…………….2239
 WARNING TAG…………….2239
 KEEP WORK PLACE CLEAN AND TIDY…………….2239
 APPOINT LEADER WHEN WORKING WITH OTHERS…………….2239
 STOP ENGINE BEFORE CARRIYING OUT INSPECTION AND MAINTENANCE…………….2239
 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…………….2240
 PROPER TOOLS…………….2241
 NO UNAUTHORIZED PERSONNEL INTO AREA…………….2241
 ATTACHMENTS…………….2241
 WORK UNDER THE MACHINE…………….2241
 NOISE…………….2241
 PRECAUTIONS WHEN USING HAMMER…………….2242
 REPAIR WELDING…………….2242
 REMOVING BATTERY TERMINAL…………….2242
 PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…………….2242
 DO NOT DISASSEMBLE RECOIL SPRING…………….2242
 PRECAUTIONS WITH HIGH-PRESSURE OIL…………….2243
 HANDLING HIGH-PRESSURE HOSES…………….2243
 WASTE MATERIAL…………….2243
 MAINTENANCE OF AIR CONDITIONER…………….2243
 COMPRESSED AIR…………….2244
 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…………….2244
OPERATION…………….2245
 GENERAL VIEW…………….2246
 GENERAL VIEW OF MACHINE…………….2246
 GENERAL VIEW OF CONTROLS AND GAUGES…………….2247
 EXPLANATION OF COMPONENTS…………….2248
 MONITOR PANEL…………….2248
 SWITCHS…………….2251
 CONTROL LEVERS AND PEDALS…………….2255
 FUSE…………….2261
 ELECTRIC POWER TAKE-OUT ADAPTER…………….2262
 DOOR-OPEN LOCK…………….2263
 SASH GLASS INTERMEDIATE LOCK…………….2263
 CAP,COVER WITH LOCK…………….2264
 DOOR POCKET…………….2265
 ASHTRAY…………….2266
 LUNCHBOX HOLDER BELT…………….2266
 CUP HOLDER…………….2266
 TOOL BOX…………….2267
 GREASE PUMP HOLDER…………….2267
 CAR STEREO,HANDLING…………….2268
 AIR CONDITIONER,HANDLING…………….2276
 OPERATION…………….2280
 CHECK BEFORE STARTING ENGINE,ADJUST…………….2280
 STARTING ENGINE…………….2297
 OPERATIONS AND CHECKS AFTER STARTING ENGINE…………….2300
 STOPPING ENGINE…………….2303
 CHECK AFTER STOPPING ENGINE…………….2303
 MACHINE OPERATION…………….2304
 SHIFTING GEAR…………….2308
 SHIFTING BETWEEN FORWARD AND REVERSE…………….2309
 STEERING MACHINE…………….2310
 PRECAUTIONS FOR OPERATION…………….2312
 WORK POSSIBLE USING BULLDOZER…………….2314
 PARKING MACHINE…………….2316
 CHECK AFTER FINISHING WORK…………….2318
 LOCKING…………….2318
 TIPS FOR LONGER UNDERCARRIAGE LIFE…………….2319
 TRANSPORTATION…………….2322
 TRANSPORTATION MEANS…………….2322
 PRECAUTIONS WHEN REMOVING WORK EQUIPMENT…………….2322
 REMOVING CAB…………….2322
 LOADING,UNLOADING WORK…………….2323
 LIFTING MACHINE…………….2326
 COLD WEATHER OPERATION…………….2327
 PRECAUTIONS FOR LOW TEMPERATURE…………….2327
 AFTER COMPLETION OF WORK…………….2329
 AFTER COLD WEATHER…………….2329
 LONG-TERM STORAGE…………….2330
 BEFORE STORAGE…………….2330
 DURING STORAGE…………….2330
 AFTER STORAGE…………….2330
 TROUBLESHOOTING…………….2331
 AFTER RUNNING OUT OF FUEL…………….2331
 MACHINE TOWING METHOD…………….2331
 IF BATTERY IS DISCHARGED…………….2336
 WHEN ENGINE DOES NOT STOP…………….2339
 OTHER TROUBLE…………….2340
MAINTENANCE…………….2344
 GUIDES TO MAINTENANCE…………….2345
 OUTLINES OF SERVICE…………….2348
 OUTLINE OF OIL,FUEL,COOLANT…………….2348
 RELATING TO ELECTRIC SYSTEM…………….2350
 WEAR PARTS LIST…………….2351
 WEAR PARTS LIST…………….2351
 USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…………….2352
 PROPER SELECTION OF FUEL,COOLANT AND LUBRICANTS…………….2352
 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…………….2356
 TORQUE LIST…………….2356
 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…………….2357
 SAFETY CRITICAL PARTS…………….2358
 MAINTENANCE SCHEDULE CHART…………….2359
 MAINTENANCE SCHEDULE CHART…………….2359
 SERVICE PROCEDURE…………….2361
 WHEN REQUIRED…………….2361
 CHECK,CLEAN AND REPLACE AIR CLEANER ELEMENT…………….2361
 CLEAN INSIDE OF COOLING SYSTEM…………….2364
 CHECK TRACK TENSION…………….2366
 CHECK AND TIGHTEN TRACK SHOE BELT…………….2368
 CHECK ELECTRICAL INTAKE AIR HEATER…………….2368
 REVERSE AND REPLACE END BITS AND CUTTING EDGES…………….2369
 CHECK IDLER OIL LEVEL,ADD OIL…………….2370
 ADJUST IDLER CLEARANCE…………….2370
 ADJUST PLAY IN CENTER BALL…………….2371
 GREASE DOOR HINGE…………….2371
 CHECK DOOR LOCK STRIKER…………….2371
 CHECK,ADJUST AIR CONDITIONER…………….2372
 CHECK WINDOW WASHER FLUID LEVEL,ADD FLUID…………….2373
 REPLACE WIPER BLADE…………….2374
 PROCEDURE FOR BLEEDING AIR IN HYDRAULIC SYSTEM…………….2375
 PROCEDURE FOR RELEASING INTERNAL PRESSURE OF HYDRAULIC SYSTEM…………….2376
 CHECK BEFORE STARTING…………….2377
 EVERY 50 HOURS SERVICE…………….2378
 DRAIN WATER,SEDIMENT FROM FUEL TANK…………….2378
 EVERY 250 HOURS SERVICE…………….2379
 LUBRICATING…………….2379
 CHECK OIL LEVEL IN FINAL DRIVE CASE,ADD OIL…………….2380
 CHECK LEVEL OF BATTRY ELECTROLYTE…………….2381
 CHECK BRAKE PERFORMANCE…………….2383
 CLEAN AIR CONDITIONER AIE FILTER(FRESH/RECIRC FILTER)…………….2384
 EVERY 500 HOURS SERVICE…………….2385
 REPLACE FUEL FILTER CARTRIDGE…………….2385
 CHANGE OIL ENGINE OIL PAN,REPLACE ENGINE OIL FILTER CARTRIDGE…………….2388
 REPLACE CORROSION RESISTER CARTRIDGE…………….2389
 CLEAN,CHECK RADIATOR FINS AND OIL COOLER FINS…………….2390
 EVERY 1000 HOURS SERVICE…………….2391
 CHANGE OIL IN FINAL DRIVE CASE…………….2391
 CHECK FAN BELT TENSION,ADJUST…………….2392
 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…………….2392
 CHECK PLAY OF TURBOCHARGER ROTOR…………….2392
 CHECK FOR LOOSE ROPS MOUNT BOLTS…………….2392
 EVERY 2000 HOURS SERVICE…………….2393
 CHANGE OIL IN HYDRAULIC TANK,REPLACE OIL FILTER CARTRIDGE AND CLEAN SUCTION STRAINER…………….2393
 CLEAN,CHECK TURBOCHARGER…………….2394
 CHECK VIVRATION DAMPER…………….2394
 CHECK ALTERNATOR,STARTING MOTOR…………….2394
 CHECK ENGINE VALVE CLEARANCE,ADJUST…………….2394
 EVERY 4000 HOURS SERVICE…………….2395
 CHECK WATER PUMP…………….2395
SPECIFICATIONS…………….2396
 SPECIFICATIONS…………….2397
ATTACHMENTS,OPTIONS…………….2398
 GENERAL PRECAUTIONS…………….2399
 PRECAUTIONS RELATED TO SAFETY…………….2399
 DELUXE SEAT…………….2400
 HEADREST…………….2401
 EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT…………….2402
INDEX…………….2403
SEAM044002T – Bulldozer GALEO D31EX-21, D31PX-21, D37EX-21, D37PX-21 Operation & Maintenance Manual…………….2406
COVER…………….2406
FOREWORD…………….2407
 FOREWORD…………….2408
 SAFETY INFORMATION…………….2409
 INTRODUCTION…………….2411
 FRONT/REAR,LEFT/RIGHT DIRECTIONS OF MACHINE…………….2411
 NECESSARY INFORMATION…………….2412
 MACHINE SERIAL NO.PLATE AND POSITION…………….2412
 ENGINE SERIAL NO.PLATE AND POSITION…………….2412
 EMISSION CONTROL INFORMATION LABEL AND POSITION…………….2413
 POSITION OF SERVICE METER…………….2413
 TABLE OF ENTER SERIAL NO.AND DISTRIBUTORN…………….2414
CONTENTS…………….2415
SAFETY…………….2418
 SAFETY…………….2419
 SAFETY LABELS…………….2421
 POSITION OF SAFETY PICTOGRAMS…………….2421
 SAFETY LABELS…………….2422
 GENERAL PRECAUTIONS…………….2425
 SAFETY RULES…………….2425
 IF ABNORMALITIES ARE FOUND…………….2425
 CLOTHING AND PERSONAL PROTECTIVE ITEMS…………….2425
 FIRE EXTINGUISHER AND FIRST AID KIT…………….2425
 SAFETY FEATURES…………….2425
 KEEP MACHINE CLEAN…………….2426
 INSIDE OPERATOR'S COMPARTMENT…………….2426
 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT…………….2426
 HANDRAILS AND STEPS…………….2427
 MOUNTING AND DISMOUNTING …………….2428
 NO PEOPLE ON ATTACHMENTS…………….2428
 CRUSHING OR CUTTING PREVENTION…………….2428
 PREVENTION OF BURNS…………….2428
 FIRE PREVENTION…………….2429
 ACTION IF FIRE OCCURS…………….2430
 WINDOW WASHER LIQUID…………….2430
 PRECAUTIONS WHEN USING ROPS…………….2430
 PRECAUTIONS FOR ATTACHMENTS…………….2430
 UNAUTHORIZED MODIFICATION…………….2430
 SAFETY AT WORKSITE…………….2430
 WORKING ON LOOSE GROUND…………….2431
 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES…………….2431
 ENSURE GOOD VISIBILITY…………….2431
 VENTILATION FOR ENCLOSED ARESA…………….2432
 CHECKING SIGNALMAN'S SIGNALS AND SIGNS…………….2432
 EMERGENCY EXIT FROM OPERATOR'S CAB…………….2432
 BE CAREFUL ABOUT ASBESTOS DUST…………….2432
 PRECAUTIONS FOR OPERATION…………….2433
 STARTING ENGINE…………….2433
 CHECKS BEFORE STARTING ENGINE…………….2433
 PRECAUTIONS WHEN STARTING…………….2433
 PRECAUTIONS IN COLD AREAS…………….2434
 OPERATION…………….2435
 CHECKS BEFORE OPERATION…………….2435
 PRECAUTIONS FOR MOVING MACHINE FORWORD OR IN REVERSE…………….2435
 PRECAUTIONS WHEN TRAVELING…………….2436
 TRAVELING ON SLOPES…………….2436
 OPERATE CAREFULLY ON SNOW…………….2438
 PARKING MACHINE…………….2438
 TRANSPORTATION…………….2439
 LOADING AND UNLOADING…………….2439
 SHIPPING…………….2439
 BATTERY…………….2440
 BATTERY HAZARD PREVENTION…………….2440
 STARTING WITH BOOSTER CABLE…………….2441
 TOWING…………….2442
 WHEN TOWING…………….2442
 PRECAUTIONS FOR MAINTENANCE…………….2443
 WARNING TAG…………….2443
 KEEP WORK PLACE CLEAN AND TIDY…………….2443
 APPOINT LEADER WHEN WORKING WITH OTHERS…………….2443
 STOP ENGINE BEFORE CARRIYING OUT INSPECTION AND MAINTENANCE…………….2443
 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…………….2444
 PROPER TOOLS…………….2445
 NO UNAUTHORIZER PERSONNEL INTO AREA…………….2445
 ATTACHMENTS…………….2445
 WORK UNDER THE MACHINE…………….2445
 NOISE…………….2445
 PRECAUTIONS WHEN USING HAMMER…………….2446
 REPAIR WELDING…………….2446
 REMOVING BATTERY TERMINAL…………….2446
 PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…………….2446
 DO NOT DISASSEMBLE RECOIL SPRING…………….2446
 PRECAUTIONS WITH HIGH-PRESSURE OIL…………….2447
 HANDLING HIGH-PRESSURE HOSES…………….2447
 WASTE MATERIAL…………….2447
 MAINTENANCE OF AIR CONDITIONER…………….2447
 COMPRESSED AIR…………….2448
 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…………….2448
OPERATION…………….2449
 GENERAL VIEW…………….2450
 GENERAL VIEW OF MACHINE…………….2450
 GENERAL VIEW OF CONTROLS AND GAUGES…………….2451
 EXPLANATION OF COMPONENTS…………….2452
 MONITOR PANEL…………….2452
 SWITCHS…………….2455
 CONTROL LEVERS AND PEDALS…………….2459
 FUSE…………….2465
 ELECTRIC POWER TAKE-OUT ADAPTER…………….2466
 DOOR-OPEN LOCK…………….2467
 SASH GLASS INTERMEDIATE LOCK…………….2467
 CAP,COVER WITH LOCK…………….2468
 DOOR POCKET…………….2469
 ASHTRAY…………….2470
 LUNCHBOX HOLDER BELT…………….2470
 CUP HOLDER…………….2470
 TOOL BOX…………….2471
 GREASE PUMP HOLDER…………….2471
 CAR STEREO,HANDLING…………….2472
 AIR CONDITIONER,HANDLING…………….2480
 OPERATION…………….2484
 CHECK BEFORE STARTING ENGINE,ADJUST…………….2484
 STARTING ENGINE…………….2501
 OPERATIONS AND CHECKS AFTER STARTING ENGINE…………….2505
 STOPPING ENGINE…………….2508
 CHECK AFTER STOPPING ENGINE…………….2508
 MACHINE OPERATION…………….2509
 SHIFTING GEAR…………….2513
 SHIFTING BETWEEN FORWARD AND REVERSE…………….2514
 STEERING MACHINE…………….2515
 PRECAUTIONS FOR OPERATION…………….2518
 WORK POSSIBLE USING BULLDOZER…………….2520
 PARKING MACHINE…………….2522
 CHECK AFTER FINISHING WORK…………….2524
 LOCKING…………….2524
 TIPS FOR LONGER UNDERCARRIAGE LIFE…………….2525
 TRANSPORTATION…………….2528
 TRANSPORTATION MEANS…………….2528
 PRECAUTIONS WHEN REMOVING WORK EQUIPMENT…………….2528
 REMOVING CAB…………….2528
 LOADING,UNLOADING WORK…………….2529
 LIFTING MACHINE…………….2532
 COLD WEATHER OPERATION…………….2533
 PRECAUTIONS FOR LOW TEMPERATURE…………….2533
 AFTER COMPLETION OF WORK…………….2535
 AFTER COLD WEATHER…………….2535
 LONG-TERM STORAGE…………….2536
 BEFORE STORAGE…………….2536
 DURING STORAGE…………….2536
 AFTER STORAGE…………….2536
 TROUBLESHOOTING…………….2537
 AFTER RUNNING OUT OF FUEL…………….2537
 MACHINE TOWING METHOD…………….2537
 IF BATTERY IS DISCHARGED…………….2542
 WHEN ENGINE DOES NOT STOP…………….2545
 OTHER TROUBLE…………….2546
MAINTENANCE…………….2550
 GUIDES TO MAINTENANCE…………….2551
 OUTLINES OF SERVICE…………….2554
 OUTLINE OF OIL,FUEL,COOLANT…………….2554
 RELATING TO ELECTRIC SYSTEM…………….2556
 WEAR PARTS LIST…………….2557
 WEAR PARTS LIST…………….2557
 USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…………….2558
 PROPER SELECTION OF FUEL,COOLANT AND LUBRICANTS…………….2558
 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…………….2562
 TORQUE LIST…………….2562
 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…………….2563
 SAFETY CRITICAL PARTS…………….2564
 MAINTENANCE SCHEDULE CHART…………….2565
 MAINTENANCE SCHEDULE CHART…………….2565
 SERVICE PROCEDURE…………….2567
 WHEN REQUIRED…………….2567
 CHECK,CLEAN AND REPLACE AIR CLEANER ELEMENT…………….2567
 CLEAN INSIDE OF COOLING SYSTEM…………….2570
 CHECK TRACK TENSION…………….2572
 CHECK AND TIGHTEN TRACK SHOE BOLTS…………….2574
 CHECK ELECTRICAL INTAKE AIR HEATER…………….2574
 REVERSE AND REPLACE END BITS AND CUTTING EDGES…………….2575
 CHECK IDLER OIL LEVEL,ADD OIL…………….2576
 ADJUST IDLER CLEARANCE…………….2576
 ADJUST PLAY IN CENTER BALL…………….2577
 GREASE DOOR HINGE…………….2577
 CHECK DOOR LOCK STRIKER…………….2577
 CHECK,ADJUST AIR CONDITIONER…………….2578
 CHECK WINDOW WASHER FLUID LEVEL,ADD FLUID…………….2579
 REPLACE WIPER BLADE…………….2579
 PROCEDURE FOR BLEEDING AIR IN HYDRAULIC SYSTEM…………….2581
 PROCEDURE FOR RELEASING INTERNAL PRESSURE OF HYDRAULIC SYSTEM…………….2582
 CHECK BEFORE STARTING…………….2583
 EVERY 50 HOURS SERVICE…………….2584
 DRAIN WATER,SEDIMENT FROM FUEL TANK…………….2584
 EVERY 250 HOURS SERVICE…………….2585
 LUBRICATING…………….2585
 CHECK OIL LEVEL IN FINAL DRIVE CASE,ADD OIL…………….2586
 CHECK LEVEL OF BATTRY ELECTROLYTE…………….2587
 CHECK BRAKE PERFORMANCE…………….2589
 CLEAN AIR CONDITIONER AIE FILTER(FRESH/RECIRC FILTER)…………….2590
 EVERY 500 HOURS SERVICE…………….2591
 REPLACE FUEL FILTER CARTRIDGE…………….2591
 CHANGE OIL ENGINE OIL PAN,REPLACE ENGINE OIL FILTER CARTRIDGE…………….2594
 REPLACE CORROSION RESISTER CARTRIDGE…………….2596
 CLEAN,CHECK RADIATOR FINS AND OIL COOLER FINS…………….2596
 EVERY 1000 HOURS SERVICE…………….2598
 CHANGE OIL IN FINAL DRIVE CASE…………….2598
 CHECK FAN BELT TENSION,ADJUST…………….2599
 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…………….2599
 CHECK PLAY OF TURBOCHARGER ROTOR…………….2599
 CHECK FOR LOOSE ROPS MOUNT BOLTS…………….2599
 EVERY 2000 HOURS SERVICE…………….2600
 CHANGE OIL IN HYDRAULIC TANK,REPLACE OIL FILTER CARTRIDGE AND CLEAN SUCTION STRAINER…………….2600
 CLEAN,CHECK TURBOCHARGER…………….2601
 CHECK VIBRATION DAMPER…………….2601
 CHECK ALTERNATOR,STARTING MOTOR…………….2601
 CHECK ENGINE VALVE CLEARANCE,ADJUST…………….2601
 EVERY 4000 HOURS SERVICE…………….2602
 CHECK WATER PUMP…………….2602
SPECIFICATIONS…………….2603
 SPECIFICATIONS…………….2604
ATTACHMENTS,OPTIONS…………….2605
 GENERAL PRECAUTIONS…………….2606
 PRECAUTIONS RELATED TO SAFETY…………….2606
 DELUXE SEAT…………….2607
 HEADREST…………….2608
 EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT…………….2609
INDEX…………….2610
TEN00109-01 – Bulldozer D31EX-21, D31PX-21, D37EX-21, D37PX-21, D39EX-21, D39PX-21 Operation & Maintenance Manual…………….2613
COVER…………….2613
FOREWORD…………….2614
 FOREWORD…………….2615
 SAFETY INFORMATION…………….2618
 INTRODUCTION…………….2620
 FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE…………….2620
 NECESSARY INFORMATION…………….2621
 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…………….2621
 ENGINE SERIAL NO. PLATE…………….2621
 POSITION OF SERVICE METER…………….2622
 TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR…………….2622
 CONTENTS…………….2623
SAFETY…………….2626
 SAFETY…………….2627
 SAFETY LABELS…………….2629
 POSITIONS OF SAFETY PICTOGRAMS…………….2629
 SAFETY LABELS…………….2630
 GENERAL PRECAUTIONS…………….2634
 PRECAUTIONS FOR OPERATION…………….2642
 STARTING ENGINE…………….2642
 OPERATION…………….2644
 TRANSPORTATION…………….2647
 BATTERY…………….2648
 TOWING…………….2650
 PRECAUTIONS FOR MAINTENANCE…………….2651
OPERATION…………….2658
 GENERAL VIEW…………….2659
 GENERAL VIEW OF MACHINE…………….2659
 GENERAL VIEW OF CONTROLS AND GAUGES…………….2660
 EXPLANATION OF COMPONENTS…………….2662
 FRONT PANEL…………….2662
 SWITCHES…………….2685
 CONTROL LEVERS AND PEDALS…………….2690
 FUSE…………….2696
 ELECTRIC POWER TAKE-OUT ADAPTER…………….2697
 DOOR – OPEN LOCK…………….2698
 SASH GLASS INTERMEDIATE LOCK…………….2698
 CAP, COVER WITH LOCK…………….2699
 DOOR POCKET…………….2700
 ASHTRAY…………….2701
 LUNCHBOX HOLDER BELT…………….2701
 CUP HOLDER…………….2701
 TOOL BOX…………….2702
 GREASE PUMP HOLDER…………….2702
 CAR STEREO, HANDLING…………….2703
 AIR CONDITIONER, HANDLING…………….2711
 OPERATION…………….2715
 CHECK BEFORE STARTING ENGINE, ADJUST…………….2715
 STARTING ENGINE…………….2731
 OPERATIONS AND CHECKS AFTER STARTING ENGINE…………….2735
 STOPPING ENGINE…………….2738
 MACHINE OPERATION…………….2739
 SHIFTING GEARS…………….2743
 SHIFTING BETWEEN FORWARD AND REVERSE…………….2744
 STEERING MACHINE…………….2745
 PRECAUTIONS FOR OPERATION…………….2747
 WORK POSSIBLE USING BULLDOZER…………….2749
 PARKING MACHINE…………….2751
 CHECK AFTER FINISHING WORK…………….2752
 LOCKING…………….2753
 TIPS FOR LONGER UNDERCARRIAGE LIFE…………….2754
 TRANSPORTATION…………….2757
 TRANSPORTATION MEANS…………….2757
 PRECAUTIONS WHEN REMOVING WORK EQUIPMENT…………….2757
 REMOVING CAB…………….2757
 LOADING, UNLOADING WORK…………….2758
 LIFTING MACHINE…………….2761
 COLD WEATHER OPERATION…………….2762
 PRECAUTIONS FOR LOW TEMPERATURE…………….2762
 AFTER COMPLETION OF WORK…………….2764
 AFTER COLD WEATHER…………….2764
 LONG-TERM STORAGE…………….2765
 BEFORE STORAGE…………….2765
 DURING STORAGE…………….2765
 AFTER STORAGE…………….2765
 TROUBLESHOOTING…………….2766
 AFTER RUNNING OUT OF FUEL…………….2766
 MACHINE TOWING METHOD…………….2766
 IF BATTERY IS DISCHARGED…………….2772
 WHEN ENGINE DOES NOT STOP…………….2775
 OTHER TROUBLE…………….2776
MAINTENANCE…………….2780
 GUIDE TO MAINTENANCE…………….2781
 OUTLINE OF SERVICE…………….2784
 OUTLINE OF OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…………….2784
 RELATING TO ELECTRIC SYSTEM…………….2786
 WEAR PARTS LIST…………….2787
 WEAR PARTS LIST…………….2787
 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…………….2789
 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS…………….2789
 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…………….2793
 TORQUE LIST…………….2793
 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…………….2794
 SAFETY CRITICAL PARTS…………….2794
 MAINTENANCE SCHEDULE CHART…………….2795
 MAINTENANCE SCHEDULE CHART…………….2795
 SERVICE PROCEDURE…………….2797
 WHEN REQUIRED…………….2797
 CHECK BEFORE STARTING…………….2814
 EVERY 50 HOURS SERVICE…………….2815
 EVERY 250 HOURS SERVICE…………….2816
 EVERY 500 HOURS SERVICE…………….2823
 EVERY 1000 HOURS SERVICE…………….2829
 EVERY 2000 HOURS SERVICE…………….2831
 EVERY 4000 HOURS SERVICE…………….2833
SPECIFICATIONS…………….2834
 SPECIFICATIONS…………….2835
ATTACHMENTS, OPTIONS…………….2838
 GENERAL PRECAUTIONS…………….2839
 PRECAUTIONS RELATED TO SAFETY…………….2839
 HANDLING HYDRAULIC RIPPER…………….2840
 GENERAL VIEW…………….2840
 EXPLANATION OF COMPONENTS…………….2841
 OPERATION…………….2842
 TROUBLESHOOTING…………….2843
 MAINTENANCE…………….2844
 DELUXE SEAT…………….2845
 HEADREST…………….2846
 EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT…………….2847
INDEX…………….2848
TEN00268-04 – Bulldozer D39EX-22, D39PX-22 Operation & Maintenance Manual (SN3001&up)…………….2852
COVER…………….2852
FOREWORD…………….2853
 BEFORE READING THIS MANUAL…………….2854
 IMPORTANT SAFETY INFORMATION…………….2856
 INTENDED USE…………….2857
 USE OF MACHINE…………….2857
 GENERAL VIEW AND DIRECTIONS OF MACHINE…………….2857
 VISIBILITY FROM OPERATOR'S SEAT…………….2857
 LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…………….2858
 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…………….2858
 EPA REGULATION, ENGINE SERIAL NO. PLATE…………….2858
 SERVICE METER POSITION…………….2859
 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…………….2859
 CONTENTS…………….2860
SAFETY…………….2863
 SAFETY…………….2864
 SAFETY LABELS…………….2867
 POSITIONS OF SAFETY PICTOGRAMS…………….2867
 SAFETY LABELS…………….2868
 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…………….2872
 PRECAUTIONS BEFORE STARTING OPERATION…………….2872
 PREPARATIONS FOR SAFE OPERATION…………….2872
 FIRE PREVENTION…………….2874
 PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…………….2876
 DO NOT GET CAUGHT IN WORK EQUIPMENT…………….2877
 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…………….2878
 UNAUTHORIZED MODIFICATION…………….2878
 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…………….2878
 PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…………….2879
 PRECAUTIONS FOR OPERATION…………….2880
 PRECAUTIONS FOR JOBSITE…………….2880
 STARTING ENGINE…………….2882
 OPERATION…………….2885
 TRANSPORTATION…………….2889
 TOWING…………….2890
 PRECAUTIONS FOR MAINTENANCE…………….2891
 PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…………….2891
 PRECAUTIONS FOR INSPECTION AND MAINTENANCE…………….2895
OPERATION…………….2901
 GENERAL VIEW…………….2902
 GENERAL VIEW OF MACHINE…………….2902
 GENERAL VIEW OF CONTROLS AND GAUGES…………….2903
 EXPLANATION OF COMPONENTS…………….2906
 FRONT PANEL…………….2906
 SWITCHES…………….2933
 CONTROL LEVERS AND PEDALS…………….2937
 FUSE…………….2943
 ELECTRIC POWER TAKE-OUT ADAPTER…………….2945
 DOOR – OPEN LOCK…………….2946
 SASH GLASS INTERMEDIATE LOCK…………….2946
 COVER, CAP WITH LOCK…………….2947
 OPENING OR CLOSING REAR MASK…………….2950
 DOOR POCKET…………….2951
 ASHTRAY…………….2951
 LUNCHBOX HOLDER BELT…………….2951
 CUP HOLDER…………….2952
 TOOL BOX…………….2952
 GREASE PUMP HOLDER…………….2952
 CAR RADIO, HANDLING…………….2953
 AIR CONDITIONER, HANDLING…………….2961
 OPERATION…………….2964
 CHECK BEFORE STARTING ENGINE, ADJUST…………….2964
 STARTING ENGINE…………….2982
 OPERATIONS AND CHECKS AFTER STARTING ENGINE…………….2987
 STOPPING ENGINE…………….2991
 MACHINE OPERATION…………….2992
 SHIFTING GEARS…………….2996
 SHIFTING BETWEEN FORWARD AND REVERSE…………….2997
 STEERING MACHINE…………….2998
 PRECAUTIONS FOR OPERATION…………….3000
 WORK POSSIBLE USING BULLDOZER…………….3002
 ADJUSTING POSTURE OF WORK EQUIPMENT…………….3004
 PARKING MACHINE…………….3006
 CHECK AFTER FINISHING WORK…………….3007
 LOCKING…………….3007
 TIPS FOR LONGER UNDERCARRIAGE LIFE…………….3009
 TRANSPORTATION…………….3012
 TRANSPORTATION MEANS…………….3012
 REMOVING CAB…………….3012
 PRECAUTIONS WHEN REMOVING WORK EQUIPMENT…………….3013
 LOADING, UNLOADING WORK…………….3014
 METHOD OF LIFTING MACHINE…………….3017
 COLD WEATHER OPERATION…………….3019
 PRECAUTIONS FOR LOW TEMPERATURE…………….3019
 AFTER COMPLETION OF WORK…………….3020
 AFTER COLD WEATHER…………….3020
 LONG-TERM STORAGE…………….3021
 BEFORE STORAGE…………….3021
 DURING STORAGE…………….3021
 AFTER STORAGE…………….3021
 TROUBLESHOOTING…………….3022
 AFTER RUNNING OUT OF FUEL…………….3022
 METHOD OF TOWING MACHINE…………….3022
 IF BATTERY IS DISCHARGED…………….3024
 OTHER TROUBLE…………….3028
MAINTENANCE…………….3033
 GUIDE TO MAINTENANCE…………….3034
 OUTLINE OF SERVICE…………….3037
 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…………….3037
 RELATING TO ELECTRIC SYSTEM…………….3041
 HANDLING HYDRAULIC SYSTEM…………….3042
 WEAR PARTS LIST…………….3043
 WEAR PARTS LIST…………….3043
 RECOMMENDED FUEL, COOLANT, AND LUBRICANT…………….3044
 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…………….3045
 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…………….3046
 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…………….3047
 TORQUE LIST…………….3047
 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…………….3048
 SAFETY CRITICAL PARTS…………….3049
 MAINTENANCE SCHEDULE CHART…………….3050
 MAINTENANCE SCHEDULE CHART…………….3050
 SERVICE PROCEDURE…………….3052
 WHEN REQUIRED…………….3052
 CHECK BEFORE STARTING…………….3077
 EVERY 50 HOURS SERVICE…………….3078
 EVERY 250 HOURS SERVICE…………….3080
 EVERY 500 HOURS SERVICE…………….3085
 EVERY 1000 HOURS SERVICE…………….3090
 EVERY 2000 HOURS SERVICE…………….3098
 EVERY 4000 HOURS SERVICE…………….3103
 EVERY 8000 HOURS SERVICE…………….3106
SPECIFICATIONS…………….3107
 SPECIFICATIONS…………….3108
ATTACHMENTS, OPTIONS…………….3109
 GENERAL PRECAUTIONS…………….3110
 PRECAUTIONS RELATED TO SAFETY…………….3110
 AIR SUSPENSION SEAT…………….3111
 EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT…………….3113
 HANDLING MACHINES EQUIPPED WITH KOMTRAX…………….3114
 BASIC PRECAUTIONS…………….3114
INDEX…………….3115
TEN00290-04 – Bulldozer D31EX-22, D31PX-22, D37EX-22, D37PX-22 Operation & Maintenance Manual (SN60001&up)…………….3119
COVER…………….3119
FOREWORD…………….3120
 BEFORE READING THIS MANUAL…………….3121
 IMPORTANT SAFETY INFORMATION…………….3123
 INTENDED USE…………….3124
 USE OF MACHINE…………….3124
 GENERAL VIEW AND DIRECTIONS OF MACHINE…………….3124
 VISIBILITY FROM OPERATOR'S SEAT…………….3124
 LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…………….3125
 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…………….3125
 EPA REGULATION, ENGINE SERIAL NO. PLATE…………….3125
 SERVICE METER POSITION…………….3126
 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…………….3126
 CONTENTS…………….3127
SAFETY…………….3130
 SAFETY…………….3131
 SAFETY LABELS…………….3134
 POSITIONS OF SAFETY PICTOGRAMS…………….3134
 SAFETY LABELS…………….3135
 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…………….3139
 PRECAUTIONS BEFORE STARTING OPERATION…………….3139
 PREPARATIONS FOR SAFE OPERATION…………….3139
 FIRE PREVENTION…………….3141
 PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…………….3143
 DO NOT GET CAUGHT IN WORK EQUIPMENT…………….3145
 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…………….3146
 UNAUTHORIZED MODIFICATION…………….3146
 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…………….3146
 PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…………….3147
 PRECAUTIONS FOR OPERATION…………….3148
 PRECAUTIONS FOR JOBSITE…………….3148
 STARTING ENGINE…………….3150
 OPERATION…………….3153
 TRANSPORTATION…………….3157
 TOWING…………….3158
 PRECAUTIONS FOR MAINTENANCE…………….3159
 PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…………….3159
 PRECAUTIONS FOR INSPECTION AND MAINTENANCE…………….3163
OPERATION…………….3168
 GENERAL VIEW…………….3169
 GENERAL VIEW OF MACHINE…………….3169
 GENERAL VIEW OF CONTROLS AND GAUGES…………….3170
 EXPLANATION OF COMPONENTS…………….3173
 FRONT PANEL…………….3173
 SWITCHES…………….3200
 CONTROL LEVERS AND PEDALS…………….3204
 FUSE…………….3210
 ELECTRIC POWER TAKE-OUT ADAPTER…………….3212
 DOOR – OPEN LOCK…………….3213
 SASH GLASS INTERMEDIATE LOCK…………….3213
 COVER, CAP WITH LOCK…………….3214
 OPENING OR CLOSING REAR MASK…………….3217
 DOOR POCKET…………….3218
 ASHTRAY…………….3218
 LUNCHBOX HOLDER BELT…………….3218
 CUP HOLDER…………….3219
 TOOL BOX…………….3219
 GREASE PUMP HOLDER…………….3219
 CAR RADIO, HANDLING…………….3220
 AIR CONDITIONER, HANDLING…………….3228
 OPERATION…………….3231
 CHECK BEFORE STARTING ENGINE, ADJUST…………….3231
 STARTING ENGINE…………….3251
 OPERATIONS AND CHECKS AFTER STARTING ENGINE…………….3256
 STOPPING ENGINE…………….3260
 MACHINE OPERATION…………….3261
 SHIFTING GEARS…………….3265
 SHIFTING BETWEEN FORWARD AND REVERSE…………….3266
 STEERING MACHINE…………….3267
 PRECAUTIONS FOR OPERATION…………….3269
 WORK POSSIBLE USING BULLDOZER…………….3271
 ADJUSTING POSTURE OF WORK EQUIPMENT…………….3273
 PARKING MACHINE…………….3275
 CHECK AFTER FINISHING WORK…………….3276
 LOCKING…………….3276
 TIPS FOR LONGER UNDERCARRIAGE LIFE…………….3278
 TRANSPORTATION…………….3281
 TRANSPORTATION MEANS…………….3281
 REMOVING CAB…………….3281
 PRECAUTIONS WHEN REMOVING WORK EQUIPMENT…………….3281
 LOADING, UNLOADING WORK…………….3282
 METHOD OF LIFTING MACHINE…………….3285
 COLD WEATHER OPERATION…………….3287
 PRECAUTIONS FOR LOW TEMPERATURE…………….3287
 AFTER COMPLETION OF WORK…………….3288
 AFTER COLD WEATHER…………….3288
 LONG-TERM STORAGE…………….3289
 BEFORE STORAGE…………….3289
 DURING STORAGE…………….3289
 AFTER STORAGE…………….3289
 TROUBLESHOOTING…………….3290
 AFTER RUNNING OUT OF FUEL…………….3290
 METHOD OF TOWING MACHINE…………….3290
 IF BATTERY IS DISCHARGED…………….3292
 OTHER TROUBLE…………….3296
MAINTENANCE…………….3300
 GUIDE TO MAINTENANCE…………….3301
 OUTLINE OF SERVICE…………….3304
 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…………….3304
 RELATING TO ELECTRIC SYSTEM…………….3307
 HANDLING HYDRAULIC SYSTEM…………….3308
 WEAR PARTS LIST…………….3309
 WEAR PARTS LIST…………….3310
 RECOMMENDED FUEL, COOLANT, AND LUBRICANT…………….3312
 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…………….3313
 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…………….3314
 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…………….3315
 TORQUE LIST…………….3315
 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…………….3316
 SAFETY CRITICAL PARTS…………….3317
 MAINTENANCE SCHEDULE CHART…………….3319
 MAINTENANCE SCHEDULE CHART…………….3319
 SERVICE PROCEDURE…………….3321
 WHEN REQUIRED…………….3321
 CHECK BEFORE STARTING…………….3347
 EVERY 50 HOURS SERVICE…………….3348
 EVERY 250 HOURS SERVICE…………….3350
 EVERY 500 HOURS SERVICE…………….3359
 EVERY 1000 HOURS SERVICE…………….3364
 EVERY 2000 HOURS SERVICE…………….3375
 EVERY 4000 HOURS SERVICE…………….3380
 EVERY 8000 HOURS SERVICE…………….3383
SPECIFICATIONS…………….3384
 SPECIFICATIONS…………….3385
ATTACHMENTS, OPTIONS…………….3388
 GENERAL PRECAUTIONS…………….3389
 PRECAUTIONS RELATED TO SAFETY…………….3389
 AIR SUSPENSION SEAT…………….3390
 EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT…………….3392
 HANDLING MACHINES EQUIPPED WITH KOMTRAX…………….3393
 BASIC PRECAUTIONS…………….3393
INDEX…………….3394
TEN00469-00 – Bulldozer D39EX-22, D39PX-22 Operation & Maintenance Manual (SN3440&up)…………….3398
COVER…………….3398
FOREWORD…………….3399
 BEFORE READING THIS MANUAL…………….3400
 IMPORTANT SAFETY INFORMATION…………….3402
 INTENDED USE…………….3403
 USE OF MACHINE…………….3403
 GENERAL VIEW AND DIRECTIONS OF MACHINE…………….3403
 VISIBILITY FROM OPERATOR'S SEAT…………….3403
 LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…………….3404
 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…………….3404
 EPA REGULATION, ENGINE SERIAL NO. PLATE…………….3404
 SERVICE METER POSITION…………….3405
 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…………….3405
 CONTENTS…………….3406
SAFETY…………….3409
 SAFETY…………….3410
 SAFETY LABELS…………….3413
 POSITIONS OF SAFETY PICTOGRAMS…………….3413
 SAFETY LABELS…………….3414
 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…………….3418
 PRECAUTIONS BEFORE STARTING OPERATION…………….3418
 PREPARATIONS FOR SAFE OPERATION…………….3418
 FIRE PREVENTION…………….3420
 PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…………….3422
 DO NOT GET CAUGHT IN WORK EQUIPMENT…………….3423
 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…………….3424
 UNAUTHORIZED MODIFICATION…………….3424
 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…………….3424
 PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…………….3425
 PRECAUTIONS FOR OPERATION…………….3426
 PRECAUTIONS FOR JOBSITE…………….3426
 STARTING ENGINE…………….3428
 OPERATION…………….3431
 TRANSPORTATION…………….3435
 TOWING…………….3436
 PRECAUTIONS FOR MAINTENANCE…………….3437
 PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…………….3437
 PRECAUTIONS FOR INSPECTION AND MAINTENANCE…………….3441
OPERATION…………….3447
 GENERAL VIEW…………….3448
 GENERAL VIEW OF MACHINE…………….3448
 GENERAL VIEW OF CONTROLS AND GAUGES…………….3449
 EXPLANATION OF COMPONENTS…………….3452
 FRONT PANEL…………….3452
 SWITCHES…………….3479
 CONTROL LEVERS AND PEDALS…………….3483
 FUSE…………….3489
 ELECTRIC POWER TAKE-OUT ADAPTER…………….3491
 DOOR – OPEN LOCK…………….3492
 SASH GLASS INTERMEDIATE LOCK…………….3492
 COVER, CAP WITH LOCK…………….3493
 OPENING OR CLOSING REAR MASK…………….3496
 DOOR POCKET…………….3497
 ASHTRAY…………….3497
 LUNCHBOX HOLDER BELT…………….3497
 CUP HOLDER…………….3498
 TOOL BOX…………….3498
 GREASE PUMP HOLDER…………….3498
 CAR RADIO, HANDLING…………….3499
 AIR CONDITIONER, HANDLING…………….3507
 OPERATION…………….3510
 CHECK BEFORE STARTING ENGINE, ADJUST…………….3510
 STARTING ENGINE…………….3528
 OPERATIONS AND CHECKS AFTER STARTING ENGINE…………….3533
 STOPPING ENGINE…………….3537
 MACHINE OPERATION…………….3538
 SHIFTING GEARS…………….3542
 SHIFTING BETWEEN FORWARD AND REVERSE…………….3543
 STEERING MACHINE…………….3544
 PRECAUTIONS FOR OPERATION…………….3546
 WORK POSSIBLE USING BULLDOZER…………….3548
 ADJUSTING POSTURE OF WORK EQUIPMENT…………….3550
 PARKING MACHINE…………….3552
 CHECK AFTER FINISHING WORK…………….3553
 LOCKING…………….3553
 TIPS FOR LONGER UNDERCARRIAGE LIFE…………….3555
 TRANSPORTATION…………….3558
 TRANSPORTATION MEANS…………….3558
 REMOVING CAB…………….3558
 PRECAUTIONS WHEN REMOVING WORK EQUIPMENT…………….3559
 LOADING, UNLOADING WORK…………….3560
 METHOD OF LIFTING MACHINE…………….3563
 COLD WEATHER OPERATION…………….3565
 PRECAUTIONS FOR LOW TEMPERATURE…………….3565
 AFTER COMPLETION OF WORK…………….3566
 AFTER COLD WEATHER…………….3566
 LONG-TERM STORAGE…………….3567
 BEFORE STORAGE…………….3567
 DURING STORAGE…………….3567
 AFTER STORAGE…………….3567
 TROUBLESHOOTING…………….3568
 AFTER RUNNING OUT OF FUEL…………….3568
 METHOD OF TOWING MACHINE…………….3568
 IF BATTERY IS DISCHARGED…………….3570
 OTHER TROUBLE…………….3574
MAINTENANCE…………….3579
 GUIDE TO MAINTENANCE…………….3580
 OUTLINE OF SERVICE…………….3583
 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…………….3583
 RELATING TO ELECTRIC SYSTEM…………….3587
 HANDLING HYDRAULIC SYSTEM…………….3588
 WEAR PARTS LIST…………….3589
 WEAR PARTS LIST…………….3589
 RECOMMENDED FUEL, COOLANT, AND LUBRICANT…………….3590
 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…………….3591
 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…………….3592
 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…………….3593
 TORQUE LIST…………….3593
 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…………….3594
 SAFETY CRITICAL PARTS…………….3595
 MAINTENANCE SCHEDULE CHART…………….3596
 MAINTENANCE SCHEDULE CHART…………….3596
 SERVICE PROCEDURE…………….3598
 WHEN REQUIRED…………….3598
 CHECK BEFORE STARTING…………….3623
 EVERY 50 HOURS SERVICE…………….3624
 EVERY 250 HOURS SERVICE…………….3626
 EVERY 500 HOURS SERVICE…………….3631
 EVERY 1000 HOURS SERVICE…………….3636
 EVERY 2000 HOURS SERVICE…………….3644
 EVERY 4000 HOURS SERVICE…………….3649
 EVERY 8000 HOURS SERVICE…………….3652
SPECIFICATIONS…………….3653
 SPECIFICATIONS…………….3654
ATTACHMENTS, OPTIONS…………….3655
 GENERAL PRECAUTIONS…………….3656
 PRECAUTIONS RELATED TO SAFETY…………….3656
 AIR SUSPENSION SEAT…………….3657
 EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT…………….3659
 HANDLING MACHINES EQUIPPED WITH KOMTRAX…………….3660
 BASIC PRECAUTIONS…………….3660
INDEX…………….3661
TEN00470-00 – Bulldozer D31EX-22, D31PX-22, D37EX-22, D37PX-22 Operation & Maintenance Manual (SN60541&up)…………….3665
COVER…………….3665
FOREWORD…………….3666
 BEFORE READING THIS MANUAL…………….3667
 IMPORTANT SAFETY INFORMATION…………….3669
 INTENDED USE…………….3670
 USE OF MACHINE…………….3670
 GENERAL VIEW AND DIRECTIONS OF MACHINE…………….3670
 VISIBILITY FROM OPERATOR'S SEAT…………….3670
 LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…………….3671
 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…………….3671
 EPA REGULATION, ENGINE SERIAL NO. PLATE…………….3671
 SERVICE METER POSITION…………….3672
 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…………….3672
 CONTENTS…………….3673
SAFETY…………….3676
 SAFETY…………….3677
 SAFETY LABELS…………….3680
 POSITIONS OF SAFETY PICTOGRAMS…………….3680
 SAFETY LABELS…………….3681
 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…………….3685
 PRECAUTIONS BEFORE STARTING OPERATION…………….3685
 PREPARATIONS FOR SAFE OPERATION…………….3685
 FIRE PREVENTION…………….3687
 PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…………….3689
 DO NOT GET CAUGHT IN WORK EQUIPMENT…………….3691
 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…………….3692
 UNAUTHORIZED MODIFICATION…………….3692
 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…………….3692
 PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…………….3693
 PRECAUTIONS FOR OPERATION…………….3694
 PRECAUTIONS FOR JOBSITE…………….3694
 STARTING ENGINE…………….3696
 OPERATION…………….3699
 TRANSPORTATION…………….3703
 TOWING…………….3704
 PRECAUTIONS FOR MAINTENANCE…………….3705
 PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…………….3705
 PRECAUTIONS FOR INSPECTION AND MAINTENANCE…………….3709
OPERATION…………….3714
 GENERAL VIEW…………….3715
 GENERAL VIEW OF MACHINE…………….3715
 GENERAL VIEW OF CONTROLS AND GAUGES…………….3716
 EXPLANATION OF COMPONENTS…………….3719
 FRONT PANEL…………….3719
 SWITCHES…………….3746
 CONTROL LEVERS AND PEDALS…………….3750
 FUSE…………….3756
 ELECTRIC POWER TAKE-OUT ADAPTER…………….3758
 DOOR – OPEN LOCK…………….3759
 SASH GLASS INTERMEDIATE LOCK…………….3759
 COVER, CAP WITH LOCK…………….3760
 OPENING OR CLOSING REAR MASK…………….3763
 DOOR POCKET…………….3764
 ASHTRAY…………….3764
 LUNCHBOX HOLDER BELT…………….3764
 CUP HOLDER…………….3765
 TOOL BOX…………….3765
 GREASE PUMP HOLDER…………….3765
 CAR RADIO, HANDLING…………….3766
 AIR CONDITIONER, HANDLING…………….3774
 OPERATION…………….3777
 CHECK BEFORE STARTING ENGINE, ADJUST…………….3777
 STARTING ENGINE…………….3797
 OPERATIONS AND CHECKS AFTER STARTING ENGINE…………….3802
 STOPPING ENGINE…………….3806
 MACHINE OPERATION…………….3807
 SHIFTING GEARS…………….3811
 SHIFTING BETWEEN FORWARD AND REVERSE…………….3812
 STEERING MACHINE…………….3813
 PRECAUTIONS FOR OPERATION…………….3815
 WORK POSSIBLE USING BULLDOZER…………….3817
 ADJUSTING POSTURE OF WORK EQUIPMENT…………….3819
 PARKING MACHINE…………….3821
 CHECK AFTER FINISHING WORK…………….3822
 LOCKING…………….3822
 TIPS FOR LONGER UNDERCARRIAGE LIFE…………….3824
 TRANSPORTATION…………….3827
 TRANSPORTATION MEANS…………….3827
 REMOVING CAB…………….3827
 PRECAUTIONS WHEN REMOVING WORK EQUIPMENT…………….3827
 LOADING, UNLOADING WORK…………….3828
 METHOD OF LIFTING MACHINE…………….3831
 COLD WEATHER OPERATION…………….3833
 PRECAUTIONS FOR LOW TEMPERATURE…………….3833
 AFTER COMPLETION OF WORK…………….3834
 AFTER COLD WEATHER…………….3834
 LONG-TERM STORAGE…………….3835
 BEFORE STORAGE…………….3835
 DURING STORAGE…………….3835
 AFTER STORAGE…………….3835
 TROUBLESHOOTING…………….3836
 AFTER RUNNING OUT OF FUEL…………….3836
 METHOD OF TOWING MACHINE…………….3836
 IF BATTERY IS DISCHARGED…………….3838
 OTHER TROUBLE…………….3842
MAINTENANCE…………….3846
 GUIDE TO MAINTENANCE…………….3847
 OUTLINE OF SERVICE…………….3850
 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…………….3850
 RELATING TO ELECTRIC SYSTEM…………….3853
 HANDLING HYDRAULIC SYSTEM…………….3854
 WEAR PARTS LIST…………….3855
 WEAR PARTS LIST…………….3856
 RECOMMENDED FUEL, COOLANT, AND LUBRICANT…………….3858
 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…………….3859
 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…………….3860
 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…………….3861
 TORQUE LIST…………….3861
 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…………….3862
 SAFETY CRITICAL PARTS…………….3863
 MAINTENANCE SCHEDULE CHART…………….3865
 MAINTENANCE SCHEDULE CHART…………….3865
 SERVICE PROCEDURE…………….3867
 WHEN REQUIRED…………….3867
 CHECK BEFORE STARTING…………….3893
 EVERY 50 HOURS SERVICE…………….3894
 EVERY 250 HOURS SERVICE…………….3896
 EVERY 500 HOURS SERVICE…………….3905
 EVERY 1000 HOURS SERVICE…………….3910
 EVERY 2000 HOURS SERVICE…………….3921
 EVERY 4000 HOURS SERVICE…………….3926
 EVERY 8000 HOURS SERVICE…………….3929
SPECIFICATIONS…………….3930
 SPECIFICATIONS…………….3931
ATTACHMENTS, OPTIONS…………….3934
 GENERAL PRECAUTIONS…………….3935
 PRECAUTIONS RELATED TO SAFETY…………….3935
 AIR SUSPENSION SEAT…………….3936
 EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT…………….3938
 HANDLING MACHINES EQUIPPED WITH KOMTRAX…………….3939
 BASIC PRECAUTIONS…………….3939
INDEX…………….3940
TEN00525-03 – Bulldozer D31EX-22, D31PX-22, D37EX-22, D37PX-22 Operation & Maintenance Manual (SN60730&up)…………….3944
COVER…………….3944
FOREWORD…………….3945
 BEFORE READING THIS MANUAL…………….3946
 IMPORTANT SAFETY INFORMATION…………….3948
 INTENDED USE…………….3949
 USE OF MACHINE…………….3949
 GENERAL VIEW AND DIRECTIONS OF MACHINE…………….3949
 VISIBILITY FROM OPERATOR'S SEAT…………….3949
 LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…………….3950
 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…………….3950
 EPA REGULATION, ENGINE SERIAL NO. PLATE…………….3950
 SERVICE METER POSITION…………….3951
 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…………….3951
 CONTENTS…………….3952
SAFETY …………….3955
 SAFETY…………….3956
 SAFETY LABELS…………….3959
 POSITIONS OF SAFETY PICTOGRAMS…………….3959
 SAFETY LABELS…………….3960
 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…………….3964
 PRECAUTIONS BEFORE STARTING OPERATION…………….3964
 PREPARATIONS FOR SAFE OPERATION…………….3964
 FIRE PREVENTION…………….3966
 PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…………….3968
 DO NOT GET CAUGHT IN WORK EQUIPMENT…………….3970
 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…………….3971
 UNAUTHORIZED MODIFICATION…………….3971
 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…………….3971
 PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…………….3972
 PRECAUTIONS FOR OPERATION…………….3973
 PRECAUTIONS FOR JOBSITE…………….3973
 STARTING ENGINE…………….3975
 OPERATION…………….3978
 TRANSPORTATION…………….3982
 TOWING…………….3983
 PRECAUTIONS FOR MAINTENANCE…………….3984
 PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…………….3984
 PRECAUTIONS FOR INSPECTION AND MAINTENANCE…………….3988
OPERATION …………….3993
 GENERAL VIEW…………….3994
 VIEW OF MACHINE…………….3994
 GENERAL VIEW OF CONTROLS AND GAUGES…………….3995
 EXPLANATION OF COMPONENTS…………….3998
 FRONT PANEL…………….3998
 SWITCHES…………….4025
 CONTROL LEVERS AND PEDALS…………….4029
 FUSE…………….4035
 ELECTRIC POWER TAKE-OUT ADAPTER…………….4037
 DOOR – OPEN LOCK…………….4038
 SASH GLASS INTERMEDIATE LOCK…………….4038
 COVER, CAP WITH LOCK…………….4039
 OPENING OR CLOSING REAR MASK…………….4042
 DOOR POCKET…………….4043
 ASHTRAY…………….4043
 LUNCHBOX HOLDER BELT…………….4043
 CUP HOLDER…………….4044
 TOOL BOX…………….4044
 GREASE PUMP HOLDER…………….4044
 CAR RADIO, HANDLING…………….4045
 AIR CONDITIONER, HANDLING…………….4053
 OPERATION…………….4056
 CHECK BEFORE STARTING ENGINE, ADJUST…………….4056
 STARTING ENGINE…………….4076
 OPERATIONS AND CHECKS AFTER STARTING ENGINE…………….4081
 STOPPING ENGINE…………….4085
 MACHINE OPERATION…………….4086
 SHIFTING GEARS…………….4090
 SHIFTING BETWEEN FORWARD AND REVERSE…………….4091
 STEERING MACHINE…………….4092
 PRECAUTIONS FOR OPERATION…………….4094
 WORK POSSIBLE USING BULLDOZER…………….4096
 ADJUSTING POSTURE OF WORK EQUIPMENT…………….4098
 PARKING MACHINE…………….4100
 CHECK AFTER FINISHING WORK…………….4101
 LOCKING…………….4101
 TIPS FOR LONGER UNDERCARRIAGE LIFE…………….4103
 TRANSPORTATION…………….4106
 TRANSPORTATION MEANS…………….4106
 REMOVING CAB…………….4106
 PRECAUTIONS WHEN REMOVING WORK EQUIPMENT…………….4106
 LOADING, UNLOADING WORK…………….4107
 METHOD OF LIFTING MACHINE…………….4110
 COLD WEATHER OPERATION…………….4112
 PRECAUTIONS FOR LOW TEMPERATURE…………….4112
 AFTER COMPLETION OF WORK…………….4113
 AFTER COLD WEATHER…………….4113
 LONG-TERM STORAGE…………….4114
 BEFORE STORAGE…………….4114
 DURING STORAGE…………….4114
 AFTER STORAGE…………….4114
 TROUBLESHOOTING…………….4115
 AFTER RUNNING OUT OF FUEL…………….4115
 METHOD OF TOWING MACHINE…………….4115
 IF BATTERY IS DISCHARGED…………….4117
 OTHER TROUBLE…………….4121
MAINTENANCE…………….4125
 GUIDE TO MAINTENANCE…………….4126
 OUTLINE OF SERVICE…………….4129
 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…………….4129
 RELATING TO ELECTRIC SYSTEM…………….4132
 HANDLING HYDRAULIC SYSTEM…………….4133
 WEAR PARTS LIST…………….4134
 WEAR PARTS LIST…………….4135
 RECOMMENDED FUEL, COOLANT, AND LUBRICANT…………….4136
 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…………….4137
 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…………….4138
 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…………….4139
 TORQUE LIST…………….4139
 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…………….4140
 SAFETY CRITICAL PARTS…………….4141
 MAINTENANCE SCHEDULE CHART…………….4143
 MAINTENANCE SCHEDULE CHART…………….4143
 SERVICE PROCEDURE…………….4145
 WHEN REQUIRED…………….4145
 CHECK BEFORE STARTING…………….4171
 EVERY 50 HOURS SERVICE…………….4172
 EVERY 250 HOURS SERVICE…………….4174
 EVERY 500 HOURS SERVICE…………….4183
 EVERY 1000 HOURS SERVICE…………….4189
 EVERY 2000 HOURS SERVICE…………….4197
 EVERY 4000 HOURS SERVICE…………….4202
 EVERY 8000 HOURS SERVICE…………….4205
SPECIFICATIONS …………….4207
 SPECIFICATIONS…………….4208
ATTACHMENTS, OPTIONS …………….4211
 GENERAL PRECAUTIONS…………….4212
 PRECAUTIONS RELATED TO SAFETY…………….4212
 AIR SUSPENSION SEAT…………….4213
 EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT…………….4215
 HANDLING MACHINES EQUIPPED WITH KOMTRAX…………….4216
 BASIC PRECAUTIONS…………….4216
INDEX…………….4217
TEN00606-02 – Bulldozer D37EX-23, D37PX-23, D39EX-23, D39PX-23 Operation & Maintenance Manual (SN80001&up)…………….4221
COVER…………….4221
FOREWORD …………….4222
 BEFORE READING THIS MANUAL …………….4223
 SAFETY INFORMATION …………….4225
 INTRODUCTION …………….4226
 USE OF MACHINE …………….4226
 DIRECTIONS OF MACHINE …………….4226
 VISIBILITY FROM OPERATOR'S SEAT …………….4227
 PRODUCT INFORMATION …………….4228
 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE …………….4228
 EPA REGULATIONS, ENGINE SERIAL NO. PLATE …………….4228
 SERVICE METER LOCATION …………….4229
 YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR …………….4229
 CONTENTS …………….4230
SAFETY …………….4234
 SAFETY …………….4235
 SAFETY LABELS …………….4237
 LOCATION OF SAFETY LABELS …………….4237
 SAFETY LABELS …………….4238
 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE …………….4242
 PRECAUTIONS BEFORE STARTING OPERATION …………….4242
 PREPARATIONS FOR SAFE OPERATION …………….4243
 FIRE PREVENTION …………….4245
 PRECAUTIONS WHEN GETTING ON OR OFF MACHINE …………….4247
 DO NOT GET CAUGHT IN WORK EQUIPMENT …………….4248
 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES …………….4249
 UNAUTHORIZED MODIFICATION …………….4249
 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS …………….4249
 PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING …………….4249
 PRECAUTIONS FOR OPERATION …………….4250
 PRECAUTIONS FOR JOBSITE …………….4250
 STARTING ENGINE …………….4253
 OPERATION …………….4256
 TRANSPORTATION …………….4260
 TOWING …………….4261
 PRECAUTIONS FOR MAINTENANCE …………….4262
 PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE …………….4262
 PRECAUTIONS FOR INSPECTION AND MAINTENANCE …………….4266
OPERATION …………….4272
 GENERAL VIEW …………….4273
 GENERAL VIEW OF MACHINE …………….4273
 GENERAL VIEW OF CONTROLS AND GAUGES …………….4275
 EXPLANATION OF COMPONENTS …………….4277
 MACHINE MONITOR …………….4277
 SWITCHES …………….4348
 CONTROL LEVERS AND PEDALS …………….4354
 FUSE …………….4360
 FUSIBLE LINK …………….4362
 AUXILIARY ELECTRIC POWER …………….4363
 OIL FILLER CAP …………….4364
 DOOR OPEN LOCK …………….4366
 SASH GLASS INTERMEDIATE LOCK …………….4366
 ASHTRAY …………….4367
 LUNCH BOX FASTENING BELT …………….4368
 CUP HOLDER …………….4368
 TOOLBOX …………….4369
 GREASE PUMP HOLDER …………….4370
 OPEN AND CLOSE REAR MASK …………….4371
 HANDLING AIR CONDITIONER …………….4372
 HANDLING RADIO …………….4376
 BATTERY DISCONNECT SWITCH …………….4381
 SYSTEM OPERATING LAMP …………….4382
 HANDLING Komatsu Closed Crankcase Ventilation (KCCV) …………….4383
 HANDLING MACHINES EQUIPPED WITH KOMTRAX …………….4384
 MACHINE OPERATIONS AND CONTROLS …………….4386
 CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE …………….4386
 STARTING ENGINE …………….4410
 OPERATIONS AND CHECKS AFTER STARTING ENGINE …………….4415
 STOPPING ENGINE …………….4420
 MACHINE OPERATION …………….4421
 SHIFTING GEARS …………….4424
 SWITCH BETWEEN FORWARD AND REVERSE …………….4427
 STEERING THE MACHINE …………….4428
 RULES FOR OPERATION …………….4431
 RECOMMENDED APPLICATIONS …………….4434
 RECOMMENDED MODE BY APPLICATION …………….4436
 ADJUST WORK EQUIPMENT …………….4439
 PARKING MACHINE …………….4440
 CHECK AFTER FINISHING WORK …………….4442
 LOCK …………….4443
 TIPS FOR LONGER UNDERCARRIAGE LIFE …………….4444
 TRANSPORTATION …………….4447
 TRANSPORTATION PROCEDURE …………….4447
 REMOVAL OF CAB …………….4447
 PRECAUTIONS WHEN REMOVING WORK EQUIPMENT …………….4448
 LOADING AND UNLOADING WITH TRAILER …………….4450
 LIFTING MACHINE …………….4453
 TRAVELING ON ROADS …………….4454
 COLD WEATHER OPERATION …………….4455
 COLD WEATHER OPERATION INFORMATION …………….4455
 AFTER DAILY WORK COMPLETION …………….4456
 AFTER COLD WEATHER SEASON …………….4457
 LONG-TERM STORAGE …………….4458
 BEFORE STORAGE …………….4458
 DURING STORAGE …………….4458
 AFTER STORAGE …………….4459
 STARTING MACHINE AFTER LONG-TERM STORAGE …………….4460
 TROUBLES AND ACTIONS …………….4461
 TOWING MACHINE …………….4461
 DISCHARGED BATTERY …………….4462
 OTHER TROUBLE …………….4467
MAINTENANCE …………….4472
 RULES FOR MAINTENANCE …………….4473
 SERVICE METER READING …………….4473
 KOMATSU GENUINE REPLACEMENT PARTS …………….4473
 KOMATSU GENUINE LUBRICANTS …………….4473
 ALWAYS USE CLEAN WASHER FLUID …………….4473
 FRESH AND CLEAN LUBRICANTS …………….4473
 CHECK DRAINED OIL AND USED FILTER …………….4473
 CAUTION FOR REFILLING OIL OR FUEL …………….4473
 WELDING INSTRUCTIONS …………….4473
 DO NOT DROP THINGS INSIDE MACHINE …………….4473
 DUSTY JOBSITES …………….4473
 AVOID MIXING OIL …………….4474
 PRECAUTIONS FOR OPENING AND CLOSING REAR MASK …………….4474
 WHEN OPENING INSPECTION COVER …………….4474
 LOCKING INSPECTION COVERS …………….4474
 BLEED AIR FROM HYDRAULIC CIRCUIT …………….4474
 PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES …………….4474
 CHECKS AFTER INSPECTION AND MAINTENANCE …………….4474
 FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE …………….4475
 OUTLINE OF MAINTENANCE …………….4476
 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC …………….4476
 HANDLING ELECTRICAL COMPONENTS …………….4480
 HANDLING HYDRAULIC COMPONENTS …………….4481
 STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS …………….4482
 TIGHTENING TORQUE LIST …………….4482
 MAINTENANCE SCHEDULE …………….4483
 MAINTENANCE SCHEDULE TABLE …………….4483
 MAINTENANCE PROCEDURE …………….4485
 WHEN REQUIRED …………….4485
 CHECKS BEFORE STARTING …………….4515
 EVERY 50 HOURS MAINTENANCE …………….4516
 EVERY 250 HOURS MAINTENANCE …………….4518
 EVERY 500 HOURS MAINTENANCE …………….4523
 EVERY 1000 HOURS MAINTENANCE …………….4529
 EVERY 2000 HOURS MAINTENANCE …………….4535
 EVERY 4000 HOURS MAINTENANCE …………….4543
 EVERY 8000 HOURS MAINTENANCE …………….4545
SPECIFICATIONS …………….4546
 SPECIFICATIONS …………….4547
ATTACHMENTS AND OPTIONS …………….4550
 GENERAL PRECAUTIONS …………….4551
 PRECAUTIONS FOR SAFETY …………….4551
 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT …………….4552
REPLACEMENT PARTS …………….4554
 SAFETY CRITICAL PARTS …………….4555
 SAFETY CRITICAL PARTS LIST …………….4555
 CONSUMABLE PARTS …………….4557
 CONSUMABLE PARTS LIST …………….4557
 RECOMMENDED FUEL, COOLANT, AND LUBRICANT …………….4559
 LUBRICATION CHART …………….4559
 USE OF FUEL, COOLANT AND LUBRICANTS TO ACCORDING TO AMBIENT TEMPERATURE …………….4561
 RECOMMENDED BRANDS AND QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL …………….4563
INDEX …………….4564

Komatsu Bulldozer D31-, D32-, D37-, D39- Series Operation Maintenance Manual

INSTANT DOWNLOAD

Posted on June 5, 2025 by admin

Komatsu Bulldozers D31EX,PX & D37EX,PX & D39EX,PX Repair Service Manuals

INSTANT DOWNLOAD

Complete service repair manuals for Komatsu Bulldozers D31EX, D31PX, D37EX, D37PX, D39EX, D39PX, with all the technical information to maintain, diagnose, repair, andservice like professional mechanics.

Komatsu Bulldozers D31EX, D31PX, D37EX, D37PX, D39EX, D39PX 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.

SEBM02560 – Bulldozer D31EX,PX-21, D37EX,PX-21 Shop Manual (SN5001&up).pdf
SEBM025607 – Bulldozer D31EX,PX-21, D37EX,PX-21 Shop Manual (SN5001&up).pdf
SEBM035005 – Bulldozer D31EX,PX-21, D37EX,PX-21, D39EX,PX-21 Shop Manual (SN1501&up).pdf
SEN04343-08 – Bulldozer D31EX-22, D31PX-22, D37EX-22, D37PX-22 Shop Manual (SN60001&up).pdf
SEN06061-03 – Bulldozer D37EX-23, D37PX-23, D39EX-23, D39PX-23 Shop Manual (SN80001&up).pdf

PRODUCT DETAILS:
Total Pages: 4,124 pages
File Format: PDF
Language: English

TABLE OF CONTENTS
Shop Manual, contents binder, binder label and tabs … SEN04343-08
00 Index and foreword .. SEN04344-08
100 Index .. SEN04352-08 q
200 Foreword and general information …SEN04353-02
01 General .. SEN04345-00
100 Specification and technical data… SEN04354-00
10 Structure, function and maintenance standard… SEN04346-00
100 Engine and cooling system .. SEN04484-00
200 Power train… SEN04485-00
300 Undercarriage and frame … SEN04486-00
410 Hydraulic system, Part 1 ..SEN04487-00
420 Hydraulic system, Part 2 ..SEN04488-00
500 Work equipment… SEN04489-00
600 Cab and its attachments .. SEN04490-00
700 Electrical system .. SEN04491-00
20 Standard value table… SEN04347-02
100 Standard service value table.. SEN04501-02
30 Testing and adjusting … SEN04348-02
110 Testing and adjusting, Part 1.. SEN04502-02
120 Testing and adjusting, Part 2.. SEN04503-01
130 Testing and adjusting, Part 3.. SEN04504-01
40 Troubleshooting.. SEN04349-01
100 Failure code table and fuse locations .. SEN04505-00
200 General information on troubleshooting… SEN04506-01
310 Troubleshooting by failure code (Display of code), Part 1 … SEN04507-01
320 Troubleshooting by failure code (Display of code), Part 2 … SEN04508-01
330 Troubleshooting by failure code (Display of code), Part 3 … SEN04509-00
340 Troubleshooting by failure code (Display of code), Part 4 … SEN04510-00
350 Troubleshooting by failure code (Display of code), Part 5 … SEN04511-00
400 Troubleshooting of electrical system (E-mode).. SEN04512-00
500 Troubleshooting of hydraulic and mechanical system (H-mode) … SEN04513-00
600 Troubleshooting of engine (S-mode).. SEN04514-01
50 Disassembly and assembly ..SEN04350-01
100 General information on disassembly and assembly…SEN04724-01
200 Engine and cooling system ..SEN04725-01
300 Power train …SEN04726-01
400 Undercarriage and frame …SEN04727-01
500 Hydraulic system ..SEN04728-00
600 Work equipment …SEN04729-00
700 Cab and its attachments…SEN04730-00
800 Electrical system ..SEN04731-00
90 Diagrams and drawings..SEN04351-03
100 Hydraulic diagrams and drawings ..SEN04355-02 q
200 Electrical diagrams and drawings…SEN04356-01

SEBM02560 – Bulldozer D31EX,PX-21, D37EX,PX-21 Shop Manual (SN5001&up)…….2
COVER…….2
CONTENTS…….3
01 GENERAL…….36
    SPECIFICATION DRAWING…….37
    SPECIFICATIONS…….39
    WEIGHT TABLE…….47
    TABLE OF FUEL, COOLANT AND LUBRICANTS…….49
10 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD…….50
    COOLING SYSTEM…….51
    ENGINE CONTROL…….52
    POWER TRAIN…….53
    POWER TRAIN SYSTEM…….54
    HST HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAM…….55
    STEERING, BRAKE CONTROL…….56
    DAMPER…….60
    SOLENOID VALVE…….61
    FINAL DRIVE…….63
    HST PUMP…….66
    SAFETY-SUCTION VALVE…….71
    CUT-OFF VALVE…….74
    CHARGE SAFETY VALVE…….75
    CHARGE PUMP…….77
    HST BRAKE QUICK RETURN CIRCUIT…….78
    TOWING VALVE…….79
    PARKING BRAKE VALVE…….80
    AS VALVE…….82
    HST MOTOR…….84
    STEERING, DIRECTIONAL PPC VALVE…….95
    AUTOMATIC GEARSHIFTING VALVE…….104
    INCHING VALVE…….109
    FRAME ASSEMBLY…….110
    TRACK FRAME, RECOIL SPRING…….111
    IDLER…….113
    TRACK ROLLER…….115
    CARRIER ROLLER…….117
    SPROCKET…….118
    TRACK SHOE…….120
    ARRANGEMENT OF HYDRAULIC EQUIPMENT FOR WORK EQUIPMENT…….124
    WORK EQUIPMENT CONTROL…….125
    HYDRAULIC TANK, FILTER…….127
    HYDRAULIC PUMP…….128
    WORK EQUIPMENT CYLINDER…….129
    CONTROL VALVE…….131
    CLSS…….139
    WORK EQUIPMENT PPC VALVE…….149
    WORK EQUIPMENT …….156
    CUTTING EDGE, END BIT…….159
    CAB RELATED…….160
    SAFETY MECHANISM WHEN STARTING ENGINE…….161
    GEARSHIFT CONTROL SYSTEM…….162
    PARKING BRAKE CONTROL SYSTEM…….163
    COMPONENT EQUIPMENT OF SYSTEM…….164
    MONITOR SYSTEM…….166
    SENSORS…….170
20 TESTING AND ADJUSTING…….173
    STANDARD VALUE TABLE FOR ENGINE…….174
    STANDARD VALUE TABLE FOR CHASSIS…….176
    STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM…….181
    TESTING AND ADJUSTING…….183
      TOOLS LIST FOR TESTING AND ADJUSTING…….184
      MEASURING ENGINE SPEED…….187
      MEASURING EXHAUST COLOR…….188
      MEASURING BLOW-BY PRESSURE…….189
      MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)…….190
      ADJUSTING VALVE CLEARANCE…….191
      TESTING ADJUSTING FUEL INJECTION TIMING…….193
      MEASURING COMPRESSION PRESSURE…….194
      ADJUSTING ENGINE STOP SOLENOIDE LINKAGE…….195
      MEASURING ENGINE OIL PRESSURE…….196
      BLEEDING AIR FROM FUEL CIRCUIT…….197
      REPLACEMENT OF FAN BELT…….198
      TESTING AND ADJUSTING TENSION OF AIR CONDITIONER COMPRESSOR BELT…….200
      MEASURING AND ADJUSTING HST OIL PRESSURE…….201
      MEASURING SOLENOID VALVE OUTPUT PRESSURE…….207
      MEASURING AND ADJUSTING WORK EQUIPMENT MAIN RELIEF PRESSURE…….208
      MEASURING PPC VALVE OUTPUT PRESSURE…….210
      MEASURING LEAKAGE INSIED CYLINDER…….211
      BLEEDING AIR FROM HYDRAULIC CYLINDERS…….211
      TESTING AND ADJUSTING TRACK SHOE TENSION…….212
      TESTING AND ADJUSTING TRAVEL DEVIATION…….213
      ADJUSTING FUEL CONTROL LINKAGE…….216
      ADJUSTING DECELERATOR PEDAL LINKAGE…….218
      ADJUSTING BRAKE PEDAL LINKAGE…….219
      ADJUSTING STEERING/DIRECTIONAL/GEAR SHIFT LEVER AND LOCK LEVER…….220
      ADJUSTING BLADE CONTROL LEVER AND LOCK LEVER…….223
      ADJUSTING WORK EQUIPMENT PPC VALVE…….224
      PROCEDURE FOR RELEASING PARKING BRAKE…….225
      PROCEDURE FOR INSPECTING DIODE…….227
    TROUBLESHOOTING…….228
      POINTS TO REMEMBER WHEN TROUBLESHOOTING…….229
      SEQUENCE OF EVENTS IN TROUBLESHOOTING…….230
      HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT…….231
      CHECKS BEFORE TROUBLESHOOTING…….241
      METHOD OF USING TROUBLESHOOTING CHARTS…….242
      TYPES AND LOCATIONS OF CONNECTORS…….243
      CONNECTOR ARRANGEMENT DIAGRAM…….245
      CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…….247
      T-BRANCH BOX AND T-BRANCH ADAPTER TABLE…….283
      TROUBLESHOOTING FOR ELECTRICAL SYSTEM (E-MODE)…….286
        TABLE OF FAILURE MODES AND CAUSES (ELECTRICAL SYSTEM)…….287
        ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM…….289
        E-1. WHEN STARTING SWITCH IS TURNED ON, STARTING MOTOR DOES NOT ROTATE…….291
        E-2. ENGINE DOES NOT START (ENGINE STOP SOLENOID DOES NOT OPERATE NORMALLY)…….293
        E-3. HEADLAMP DOES NOT LIGHT UP…….294
        E-4. WHEN STARTING SWITCH IS TURNED TO HEAT POSITION, ENGINE IS NOT HEATED…….296
        E-5. WINDSHIELD WIPER DOES NOT OPERATE…….297
        E-6. WASHING WATER DOES NOT SPOUT…….299
        E-7. AIR CONDITIONER DOES NOT WORK…….301
          a) AIR DOES NOT BLOW OUT…….301
          b) AIR IS NOT COOLED…….304
        E-8. PARKING BRAKE CANNOT BE RELEASED (PARKING BRAKE SOLENOID DOES NOT OPERATE)…….308
        E-9. TRAVEL SPEED CONTROL IS ABNORMAL…….309
          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)…….309
          b) GEAR SPEED CANNOT BE SELECTED NORMALLY (TRAVEL SPEED CHANGEOVER SOLENOID IS ABNORMAL)…….310
        E-10. BACKUP ALARM DOES NOT SOUND DURING REVERSE TRAVEL…….312
        E-11. HORN DOES NOT SOUND…….314
      TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)…….315
        TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC AND MECHANICAL SYSTEMS)…….316
        H-1. MACHINE DOES NOT TRAVEL IN EITHER DIRECTION OR IT STOPS SUDDENLY…….318
        H-2. MACHINE DOES NOT TRAVEL IN ONE DIRECTION…….319
        H-3. MACHINE TRAVELS WHILE TRAVEL LEVER IS IN NEUTRAL…….319
        H-5. MACHINE DEVIATES WHILE TRAVEL LEVER IS IN PARTIAL POSITION…….319
        H-7. MACHINE SWHINGS MOMENTARILY WHEN IT STARTS ON FLAT GROUND…….319
        H-11. TURNING TIME LAG IS LARGE…….319
        H-12. WHEN OPERATOR INTENDS TO TURN GARDUALLY, MACHINE TURNS SHARPLY…….319
        H-13. MACHINE DOES NOT RETURN QUICKLY TO STRAIGHT TRAVEL POSITION…….319
        H-14. MACHINE IS NOT DECELERATED SMOOTHLY OR TRAVEL SPEED CANNOT BE CONTROLLED ON DOWNHILL GROUND…….319
        H-15. MACHINE DEVIATES WHEN IT IS DECELERATED…….319
        H-4. MACHINE DEVIATES WHEN TRAVEL LEVER IS MOVED TO STROKE END…….320
        H-6. MACHINE MOVES BACK WHEN OPERATOR STARTS ON UPHILL GROUND…….320
        H-8. MACHINE STARTS SHARPLY…….320
        H-9. MACHINE SWINGS MOMENTARLLY WHEN IT STARTS…….321
        H-10. STARTING TIME LAG IS LARGE…….322
        H-16. MAXIMUM TRAVEL SPEED IS LOW OR OUTPUT POWER IS INSUFFICIENT OR ACCELERATION IS LOW…….323
        H-17. ENGINE STALLS…….324
        H-18. HST NOISE IS LARGE…….325
        H-19. HST OIL TEMPERATURE RISES TOO HIGH…….326
        H-20. GEAR SPEED DOES NOT CHANGE…….326
        H-21. ABNORMAL SOUND IS HEARD FROM AROUND WORK EQUIPMENT PUMP OR HST PUMP…….327
        H-22. ANY WORK EQUIPMENT DOES NOT MOVE…….327
        H-23. SPEED OR POWER OF EACH WORK EQUIPMENT IS LOW…….328
        H-24. SPEED OR POWER OF BLADE LIFT OF BLADE TILT CYLINDER IS LOW…….328
        H-25. SPEED OR POWER OF BLADE ANGLE CYLINDER IS LOW…….329
        H-26. HYDRAULIC DRIFT OF BLADE LIFT CYLINDER IS LARGE…….330
        H-27. HYDRAULIC DRIFT OF BLADE TILT CYLINDER IS LARGE…….330
        H-28. HYDRAULIC DRIFT OF BLADE ANGLE CYLINDER IS LARGE…….331
      TROUBLESHOOTING FOR MACHINE MONITOR SYSTEM (M-MODE)…….332
        TABLE OF FAILURE MODES AND CAUSES (MACHINE MONITOR SYSTEM)…….333
        ELECTRIC CIRCUIT DIAGRAM FOR EACH SYSTEM…….334
        M-1. WHEN STARTING SWITCH IS TURNED ON , MONITOR PANEL IS NOT TURNED ON…….336
        M-2. TROUBLE IN PREHEATING CAUTION LAMP…….337
          a) PREHEATING MONITOR DOES NOT LIGHT UP…….337
          b) PREHEATING MONITOR KEEPS LIGHTING UP…….337
        M-3. CAUTION ITEM LIGHTS UP…….338
          a) CHARGE CAUTION LAMP LIGHTS UP WHILE ENGINE IS RUNNING…….338
          b) OIL PRESSURE CAUTION LAMP LIGHTS UP WHILE ENGINE IS RUNNING…….339
          c) HST FILTER CLOGGING CAUTION LAMP LIGHTS UP (WHILE FILTER IS NOT CLOGGED)…….339
        M-4. TROUBLE IN HST OIL TEMPERATURE GAUGE…….340
          a) GAUGE DOES NOT RISE ABOVE C (LOWEST POINT)…….340
          b) GAUGE DOES NOT LOWER BELOW H (HIGHEST POINT)…….340
          c) HST OIL TEMPERATURE INDICATED BY GAUGE IS DIFFERENT FROM ACTUAL TEMPERATURE…….341
        M-5. TROUBLE IN ENGINE WATER TEMPERATURE GAUGE…….342
          a) GAUGE DOES NOT RISE ABOVE C (LOWEST POINT)…….342
          b) GAUGE DOES NOT LOWER BELOW H (HIGHEST POINT)…….342
          c) ENGINE WATER TEMPERATURE INDICATED BY GAUGE IS DIFFERENT FROM ACTUAL TEMPERATURE…….343
        M-6. TROUBLE IN FUEL LEVEL GAUGE…….344
          a) GAUGE DOES NOT RISE ABOVE E (LOWEST POINT)…….344
          b) GAUGE DOES NOT LOWER BELOW F (HIGHEST POINT)…….344
          c) FUEL LEVEL INDICATED BY GAUGE IS DIFFERENT FROM ACTUAL LEVEL…….345
        M-7. SERVICE METER DOES NOT OPERATE AFTER ENGINE IS STARTED…….346
        M-8. MONITOR PANEL LAMP DOES NOT LIGHT UP (WHILE HEADLAMP IS NORMAL)…….347
        M-9. TROUBLE IN DISPLAY OF TRAVEL SPEED (WHILE ACTUAL TRAVEL SPEED IS NORMAL)…….348
          a) TRAVEL SPEED IS NOT DISPLAYED…….348
          b) DISPLAYED SPEED IS DIFFERENT FROM ACTUAL TRAVEL SPEED…….348
      TROUBLESHOOTING FOR ENGINE SYSTEM (S-MODE)…….350
        METHOD OF USING TROUBLESHOOTING CHARTS…….351
        S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) …….355
        S-2 ENGINE DOES NOT START…….356
        S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)…….359
        S-4 ENGINE STOPS DURING OPERATIONS…….360
        S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)…….361
        S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)…….362
        S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)…….363
        S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)…….364
        S-9 OIL BECOMES CONTAMINATED QUICKLY…….365
        S-10 FUEL CONSUMPTION IS EXCESSIVE…….366
        S-11 OIL IS IN COOLANT, OR COOLANT SPURTS BACK, OR COOLANT LEVEL GOES DOWN…….367
        S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)…….368
        S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)…….369
        S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)…….370
        S-15 ABNORMAL NOISE IS MADE…….371
        S-16 VIBRATION IS EXCESSIVE…….372
30 DISASSEMBLY AND ASSEMBLY…….374
    HOW TO READ THIS MANUAL…….375
    COATING MATERIALS LIST…….377
    SPECIAL TOOL LIST…….380
    SKETCHES OF SPECIAL TOOLS…….382
    REMOVAL OF FUEL INJECTION PUMP ASSEMBLY…….383
    INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY…….385
    REMOVAL OF CYLINDER HEAD ASSEMBLY…….387
    INSTALLATION OF CYLINDER HEAD ASSEMBLY…….392
    REMOVAL OF ENGINE FRONT SEAL…….394
    INSTALLATION OF ENGINE FRONT SEAL…….395
    REMOVAL OF ENGINE REAR SEAL…….396
    INSTALLATION OF ENGINE REAR SEAL…….397
    REMOVAL OF RADIATOR GUARD ASSEMBLY…….398
    INSTALLATION OF RADIATOR GUARD ASSEMBLY…….400
    DISASSEMBLY OF RADIATOR, OIL COOLER, AND CHARGE AIR COOLER ASSEMBLIES…….401
    ASSEMBLY OF RADIATOR, OIL COOLER, AND CHARGE AIR COOLER ASSEMBLIES…….403
    REMOVAL OF ENGINE ASSEMBLY…….405
    INSTALLATION OF ENGINE ASSEMBLY…….407
    REMOVAL OF DAMPER…….408
    INSTALLATION OF DAMPER…….408
    REMOVAL OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY…….409
    INSTALLATION OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY…….410
    DISASSEMBLY OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY…….411
    ASSEMBLY OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY…….415
    REMOVAL OF IDLER AND RECOIL SPRING ASSEMBLY…….420
    INSTALLATION OF IDLER AND RECOIL SPRING ASSEMBLY…….420
    DISASSEMBLY OF RECOIL SPRING ASSEMBLY…….421
    ASSEMBLY OF RECOIL SPRING ASSEMBLY…….422
    DISASSEMBLY OF IDLER ASSEMBLY…….424
    ASSEMBLY OF IDLER ASSEMBLY…….425
    DISASSEMBLY OF TRACK ROLLER ASSEMBLY…….427
    ASSEMBLY OF TRACK ROLLER ASSEMBLY…….428
    DISASSEMBLY OF CARRIER ROLLER ASSEMBLY…….431
    ASSEMBLY OF CARRIER ROLLER ASSEMBLY…….432
    SPREADING TRACK SHOE ASSEMBLY…….433
    INSTALLATION OF TRACK SHOE ASSEMBLY…….434
    REMOVAL OF HST PUMP ASSEMBLY…….435
    INSTALLATION OF HST PUMP ASSEMBLY…….436
    REMOVAL OF MAIN CONTROL VALVE ASSEMBLY…….437
    INSTALLATION OF MAIN CONTROL VALVE ASSEMBLY…….438
    DISASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY…….439
    ASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY…….443
    DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLIES…….447
    ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLIES…….448
    REMOVAL OF BLADE ASSEMBLY…….450
    INSTALLATION OF BLADE ASSEMBLY…….451
    REMOVAL OF OPERATOR'S SEAT TRAME ASSEMBLY…….452
    INSTALLATION OF OPERATOR'S SEAT FRAME ASSEMBLY…….455
    REMOVAL OF FUEL TANK ASSEMBLY…….456
    INSTALLATION OF FUEL TANK ASSEMBLY…….456
    REMOVAL OF HYDRAULIC TANK ASSEMBLY…….457
    INSTALLATION OF HYDRAULIC TANK ASSEMBLY…….458
90 OTHERS…….459
    HYDRAULIC CIRCUIT DIAGRAM (1/2)(D31EX-21 SERIAL NO.50001-50097 D31PX-21 SERIAL NO.50001-50181 D37EX-21 SERIAL NO. 5001-5104 D37PX-21 SERIAL NO. 5001-5090)…….460
    HYDRAULIC CIRCUIT DIAGRAM (1/2)(D31EX-21 SERIAL NO.50098 AND UP D31PX-21 SERIAL NO.50182 AND UP D37EX-21 SERIAL NO.5105 AND UP D37PX-21 SERIAL NO.5091 AND UP)…….461
    HYDRAULIC CIRCUIT DIAGRAM (2/2)…….462
    HYDRAULIC CIRCUIT DIAGRAM (2/2) (FOR D37EX, PX-21 EU SPEC.)…….463
    ELECTRICAL CIRCUIT DIAGRAM (1/2)…….464
    ELECTRICAL CIRCUIT DIAGRAM (2/2)…….465
    ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER…….466
SEBM025607 – Bulldozer D31EX,PX-21, D37EX,PX-21 Shop Manual (SN5001&up)…….467
COVER…….467
CONTENTS…….468
01 GENERAL…….492
    SPECIFICATION DRAWING…….493
    SPECIFICATIONS…….495
    WEIGHT TABLE…….503
    TABLE OF FUEL, COOLANT AND LUBRICANTS…….505
10 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD…….506
    COOLING SYSTEM…….507
    ENGINE CONTROL…….508
    POWER TRAIN…….509
    POWER TRAIN SYSTEM…….510
    HST HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAM…….511
    STEERING, BRAKE CONTROL…….512
    DAMPER…….516
    SOLENOID VALVE…….517
    FINAL DRIVE…….519
    HST PUMP…….522
    SAFETY-SUCTION VALVE…….527
    CUT-OFF VALVE…….530
    CHARGE SAFETY VALVE…….531
    CHARGE PUMP…….533
    HST BRAKE QUICK RETURN CIRCUIT…….534
    TOWING VALVE…….535
    PARKING BRAKE VALVE…….536
    AS VALVE…….538
    HST MOTOR…….540
    STEERING, DIRECTIONAL PPC VALVE…….551
    AUTOMATIC GEARSHIFTING VALVE…….560
    INCHING VALVE…….565
    FRAME ASSEMBLY…….566
    TRACK FRAME, RECOIL SPRING…….567
    IDLER…….569
    TRACK ROLLER…….571
    CARRIER ROLLER…….573
    SPROCKET…….574
    TRACK SHOE…….576
    ARRANGEMENT OF HYDRAULIC EQUIPMENT FOR WORK EQUIPMENT…….580
    WORK EQUIPMENT CONTROL…….581
    HYDRAULIC TANK, FILTER…….583
    HYDRAULIC PUMP…….584
    WORK EQUIPMENT CYLINDER…….585
    CONTROL VALVE…….587
    CLSS…….595
    WORK EQUIPMENT PPC VALVE…….605
    WORK EQUIPMENT …….612
    CUTTING EDGE, END BIT…….615
    CAB RELATED…….616
    SAFETY MECHANISM WHEN STARTING ENGINE…….617
    GEARSHIFT CONTROL SYSTEM…….618
    PARKING BRAKE CONTROL SYSTEM…….619
    COMPONENT EQUIPMENT OF SYSTEM…….620
    MONITOR SYSTEM…….622
    SENSORS…….626
20 TESTING AND ADJUSTING…….629
    STANDARD VALUE TABLE FOR ENGINE…….630
    STANDARD VALUE TABLE FOR CHASSIS…….632
    STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM…….637
    TESTING AND ADJUSTING…….639
      TOOLS LIST FOR TESTING AND ADJUSTING…….640
      MEASURING ENGINE SPEED…….641
      MEASURING EXHAUST COLOR…….642
      MEASURING BLOW-BY PRESSURE…….643
      MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)…….644
      ADJUSTING VALVE CLEARANCE…….645
      TESTING ADJUSTING FUEL INJECTION TIMING…….647
      MEASURING COMPRESSION PRESSURE…….648
      ADJUSTING ENGINE STOP SOLENOIDE LINKAGE…….649
      MEASURING ENGINE OIL PRESSURE…….650
      BLEEDING AIR FROM FUEL CIRCUIT…….651
      TESTING AND ADJUSTING TENSION OF AIR CONDITIONER COMPRESSOR BELT…….652
      MEASURING AND ADJUSTING HST OIL PRESSURE…….653
      MEASURING SOLENOID VALVE OUTPUT PRESSURE…….659
      MEASURING AND ADJUSTING WORK EQUIPMENT MAIN RELIEF PRESSURE…….660
      MEASURING PPC VALVE OUTPUT PRESSURE…….662
      MEASURING LEAKAGE INSIED CYLINDER…….663
      BLEEDING AIR FROM HYDRAULIC CYLINDERS…….663
      TESTING AND ADJUSTING TRACK SHOE TENSION…….664
      TESTING AND ADJUSTING TRAVEL DEVIATION…….665
      ADJUSTING FUEL CONTROL LINKAGE…….668
      ADJUSTING DECELERATOR PEDAL LINKAGE…….670
      ADJUSTING BRAKE PEDAL LINKAGE…….671
      ADJUSTING STEERING/DIRECTIONAL/GEAR SHIFT LEVER AND LOCK LEVER…….672
      ADJUSTING BLADE CONTROL LEVER AND LOCK LEVER…….675
      ADJUSTING WORK EQUIPMENT PPC VALVE…….676
      PROCEDURE FOR RELEASING PARKING BRAKE…….677
      PROCEDURE FOR INSPECTING DIODE…….679
    TROUBLESHOOTING…….680
      POINTS TO REMEMBER WHEN TROUBLESHOOTING…….681
      SEQUENCE OF EVENTS IN TROUBLESHOOTING…….682
      POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…….683
      CHECKS BEFORE TROUBLESHOOTING…….691
      METHOD OF USING TROUBLESHOOTING CHARTS…….692
      TYPES AND LOCATIONS OF CONNECTORS…….693
      CONNECTOR ARRANGEMENT DIAGRAM…….695
      CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…….697
      TROUBLESHOOTING FOR ELECTRICAL SYSTEM (E-MODE)…….719
        TABLE OF FAILURE MODES AND CAUSES (ELECTRICAL SYSTEM)…….720
        ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM…….722
        E-1. WHEN STARTING SWITCH IS TURNED ON, STARTING MOTOR DOES NOT ROTATE…….724
        E-2. ENGINE DOES NOT START (ENGINE STOP SOLENOID DOES NOT OPERATE NORMALLY)…….726
        E-3. HEADLAMP DOES NOT LIGHT UP…….727
        E-4. WHEN STARTING SWITCH IS TURNED TO HEAT POSITION, ENGINE IS NOT HEATED…….729
        E-5. WINDSHIELD WIPER DOES NOT OPERATE…….730
        E-6. WASHING WATER DOES NOT SPOUT…….732
        E-7. AIR CONDITIONER DOES NOT WORK…….734
          a) AIR DOES NOT BLOW OUT…….734
          b) AIR IS NOT COOLED…….737
        E-8. PARKING BRAKE CANNOT BE RELEASED (PARKING BRAKE SOLENOID DOES NOT OPERATE)…….741
        E-9. TRAVEL SPEED CONTROL IS ABNORMAL…….742
          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)…….742
          b) GEAR SPEED CANNOT BE SELECTED NORMALLY (TRAVEL SPEED CHANGEOVER SOLENOID IS ABNORMAL)…….743
        E-10. BACKUP ALARM DOES NOT SOUND DURING REVERSE TRAVEL…….745
        E-11. HORN DOES NOT SOUND…….747
      TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)…….748
        TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC AND MECHANICAL SYSTEMS)…….749
        H-1. MACHINE DOES NOT TRAVEL IN EITHER DIRECTION OR IT STOPS SUDDENLY…….751
        H-2. MACHINE DOES NOT TRAVEL IN ONE DIRECTION…….752
        H-3. MACHINE TRAVELS WHILE TRAVEL LEVER IS IN NEUTRAL…….752
        H-5. MACHINE DEVIATES WHILE TRAVEL LEVER IS IN PARTIAL POSITION…….752
        H-7. MACHINE SWHINGS MOMENTARILY WHEN IT STARTS ON FLAT GROUND…….752
        H-11. TURNING TIME LAG IS LARGE…….752
        H-12. WHEN OPERATOR INTENDS TO TURN GARDUALLY, MACHINE TURNS SHARPLY…….752
        H-13. MACHINE DOES NOT RETURN QUICKLY TO STRAIGHT TRAVEL POSITION…….752
        H-14. MACHINE IS NOT DECELERATED SMOOTHLY OR TRAVEL SPEED CANNOT BE CONTROLLED ON DOWNHILL GROUND…….752
        H-15. MACHINE DEVIATES WHEN IT IS DECELERATED…….752
        H-4. MACHINE DEVIATES WHEN TRAVEL LEVER IS MOVED TO STROKE END…….753
        H-6. MACHINE MOVES BACK WHEN OPERATOR STARTS ON UPHILL GROUND…….753
        H-8. MACHINE STARTS SHARPLY…….753
        H-9. MACHINE SWINGS MOMENTARLLY WHEN IT STARTS…….754
        H-10. STARTING TIME LAG IS LARGE…….755
        H-16. MAXIMUM TRAVEL SPEED IS LOW OR OUTPUT POWER IS INSUFFICIENT OR ACCELERATION IS LOW…….756
        H-17. ENGINE STALLS…….757
        H-18. HST NOISE IS LARGE…….758
        H-19. HST OIL TEMPERATURE RISES TOO HIGH…….759
        H-20. GEAR SPEED DOES NOT CHANGE…….759
        H-21. ABNORMAL SOUND IS HEARD FROM AROUND WORK EQUIPMENT PUMP OR HST PUMP…….760
        H-22. ANY WORK EQUIPMENT DOES NOT MOVE…….760
        H-23. SPEED OR POWER OF EACH WORK EQUIPMENT IS LOW…….761
        H-24. SPEED OR POWER OF BLADE LIFT OF BLADE TILT CYLINDER IS LOW…….761
        H-25. SPEED OR POWER OF BLADE ANGLE CYLINDER IS LOW…….762
        H-26. HYDRAULIC DRIFT OF BLADE LIFT CYLINDER IS LARGE…….763
        H-27. HYDRAULIC DRIFT OF BLADE TILT CYLINDER IS LARGE…….763
        H-28. HYDRAULIC DRIFT OF BLADE ANGLE CYLINDER IS LARGE…….764
      TROUBLESHOOTING FOR MACHINE MONITOR SYSTEM (M-MODE)…….765
        TABLE OF FAILURE MODES AND CAUSES (MACHINE MONITOR SYSTEM)…….766
        ELECTRIC CIRCUIT DIAGRAM FOR EACH SYSTEM…….767
        M-1. WHEN STARTING SWITCH IS TURNED ON , MONITOR PANEL IS NOT TURNED ON…….769
        M-2. TROUBLE IN PREHEATING CAUTION LAMP…….770
          a) PREHEATING MONITOR DOES NOT LIGHT UP…….770
          b) PREHEATING MONITOR KEEPS LIGHTING UP…….770
        M-3. CAUTION ITEM LIGHTS UP…….771
          a) CHARGE CAUTION LAMP LIGHTS UP WHILE ENGINE IS RUNNING…….771
          b) OIL PRESSURE CAUTION LAMP LIGHTS UP WHILE ENGINE IS RUNNING…….772
          c) HST FILTER CLOGGING CAUTION LAMP LIGHTS UP (WHILE FILTER IS NOT CLOGGED)…….772
        M-4. TROUBLE IN HST OIL TEMPERATURE GAUGE…….773
          a) GAUGE DOES NOT RISE ABOVE C (LOWEST POINT)…….773
          b) GAUGE DOES NOT LOWER BELOW H (HIGHEST POINT)…….773
          c) HST OIL TEMPERATURE INDICATED BY GAUGE IS DIFFERENT FROM ACTUAL TEMPERATURE…….774
        M-5. TROUBLE IN ENGINE WATER TEMPERATURE GAUGE…….775
          a) GAUGE DOES NOT RISE ABOVE C (LOWEST POINT)…….775
          b) GAUGE DOES NOT LOWER BELOW H (HIGHEST POINT)…….775
          c) ENGINE WATER TEMPERATURE INDICATED BY GAUGE IS DIFFERENT FROM ACTUAL TEMPERATURE…….776
        M-6. TROUBLE IN FUEL LEVEL GAUGE…….777
          a) GAUGE DOES NOT RISE ABOVE E (LOWEST POINT)…….777
          b) GAUGE DOES NOT LOWER BELOW F (HIGHEST POINT)…….777
          c) FUEL LEVEL INDICATED BY GAUGE IS DIFFERENT FROM ACTUAL LEVEL…….778
        M-7. SERVICE METER DOES NOT OPERATE AFTER ENGINE IS STARTED…….779
        M-8. MONITOR PANEL LAMP DOES NOT LIGHT UP (WHILE HEADLAMP IS NORMAL)…….780
        M-9. TROUBLE IN DISPLAY OF TRAVEL SPEED (WHILE ACTUAL TRAVEL SPEED IS NORMAL)…….781
          a) TRAVEL SPEED IS NOT DISPLAYED…….781
          b) DISPLAYED SPEED IS DIFFERENT FROM ACTUAL TRAVEL SPEED…….781
30 DISASSEMBLY AND ASSEMBLY…….783
    METHOD OF USING MANUAL…….784
    PRECAUTIONS WHEN CARRYING OUT OPERATION…….785
    SPECIAL TOOL LIST…….787
    SKETCHES OF SPECIAL TOOLS…….789
    REMOVAL OF FUEL INJECTION PUMP ASSEMBLY…….790
    INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY…….792
    REMOVAL OF CYLINDER HEAD ASSEMBLY…….794
    INSTALLATION OF CYLINDER HEAD ASSEMBLY…….799
    REMOVAL OF ENGINE FRONT SEAL…….801
    INSTALLATION OF ENGINE FRONT SEAL…….802
    REMOVAL OF ENGINE REAR SEAL…….803
    INSTALLATION OF ENGINE REAR SEAL…….804
    REMOVAL OF RADIATOR GUARD ASSEMBLY…….805
    INSTALLATION OF RADIATOR GUARD ASSEMBLY…….807
    DISASSEMBLY OF RADIATOR, OIL COOLER, AND CHARGE AIR COOLER ASSEMBLIES…….808
    ASSEMBLY OF RADIATOR, OIL COOLER, AND CHARGE AIR COOLER ASSEMBLIES…….810
    REMOVAL OF ENGINE ASSEMBLY…….812
    INSTALLATION OF ENGINE ASSEMBLY…….814
    REMOVAL OF DAMPER…….815
    INSTALLATION OF DAMPER…….815
    REMOVAL OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY…….816
    INSTALLATION OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY…….817
    DISASSEMBLY OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY…….818
    ASSEMBLY OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY…….822
    REMOVAL OF IDLER AND RECOIL SPRING ASSEMBLY…….827
    INSTALLATION OF IDLER AND RECOIL SPRING ASSEMBLY…….827
    DISASSEMBLY OF RECOIL SPRING ASSEMBLY…….828
    ASSEMBLY OF RECOIL SPRING ASSEMBLY…….829
    DISASSEMBLY OF IDLER ASSEMBLY…….831
    ASSEMBLY OF IDLER ASSEMBLY…….832
    DISASSEMBLY OF TRACK ROLLER ASSEMBLY…….834
    ASSEMBLY OF TRACK ROLLER ASSEMBLY…….835
    DISASSEMBLY OF CARRIER ROLLER ASSEMBLY…….838
    ASSEMBLY OF CARRIER ROLLER ASSEMBLY…….839
    SPREADING TRACK SHOE ASSEMBLY…….840
    INSTALLATION OF TRACK SHOE ASSEMBLY…….841
    REMOVAL OF HST PUMP ASSEMBLY…….842
    INSTALLATION OF HST PUMP ASSEMBLY…….843
    REMOVAL OF MAIN CONTROL VALVE ASSEMBLY…….844
    INSTALLATION OF MAIN CONTROL VALVE ASSEMBLY…….845
    DISASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY…….846
    ASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY…….850
    DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLIES…….854
    ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLIES…….855
    REMOVAL OF BLADE ASSEMBLY…….857
    INSTALLATION OF BLADE ASSEMBLY…….858
    REMOVAL OF OPERATOR'S SEAT TRAME ASSEMBLY…….859
    INSTALLATION OF OPERATOR'S SEAT FRAME ASSEMBLY…….862
    REMOVAL OF FUEL TANK ASSEMBLY…….863
    INSTALLATION OF FUEL TANK ASSEMBLY…….863
    REMOVAL OF HYDRAULIC TANK ASSEMBLY…….864
    INSTALLATION OF HYDRAULIC TANK ASSEMBLY…….865
90 OTHERS…….866
    HYDRAULIC CIRCUIT DIAGRAM (1/2)(D31EX-21 SERIAL NO.50001-50097 D31PX-21 SERIAL NO.50001-50181 D37EX-21 SERIAL NO. 5001-5104 D37PX-21 SERIAL NO. 5001-5090)…….867
    HYDRAULIC CIRCUIT DIAGRAM (1/2)(D31EX-21 SERIAL NO.50098 AND UP D31PX-21 SERIAL NO.50182 AND UP D37EX-21 SERIAL NO.5105 AND UP D37PX-21 SERIAL NO.5091 AND UP)…….868
    HYDRAULIC CIRCUIT DIAGRAM (2/2)…….869
    HYDRAULIC CIRCUIT DIAGRAM (2/2) (FOR D37EX, PX-21 EU SPEC.)…….870
    ELECTRICAL CIRCUIT DIAGRAM (1/2)…….871
    ELECTRICAL CIRCUIT DIAGRAM (2/2)…….872
    ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER…….873
SEBM035005 – Bulldozer D31EX,PX-21, D37EX,PX-21, D39EX,PX-21 Shop Manual (SN1501&up)…….874
COVER…….874
CONTENTS…….875
01 GENERAL…….910
    SPECIFICATION DRAWING…….911
    SPECIFICATIONS…….913
    WEIGHT TABLE…….921
    TABLE OF FUEL, COOLANT AND LUBRICANTS…….925
10 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD…….927
    COOLING SYSTEM…….928
    ENGINE CONTROL…….929
    POWER TRAIN…….930
    POWER TRAIN SYSTEM…….931
    DAMPER …….932
    HST HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAM…….933
    STEERING, BRAKE CONTROL…….934
    SOLENOID VALVE…….936
    TOWING VALVE…….938
    FINAL DRIVE…….939
    HST PUMP…….942
    SAFETY-SUCTION VALVE…….949
    CHARGE SAFETY VALVE…….952
    CHARGE PUMP…….954
    TOWING VALVE…….955
    HST MOTOR…….956
    ELECTRIC LEVER (FOR STEERING)…….968
    FRAME ASSEMBLY…….971
    TRACK FRAME, RECOIL SPRING…….972
    IDLER…….974
    TRACK ROLLER…….978
    CARRIER ROLLER…….982
    SPROCKET…….984
    TRACK SHOE…….988
    ARRANGEMENT OF HYDRAULIC EQUIPMENT FOR WORK EQUIPMENT…….993
    WORK EQUIPMENT CONTROL…….994
    HYDRAULIC TANK, FILTER…….996
    PPC LOCK VALVE…….997
    ACCUMULATOR…….998
    HYDRAULIC PUMP…….999
    WORK EQUIPMENT CYLINDER…….1000
    CONTROL VALVE…….1004
    CLSS…….1012
    PPC VALVE…….1022
    WORK EQUIPMENT…….1032
    CUTTING EDGE, END BIT…….1036
    RIPPER…….1037
    CAB RELATED…….1038
    ENGINE CONTROL…….1039
    HST CONTROL SYSTEM…….1040
    GEAR SHIFT CONTROL SYSTEM…….1041
    PARING BRAKE CONTROL SYSTEM…….1045
    COMPONENT EQUIPMENT OF SYSTEM…….1047
    MONITOR SYSTEM…….1051
    MONITOR PANEL…….1053
    SENSORS…….1057
20 TESTING AND ADJUSTING…….1062
    STANDARD VALUE TABLE FOR ENGINE …….1063
    STANDARD VALUE TABLE FOR CHASSIS…….1066
    TESTING AND ADJUSTING…….1080
      LIST OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING…….1081
      SKETCH OF SPECIAL TOOL…….1085
      MEASURING ENGINE SPEED…….1086
      MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)…….1087
      MEASURING EXHAUST TEMPERATURE …….1089
      MEASURING EXHAUST GAS COLOR…….1091
      ADJUSTING VALVE CLEARANCE…….1092
      MEASURING COMPRESSION PRESSURE…….1094
      MEASURING BLOW-BY PRESSURE…….1095
      MEASURING ENGINE OIL PRESSURE…….1096
      TESTING AND ADJUSTING FUEL INJECTION TIMING…….1097
      BLEEDING AIR FROM FUEL CIRCUIT…….1099
      ADJUSTING ENGINE STOP SOLENOID LINKAGE…….1100
      ADJUSTING ENGINE SPEED SENSOR…….1101
      REPLACEMENT OF FAN BELT…….1101
      TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION (WITH CAB)…….1102
      ADJUSTING FUEL CONTROL LEVER AND DECELERATOR PEDAL…….1104
      TESTING AND ADJUSTING HST OIL PRESSURE…….1107
      MEASURING HST SOLENOID VALVE OUTLET PRESSURE…….1111
      TESTING TRAVEL DEVIATION…….1113
      ADJUSTING HST MOTOR SPEED SENSOR…….1114
      ADJUSTING PARKING BRAKE LEVER…….1117
      PROCEDURE OF SIMPLE TEST OF BRAKE PERFORMANCE…….1118
      ADJUSTING BRAKE PEDAL LINKAGE…….1119
      METHOD OF RELEASING PARKING BRAKE (PROCEDURE FOR EMERGENCY ESCAPE)…….1120
      TESTING AND ADJUSTING IDLER CLEARANCE…….1122
      TESTING AND ADJUSTING TRACK SHOE TENSION…….1123
      TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE…….1124
      MEASURING WORK EQUIPMENT PPC VALVE OUTPUT PRESSURE…….1126
      ADJUSTING PLAY OF WORK EQUIPMENT PPC VALVE…….1128
      ADJUSTING WORK EQUIPMENT LOCK LEVER…….1129
      MEASURING LEAKAGE IN WORK EQUIPMENT CYLINDER…….1130
      RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT…….1131
      BLEEDING AIR FROM HYDRAULIC CIRCUIT…….1132
      ADJUSTING PLAY OF BLAD CENTER BALL…….1133
      PROCEDURE FOR TESTING DIODES…….1134
      SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)…….1135
      PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM…….1176
      PM-CLINIC…….1177
    TROUBLESHOOTING…….1206
      POINTS TO REMEMBER WHEN TROUBLESHOOTING…….1207
      SEQUENCE OF EVENTS IN TROUBLESHOOTING…….1208
      HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT…….1209
      CHECKS BEFORE TROUBLESHOOTING…….1219
      CLASSIFICATION AND PROCEDURE FOR TROUBLESHOOTING…….1220
      CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM…….1223
      CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…….1236
      T-BRANCH BOX AND T-BRANCH ADAPTER TABLE…….1272
      TROUBLESHOOTING WHEN ERROR CODE IS DISPLAYED…….1275
        ERROR CODES TABLE…….1277
        INFORMATION IN TROUBLESHOOTING TABLE…….1280
        ERROR CODE [6091NX] (HST CHARGE FILTER ELEMENT:CLOGGING)…….1282
        ERROR CODE [AB00MA] (ALTERNATOR: MALFUNCTION)…….1283
        ERROR CODE [B@BAZG] (ENGINE OIL: LOWERING OF OIL PRESSURE)…….1284
        ERROR CODE [B@BCNS] (COOLANT: OVERHEATING)…….1285
        ERROR CODE [B@CRNS] (HST OIL: OVERHEATING)…….1286
        ERROR CODE [B@CRZG] (HST OIL: LOWERING OF OIL PRESSURE)…….1287
        ERROR CODE [D110KB] (BATTERY RELAY: SHORT CIRCUIT)…….1288
        ERROR CODE [D130KA] (SAFETY RELAY: DISCONNECTION)…….1290
        ERROR CODE [D130KB] (SAFETY RELAY: SHORT CIRCUIT)…….1292
        ERROR CODE[DAFRKR](MONITOR CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM))…….1294
        ERROR CODE [DAJ0KK] (HST CONTROLLER: LOWERING OF SOURCE VOLTAGE(INPUT))…….1296
        ERROR CODE [DAJ0KT] (HST CONTROLLER: INTERNAL DEFECT OF CONTROLLER)…….1298
        ERROR CODE [DAJ5KK] (HST CONTROLLER SENSOR POWER SUPPLY OUTPUT: LOWERING OF SOURCE VOLTAGE (INPUT))…….1300
        ERROR CODE [DD12KA] (SHIFT-UP SWITCH: DISCONNECTION)…….1303
        ERROR CODE [DD12KB] (SHIFT-UP SWITCH: SHORT CIRCUIT)…….1305
        ERROR CODE [DD13KA] (SHIFT-DOWN SWITCH: DISCONNECTION)…….1307
        ERROR CODE [DD13KB] (SHIFT-DOWN SWITCH: SHORT CIRCUIT)…….1309
        ERROR CODE [DD14KB] (TRAVEL LOCK SW1: SHORT CIRCUIT)…….1311
        ERROR CODE [DDDCKB] (REVERSE TRAVEL SPEED SWITCH: SHORT CIRCUIT)…….1313
        ERROR CODE [DDP6KB] (BRAKE PRESSURE SWITCH: SHORT CIRCUIT)…….1315
        ERROR CODE [DDQ2KA] (TRAVEL LOCK SW1: DISCONNECTION)…….1317
        ERROR CODE [DDU1FS] (PARKING BRAKE ON-OFF SWITCH: STICK)…….1319
        ERROR CODE [DDU1KA] (PARKING BRAKE ON-OFF SWITCH: DISCONNECTION)…….1321
        ERROR CODE [DDU1KB] (PARKING BRAKE ON-OFF SWITCH:SHORT CIRCUIT)…….1323
        ERROR CODE [DDU1KY] (PARKING BRAKE ON-OFF SWITCH: SHORT CIRCUIT WITH POWER SUPPLY LINE)…….1325
        ERROR CODE [DDU1L4] (PARKING BRAKE ON-OFF SWITCH: DISAGREEMENT OF ON AND OFF SIGNALS)…….1327
        ERROR CODE [DGS1KX] (HYDRAULIC TANK OIL TEMPERATURE SENSOR: OUT OF INPUT SIGNAL RANGE)…….1329
        ERROR CODE [DHH5KA] (LH PUMP PRESSURE SENSOR: DISCONNECTION)…….1331
        ERROR CODE [DHH5KB] (LH PUMP PRESSURE SENSOR: SHORT CIRCUIT)…….1333
        ERROR CODE [DHH6KA] (RH PUMP PRESSURE SENSOR: DISCONNECTION)…….1335
        ERROR CODE [DHH6KB] (RH PUMP PRESSURE SENSOR: SHORT CIRCUIT)…….1337
        ERROR CODE [DK10KA] (THROTTLE ANGLE SENSOR: DISCONNECTION)…….1339
        ERROR CODE [DK10KB] (THROTTLE ANGLE SENSOR: SHORT CIRCUIT)…….1341
        ERROR CODE [DK12KA] (DECELERATION SENSOR: DISCONNECTION)…….1343
        ERROR CODE [DK12KB] (DECELERATION SENSOR: SHORT CIRCUIT)…….1345
        ERROR CODE [DK30KA] (STEERING ANGLE SENSOR: DISCONNECTION)…….1347
        ERROR CODE [DK30KB] (STEERING ANGLE SENSOR: SHORT CIRCUIT)…….1349
        ERROR CODE [DK30KX] (STEERING ANGLE SENSOR: OUT OF INPUT SIGNAL RANGE)…….1351
        ERROR CODE [DK30KZ] (STEERING ANGLE SENSOR: DISCONNECTION OR SHORT CIRCUIT)…….1352
        ERROR CODE [DA30L8] (STEERING ANGLE SENSOR: DISAGREEMENT OF ANALOG SIGNALS)…….1353
        ERROR CODE [DK31KA] (STEERING ANGLE SENSOR 2: DISCONNECTION)…….1354
        ERROR CODE [DK31KB] (STEERING ANGLE SENSOR 2: SHORT CIRCUIT)…….1356
        ERROR CODE [DK40KA] (BRAKE ANGLE SENSOR: DISCONNECTION)…….1358
        ERROR CODE [DK40KB] (BRAKE ANGLE SENSOR: SHORT CIRCUIT)…….1360
        ERROR CODE [DK55KX] (DIRECTIONAL POTENTIOMETER: OUT OF INPUT SIGNAL RANGE)…….1362
        ERROR CODE [DK55KZ] (DIRECTIONAL POTENTIOMETER: DISCONNECTION OR SHORT CIRCUIT)…….1363
        ERROR CODE [DK55L8] (DIRECTIONAL POTENTIOMETER: DISAGREEMENT OF ANALOG SIGNALS)…….1364
        ERROR CODE [DK56KA] (DIRECTIONAL POTENTIOMETER1: DISCONNECTION)…….1365
        ERROR CODE [DK56KB] (DIRECTIONAL POTENTIOMETER 1: SHORT CIRCUIT)…….1367
        ERROR CODE [DK57KA] (DIRECTIONAL POTENTIOMETER 2: DISCONNECTION)…….1369
        ERROR CODE [DK57KB] (DIRECTIONAL POTENTIOMETER 2: SHORT CIRCUIT)…….1371
        ERROR CODE [DLE2KA] (ENGINE SPEED SENSOR: DISCONNECTION)…….1373
        ERROR CODE [DLE2KB] (ENGINE SPEED SENSOR: SHORT CIRCUIT)…….1375
        ERROR CODE [DLM0KX] (MOTOR SPEED SENSOR: OUT OF INPUT SIGNAL RANGE)…….1377
        ERROR CODE [DLM1KA] (LEFT HAT MOTOR SPEED SENSOR: DISCONNECTION)…….1378
        ERROR CODE [DLM1KB] (LEFT HAT MOTOR SPEED SENSOR: SHORT CIRCUIT)…….1380
        ERROR CODE [DLM1MA] (LEFT HAT MOTOR SPEED SENSOR: MALFUNCTION)…….1382
        ERROR CODE [DLM2KA] (RIGHT HST MOTOR SPEED SENSOR: DISCONNECTION)…….1384
        ERROR CODE [DLM2KB] (RIGHT HST MOTOR SPEED SENSOR: SHORT CIRCUIT)…….1386
        ERROR CODE [DLM2MA] (RIGHT HST MOTOR SPEED SENSOR: MALFUNCTION)…….1388
        ERROR CODE [DN21FS] (CENTER BRAKE LIMIT SWITCH: FIXING)…….1390
        ERROR CODE [DV00KB] (BUZZER: SHORT CIRCUIT)…….1392
        ERROR CODE [DV20KB] (BACKUP ALARM BUZZER: SHORT CIRCUIT)…….1393
        ERROR CODE [DW28KA] (2ND GEAR SPEED SOLENOID VALVE: DISCONNECTION)…….1395
        ERROR CODE [DW28KB] (2ND GEAR SPEED SOLENOID VALVE: SHORT CIRCUIT)…….1397
        ERROR CODE [DW29KA] (3ND GEAR SPEED SOLENOID VALVE: DISCONNECTION)…….1399
        ERROR CODE [DW29KB] (3ND GEAR SPEED SOLENOID VALVE: SHORT CIRCUIT)…….1401
        ERROR CODE [DW4BKA] (PARKING BRAKE SOLENOID VALVE: DISCONNECTION)…….1403
        ERROR CODE [DW4BKB] (PARKING BRAKE SOLENOID VALVE: SHORT CIRCUIT)…….1405
        ERROR CODE [DW7EKA] (SLOW BRAKE SOLENOID VALVE: DISCONNECTION)…….1407
        ERROR CODE [DW7EKB] (SLOW BRAKE SOLENOID VALVE: SHORT CIRCUIT)…….1409
        ERROR CODE [DXA4KA] (LH PUMP F-EPC SOLENOID VALVE: DISCONNECTION)…….1411
        ERROR CODE [DXA4KB] (LH PUMP F-EPC SOLENOID VALVE: SHORT CIRCUIT)…….1413
        ERROR CODE [DXA5KA] (LH PUMP F-EPC SOLENOID VALVE: DISCONNECTION)…….1415
        ERROR CODE [DXA5KB] (LH PUMP F-EPC SOLENOID VALVE: SHORT CIRCUIT)…….1417
        ERROR CODE [DXA6KA] (RH PUMP F-EPC SOLENOID VALVE: DISCONNECTION)…….1419
        ERROR CODE [DXA6KB] (RH PUMP F-EPC SOLENOID VALVE: SHORT CIRCUIT)…….1421
        ERROR CODE [DXA7KA] (RH PUMP F-EPC SOLENOID VALVE: DISCONNECTION)…….1423
        ERROR CODE [DXA7KB] (RH PUMP F-EPC SOLENOID VALVE: SHORT CIRCUIT)…….1425
      TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)…….1427
        BEFORE CARRYING OUT TROUBLESHOOTING FOR ELECTRICAL SYSTEM (E-MODE)…….1428
        INFORMATION IN TROUBLESHOOTING TABLE…….1430
        E-1 ENGINE DOES NOT START…….1431
        E-2 ENGINE IS NOT PREHEATED…….1436
        E-3 ENGINE DOES NOT STOP…….1438
        E-4 WHEN STARTING SWITCH IS TURNED ON,ANY ITEM DOES NOT LIGHT UP…….1440
        E-5 WHEN STARTING SWITCH IS TURNED ON, ALL ITEMS LIGHT UP AND NONE OF THEM GOES OFF…….1442
        E-6 CHARGE LEVEL CAUTION FLASHES WHILE ENGINE IS RUNNING…….1442
        E-7 EMERGENCY WARNING ITEMS FLASH WHILE ENGINE IS RUNNING …….1444
        E-8 PREHEATING PILOT LAMP DOES NOT LIGHT UP DURING PREHEATING OPERATION…….1449
        E-9 ENGINE COOLANT THERMOMETER IS ABNORMAL…….1451
        E-10 HST OIL THERMOMETER ID ABNORMAL…….1453
        E-11 FUEL LEVEL GAUGE IS ABNORMAL…….1455
        E-12 REVERSE TRAVEL SPEED INDICATOR IS ABNORMAL…….1457
        E-13 GEAR SPEED,SET TRAVEL SPEED,ANF SHIFT MODE INDICATOR IS ABNORMAL…….1457
        E-14 MULTI-INFORMATION SECTION ID ABNORMAL…….1457
        E-15 CAUTION LAMP DOES NOT FLASH OR DOES NOT GO OFF…….1457
        E-16 CAUTION BUZZER DOES NOT SOUND OR DOES NOT STOP…….1458
        E-17 REVERSE TRAVEL SPEED SETTING SWITCH DOES NOT FUNCTION…….1459
        E-18 SHIFT MODE SWITCH DOES NOT FUNCTION…….1461
        E-19 BUZZER CANCEL SWITCH DOES NOT FUNCTION…….1462
        E-20 INFORMATION SWITCH DOES NOT FUNCTION…….1464
        E-21 SYSTEM IS NOT SET IN SERVICE MODE OR IS NOT SET OUT OF SERVICE MODE…….1466
        E-23 HEADLAMP OR REAR LAMP DOES NOT LIGHT UP…….1468
        E-24 CANOPY HEATER DOES NOT OPERATE[CANOPY SPECIFICATION]…….1470
        E-25 AIR CONDITIONER DOES NOT OPERATE[CAB SPECIFICATION]…….1472
        E-26 WINDSHIELD WIPER AND WINDSHIELD WASHER DO NOT OPERATE[CAB SPECIFICATION]…….1477
      TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)…….1483
        INFORMATION IN TROUBLESHOOTING TABLE…….1484
        H-1 RIGHT AND LEFT TRAVEL SYSTEMS DO NOT OPERATE FORWARD AND IN REVERSE (NO TRAVEL SYSTEMS OPERATE)…….1485
        H-2 RIGHT AND LEFT TRAVEL SYSTEMS DO NOT OPERATE FORWARD AND IN REVERSE (ONLY RIGHT OR LEFT TRAVEL SYSTEM DOES NOT OPERATE)…….1486
        H-3 RIGHT AND LEFT TRAVEL SYSTEMS DO NOT OPERATE FORWARD AND IN REVERSE (ONLY 1 SYSTEM DOES NOT OPERATE)…….1486
        H-4 SPEED OR POWER OF TRAVEL IS LOW…….1487
        H-5 GEAR IS NOT SHIFTED…….1488
        H-6 LARGE SHOCK IS MADE WHEN MACHINE STOPS TRAVELING…….1489
        H-7 MACHINE DEVIATES LARGELY DURING TRAVEL…….1489
        H-8 HYDRAULIC DRIFT OF TRAVEL IS LARGER…….1490
        H-9 ENGINE STALLS OR ENGINE SPEED LOWERS EXTREMELY DURING TRAVEL…….1490
        H-10 ABNORMAL SOUND COMES OUT FROM AROUND HST PUMP AND MOTOR …….1491
        H-11 WORK EQUIPMENT DOES NOT OPERATE AT ALL…….1492
        H-12 SPEED OR POWER OF WHOLE WORK EQUIPMENT IS LOW…….1493
        H-13 SPEED OR POWER OF LIFTING BLADE IS LOW…….1494
        H-14 SPEED OR POWER OF TILTING BLADE IS LOW…….1494
        H-15 SPEED OR POWER OF ANGLING BLADE IS LOW…….1495
        H-16 TIME LAG IN LIFTING BLADE IS LARGE…….1496
        H-17 HYDRAULIC DRIFT OF LIFTING BLADE IS LARGE…….1496
        H-18 HYDRAULIC DRIFT OF TILTING BLADE IS LARGE…….1496
        H-19 ABNORMAL SOUND COMES OUT FROM AROUND WORK EQUIPMENT PUMP AND CONTROL VALVE…….1497
        H-20 HST OIL TEMPERATURE (HYDRAULIC OIL TEMPERATURE) RISES TOO HIGH…….1498
      TROUBLESHOOTING OF ENGINE (S MODE)…….1499
        METHOD OF USING TROUBLESHOOTING CHARTS…….1500
        S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)…….1504
        S-2 ENGINE DOES NOT START…….1505
        S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)…….1508
        S-4 ENGINE STOPS DURING OPERATIONS…….1509
        S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)…….1510
        S-6 ENGINE TACKS OUTPUT (OR TACKS POWER)…….1511
        S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)…….1512
        S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)…….1513
        S-9 OIL BECOMES CONTAMINATED QUICKLY…….1514
        S-10 FUEL CONSUMPTION IS EXCESSIVE …….1515
        S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN…….1516
        S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)…….1517
        S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)…….1518
        S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)…….1519
        S-15 ABNORMAL NOISE IS MADE…….1520
        S-16 VIBRATION IS EXCESSIVE…….1521
30 DISASSEMBLY AND ASSEMBLY…….1522
    HOW TO READ THIS MANUAL…….1523
    COATING MATERIALS LIST…….1525
    SPECIAL TOOL LIST…….1529
    SKETCHES OF SPECIAL TOOLS…….1531
    REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY…….1532
    REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY…….1536
    REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL…….1543
    REMOVAL AND INSTALLATION OF ENGINE REAR SEAL…….1546
    REMOVAL AND INSTALLATION OF RADIATOR GUARD ASSEMBLY…….1548
    DISASSEMBLY AND ASSEMBLY OF RADIATOR, OIL COOLER, AND CHARGE AIR COOLER ASSEMBLIES…….1551
    REMOVAL AND INSTALLATION OF ENGINE AND HST PUMP ASSEMBLY…….1555
    REMOVAL AND INSTALLATION OF DAMPER…….1558
    SPREADING AND INSTALLATION OF TRACK SHOE ASSEMBLY…….1559
    REMOVAL AND INSTALLATION OF HST MOTOR AND FINAL DRIVE ASSEMBLY…….1561
    DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY…….1563
    REMOVAL AND INSTALLATION OF IDLER AND RECOIL SPRING ASSEMBLY…….1573
    DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY…….1574
    DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY…….1577
    DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY…….1580
    DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY…….1584
    REMOVAL AND INSTALLATION OF HST PUMP ASSEMBLY…….1586
    REMOVAL AND INSTALLATION OF MAIN CONTROL VALVE ASSEMBLY…….1588
    DISASSEMBLY AND ASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY…….1590
    REMOVAL AND INSTALLATION OF BLADE ASSEMBLY…….1598
    DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLIES…….1600
    REMOVAL AND INSTALLATION OF OPERATOR'S SEAT FRAME ASSEMBLY…….1603
    REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY…….1607
    REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY…….1608
    REMOVAL AND INSTALLATION OF HST CONTROLLER ASSEMBLY…….1610
90 OTHERS…….1611
    HYDRAULIC CIRCUIT DIAGRAM(1/2)…….1612
    HYDRAULIC CIRCUIT DIAGRAM(2/2)…….1613
    ELECTRICAL CIRCUIT DIAGRAM(1/4)…….1614
    ELECTRICAL CIRCUIT DIAGRAM(2/4)…….1615
    ELECTRICAL CIRCUIT DIAGRAM(3/4)…….1616
    ELECTRICAL CIRCUIT DIAGRAM(4/4)…….1617
    AIR CONDITIONER CIRCUIT DIAGRAM…….1618
SEN04343-08 – Bulldozer D31EX-22, D31PX-22, D37EX-22, D37PX-22 Shop Manual (SN60001&up)…….1619
COVER…….1619
00 Index and foreword…….0
    100 Index…….1621
      Composition of shop manual…….1622
      Table of contents…….1624
    200 Foreword and general information…….1633
      Safety notice…….1634
      How to read the shop manual…….1639
      Explanation of terms for maintenance standard…….1641
      Handling of electric equipment and hydraulic component…….1643
      Handling of connectors newly used for engines…….1652
      How to read electric wire code…….1655
      Precautions when carrying out operation…….1658
      Method of disassembling and connecting push-pull type coupler…….1661
      Standard tightening torque table…….1664
      Conversion table…….1668
01 General…….0
    100 Specification and technical data…….1675
      Specification dimensional drawing…….1676
      Specifications…….1678
      Weight table…….1686
      Table of fuel, coolant and lubricants…….1690
10 Structure, function and maintenance standard…….0
    100 Engine and cooling system…….1693
      Engine system parts…….1694
      Cooling system…….1695
      Cooling fan pump…….1696
      Cooling fan motor…….1697
      Oil cooler bypass valve…….1702
    200 Power train…….1707
      Power train…….1708
      Power train system…….1709
      Damper…….1710
      HST hydraulic equipment arrangement diagram…….1711
      Steering and brake control…….1712
      Solenoid valve…….1714
      Final drive…….1721
      HST pump…….1724
      HST motor…….1736
      Charge pump…….1746
    300 Undercarriage and frame…….1749
      Main frame…….1750
      Track frame and idler cushion…….1752
      Idler…….1754
      Track roller…….1756
      Carrier roller…….1758
      Sprocket…….1760
      Track shoe…….1762
    410 Hydraulic system, Part 1…….1767
      Arrangement of hydraulic equipment for work equipment…….1768
      Work equipment control…….1770
      Hydraulic tank and filter…….1772
      Work equipment and fan pump…….1774
      Control valve…….1782
      CLSS…….1794
      Functions and operation of each valve…….1797
    420 Hydraulic system, Part 2…….1807
      Blade PPC valve…….1808
      Accumulator…….1817
    500 Work equipment…….1819
      Work equipment…….1820
      Cutting edge and end bit…….1824
      Ripper…….1825
      Work equipment cylinder…….1826
      Piston valve…….1829
    600 Cab and its attachments…….1831
      ROPS cab…….1832
      Cab mount…….1833
      Canopy mount…….1834
      Air conditioner…….1835
    700 Electrical system…….1839
      Monitor system…….1840
      Engine control…….1842
      Engine control system…….1843
      Cooling control system…….1844
      HST control system…….1846
      Parking brake control system…….1852
      KOMTRAX system…….1854
      Component equipment of system…….1856
      PCCS lever (for steering)…….1865
      Sensor…….1868
20 Standard value table…….0
    100 Standard service value table…….1881
      Standard service value table for engine…….1882
      Standard service value table for chassis…….1884
30 Testing and adjusting…….0
    110 Testing and adjusting, Part 1…….1895
      Tools for testing, adjusting, and troubleshooting…….1897
      Measuring engine speed…….1901
      Measuring intake air pressure (boost pressure)…….1902
      Testing exhaust temperature…….1904
      Measuring exhaust gas color (boost pressure)…….1905
      Adjusting valve clearance…….1906
      Testing compression pressure…….1908
      Measuring blow-by pressure…….1910
      Testing oil pressure…….1912
      Handling fuel system equipment…….1913
      Releasing residual pressure in fuel system…….1913
      Bleeding air from fuel circuit…….1914
      Testing fuel pressure…….1917
      Testing leakage from pressure limiter and return rate from injector…….1918
      Testing leakage in fuel system…….1921
      Measuring fan circuit pressure and fan speed…….1922
      Adjustment of fan speed sensor…….1923
      Handling reduced cylinder mode operation…….1924
      Handling no-injection cranking operation…….1924
      Check of muffler and muffler stack for looseness and damage…….1925
      Check of muffler function…….1925
      Check of installed condition of cylinder head and manifolds…….1926
      Check of engine piping for damage and looseness…….1926
      Testing and adjusting alternator belt tension…….1927
      Testing and adjusting air conditioner compressor belt tension…….1928
    120 Testing and adjusting, Part 2…….1931
      Adjusting decelerator pedal…….1932
      Testing and adjusting HST oil pressure…….1934
      Measuring solenoid valve output oil pressure…….1939
      Testing travel deviation…….1942
      Adjusting parking brake lever…….1943
      Simple brake performance test procedure…….1945
      Adjusting brake pedal…….1946
      Method of releasing parking brake (Procedure for emergency escape)…….1948
      Testing and adjusting idler clearance…….1950
      Testing and adjusting track shoe tension…….1951
      Testing work equipment oil pressure…….1952
      Testing work equipment PPC valve output oil pressure…….1954
      Adjusting play of work equipment PPC valve…….1956
      Adjusting work equipment lock lever…….1957
      Testing internal leakage of work equipment cylinder…….1958
      Releasing residual pressure in hydraulic circuit…….1960
      Bleeding air from hydraulic circuit…….1961
      Adjusting play of blade center ball…….1962
      Procedure for testing diodes…….1963
      Preparation work for troubleshooting for electrical system…….1964
      How to start operation of KOMTRAX terminal…….1968
      Lamp display of KOMTRAX terminal…….1971
    130 Testing and adjusting, Part 3…….1975
      Special functions of monitor panel (EMMS)…….1976
      Items to be adjusted when electric/hydraulic devices are adjusted/replaced…….2036
      Adjustment procedure after replacement of HST controller…….2037
      Adjustment procedure after replacement of monitor panel…….2039
      Pm-clinic service (D31EX-22, D31PX-22)…….2041
      Pm-clinic service (D37EX-22, D37PX-22)…….2049
40 Troubleshooting…….0
    100 Failure code table and fuse locations…….2059
      Failure code table…….2060
      Before carrying out troubleshooting for electrical system (E-mode)…….2066
    200 General information on troubleshooting…….2071
      Points to remember when troubleshooting…….2072
      Sequence of events in troubleshooting…….2073
      Testing before troubleshooting…….2074
      Classification and procedures of troubleshooting…….2075
      Information contained in troubleshooting table…….2078
      Connection table for connector pin numbers…….2080
      T- branch box and T- branch adapter table…….2116
    310 Troubleshooting by failure code (Display of code), Part 1…….2121
      Failure code [6091NX] HST charge filter element: Clogging…….2123
      Failure code [AA10NX] Air cleaner: Clogging…….2124
      Failure code [AB00MA] Alternator: Malfunction…….2126
      Failure code [B@BAZG] Engine oil: Lowering of oil pressure…….2127
      Failure code [B@BCNS] Coolant: Overheat…….2128
      Failure code [B@CRNS] HST oil: Overheating…….2129
      Failure code [B@CRZG] HST oil: Lowering of oil pressure…….2130
      Failure code [CA111] Engine controller: Abnormality in controller…….2131
      Failure code [CA115] Abnormal engine Ne and Bkup speed sensors: Abnormal speed sensor signal…….2134
      Failure code [CA122] Charge pressure sensor tool high: Excessively high voltage detected…….2135
      Failure code [CA123] Charge pressure sensor too low: Excessively low voltage detected…….2137
      Failure code [CA131] Decelerator pedal sensor tool high: Excessively high voltage detected…….2138
      Failure code [CA132] Decelerator pedal sensor too low: Excessively low voltage detected…….2140
      Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected…….2142
      Failure code [CA145] Coolant temperature sensor too low: Excessively low voltage detected…….2144
      Failure code [CA153] Charge air temperature sensor too high: Excessively high voltage detected…….2146
      Failure code [CA154] Charge temperature sensor too low: Excessively low voltage detected…….2148
      Failure code [CA187] Sensor power source 2 too low: Excessively low voltage detected…….2149
      Failure code [CA221] Atmospheric pressure sensor too high: Excessively high voltage detected…….2150
      Failure code [CA222] Atmospheric pressure sensor too low: Excessively low voltage detected…….2152
      Failure code [CA227] Sensor power source 2 too high: Excessively high voltage detected…….2154
      Failure code [CA234] Engine over speed: Excessively high speed…….2156
      Failure code [CA238] Abnormal power source for Ne speed sensor: Excessively low voltage detected…….2158
      Failure code [CA271] IMV/PCV1 short circuit: Short circuit…….2160
      Failure code [CA272] IMV/PCV1 disconnection: Disconnection…….2162
    320 Troubleshooting by failure code (Display of code), Part 2…….2165
      Failure code [CA322] Injector No. 1 system disconnection or short circuit: disconnection, short circuit…….2168
      Failure code [CA324] Injector No. 3 system disconnection or short circuit: disconnection, short circuit…….2170
      Failure code [CA331] Injector No. 2 system disconnection or short circuit: disconnection, short circuit…….2172
      Failure code [CA332] Injector No. 4 system disconnection or short circuit: disconnection, short circuit…….2174
      Failure code [CA351] Injector drive circuit abnormality: Abnormal circuit…….2176
      Failure code [CA352] Sensor power source 1 too low: Excessively low voltage detected…….2178
      Failure code [CA386] Sensor power source 1 too high: Excessively high voltage detected…….2180
      Failure code [CA435] Abnormal engine oil pressure switch: Abnormal signal circuit…….2182
      Failure code [CA441] Power source voltage too low: Excessively low voltage detected…….2183
      Failure code [CA442] Power source voltage too high: Excessively high voltage has occurred in the controller power source circuit…….2184
      Failure code [CA449] Common rail pressure too high (2): Excessively high pressure trouble occurred…….2185
      Failure code [CA451] Common rail pressure sensor too high: Excessively high voltage detected…….2186
      Failure code [CA452] Common rail pressure sensor too low: Excessively low voltage detected…….2188
      Failure code [CA553] Common rail pressure too high (1): Excessively high pressure detected…….2189
      Failure code [CA559] Loss of pressure feed from supply pump (1): Loss of pressure feed detected…….2190
      Failure code [CA689] Abnormal engine Ne speed sensor: Abnormal signal…….2194
      Failure code [CA731] Abnormal engine Bkup speed sensor phase: Abnormal phase…….2196
      Failure code [CA757] Loss of all engine controller data: Loss of all data…….2197
      Failure code [CA778] Abnormal engine Bkup speed sensor: Abnormal Bkup signal…….2198
      Failure code [CA1633] Abnormal KOMNET: Abnormal communication…….2200
      Failure code [CA2185] Decelerator pedal sensor power source too high: Excessively high voltage detected…….2202
      Failure code [CA2186] Decelerator pedal sensor power source too low: Excessively low voltage detected…….2204
      Failure code [CA2249] Loss of pressure feed from supply pump (2): Loss of pressure feed detected…….2205
      Failure code [CA2311] Abnormal IMV solenoid: Abnormal resistance…….2206
      Failure code [CA2555] Air intake heater relay disconnection: Disconnection…….2208
      Failure code [CA2556] Air intake heater relay short circuit: Short circuit…….2210
    330 Troubleshooting by failure code (Display of code), Part 3…….2213
      Failure code [D130KA] Neutral safety relay: Disconnection…….2216
      Failure code [D130KB] Neutral safety relay: Short circuit…….2218
      Failure code [DAFRKR] CAN communication (Monitor panel – HST controller): Defective communication (Abnormality in objective component system)…….2220
      Failure code [DAFRMC] CAN communication (Monitor panel – ENGINE controller): Defective communication (Abnormality in objective component system)…….2223
      Failure code [DAJ000] HST controller: Memory error…….2226
      Failure code [DAJ0KK] HST controller: Lowing of source voltage…….2228
      Failure code [DAJ0KQ] HST controller: Machine code error…….2230
      Failure code [DAJ0KT] HST controller: Memory error…….2231
      Failure code [DAJ5KK] HST controller sensor 5 V power supply No.1: Lowing of source voltage/Input…….2232
      Failure code [DAJ6KK] HST controller sensor 5 V power supply No.2: Lowing of source voltage/Input…….2234
      Failure code [DAJRKR] CAN communication (HST controller – Monitor panel): Defective communication (Abnormality in objective component system)…….2236
      Failure code [DB2RKR] CAN communication (HST controller – Engine controller): Defective communication (Abnormality in objective component system)…….2239
      Failure code [DD12KA] Shift up switch: Disconnection…….2242
      Failure code [DD12KB] Shift up switch: Short circuit…….2244
      Failure code [DD13KA] Shift down switch: Disconnection…….2246
      Failure code [DD13KB] Shift down switch: Short circuit…….2248
      Failure code [DD14KB] Travel lock limit switch 1: Short circuit…….2250
      Failure code [DD1NL4] Fan rotation selector switch: Disagreement of ON, OFF Signals…….2252
      Failure code [DDDCKB] Reverse travel speed switch: Short circuit…….2254
      Failure code [DDP6KA] Brake oil pressure sensor: Disconnection…….2256
      Failure code [DDP6KB] Brake oil pressure sensor: Short circuit…….2258
      Failure code [DDP6MA] Brake oil pressure sensor: Malfunction…….2260
      Failure code [DDQ2KA] Travel lock limit switch 1: Disconnection…….2262
      Failure code [DDT0L4] Shift mode switch: Disagreement of ON/ OFF Signals…….2264
      Failure code [DDU1FS] Travel lock limit switches 1 and 2: Fixing…….2266
      Failure code [DDU1KA] Travel lock limit switch 2: Disconnection…….2268
      Failure code [DDU1KY] Travel lock limit switch 2: Short circuit with power supply line…….2270
      Failure code [DGS1KA] HST oil temperature sensor: Disconnection…….2272
      Failure code [DGS1KX] HST oil temperature sensor: Out of Input signal range…….2274
    340 Troubleshooting by failure code (Display of code), Part 4…….2277
      Failure code [DHH5KA] Left HST pump pressure sensor: Disconnection…….2280
      Failure code [DHH5KB] Left HST pump pressure sensor: Short circuit…….2282
      Failure code [DHH6KA] Right HST pump pressure sensor: Disconnection…….2284
      Failure code [DHH6KB] Right HST pump pressure sensor: Short circuit…….2286
      Failure code [DK10KA] Fuel dial sensor: Disconnection…….2288
      Failure code [DK10KB] Fuel dial sensor: Short circuit…….2290
      Failure code [DK30KA] Steering angle sensor 1: Disconnection…….2292
      Failure code [DK30KB] Steering angle sensor 1: Short circuit…….2294
      Failure code [DK30KX] Steering angle sensor: Out of input signal range…….2296
      Failure code [DK30KZ] Steering angle sensor: Disconnection or short circuit…….2297
      Failure code [DK30L8] Steering angle sensor: Disagreement of analog signals…….2298
      Failure code [DK31KA] Steering angle sensor 2: Disconnection…….2300
      Failure code [DK31KB] Steering angle sensor 2: Short circuit…….2302
      Failure code [DK40KA] Brake pedal sensor: Disconnection…….2304
      Failure code [DK40KB] Brake pedal sensor: Short circuit…….2306
      Failure code [DK55KX] Directional potentiometer: Out of input signal range…….2308
      Failure code [DK55KZ] Directional potentiometer: Disconnection or short circuit…….2309
      Failure code [DK55L8] Directional potentiometer: Disagreement of analog signals…….2310
      Failure code [DK56KA] Directional potentiometer 1: Disconnection…….2312
      Failure code [DK56KB] Directional potentiometer 1: Short circuit…….2314
      Failure code [DK57KA] Directional potentiometer 2: Disconnection…….2316
      Failure code [DK57KB] Directional potentiometer 2: Short circuit…….2318
      Failure code [DLM0KX] HST motor speed sensors: Out of input signal range…….2320
      Failure code [DLM1KA] Left HST motor speed sensor: Disconnection…….2322
      Failure code [DLM1KB] Left HST motor speed sensor: Short circuit…….2324
      Failure code [DLM1MA] Left HST motor speed sensor: Malfunction…….2326
      Failure code [DLM2KA] Right HST motor speed sensor: Disconnection…….2328
      Failure code [DLM2KB] Right HST motor speed sensor: Short circuit…….2330
      Failure code [DLM2MA] Right HST motor speed sensor: Malfunction…….2332
      Failure code [DLM3KA] Fan speed sensor: Disconnection…….2334
      Failure code [DLM3KB] Fan speed sensor: Short circuit…….2336
    350 Troubleshooting by failure code (Display of code), Part 5…….2339
      Failure code [DN21FS] Brake pedal and proximity switch: Fixing…….2342
      Failure code [DV00KB] Caution buzzer: Short circuit…….2344
      Failure code [DV20KB] Back alarm buzzer: Short circuit…….2345
      Failure code [DW4BKA] Parking brake solenoid valve: Disconnection…….2346
      Failure code [DW4BKB] Parking brake solenoid valve: Short circuit…….2348
      Failure code [DW4BKY] Parking brake solenoid valve: Short circuit with power supply line…….2350
      Failure code [DW7BKA] Fan reverse solenoid valve: Disconnection…….2352
      Failure code [DW7BKB] Fan reverse solenoid valve: Short circuit…….2354
      Failure code [DW7BKY] Fan reverse solenoid valve: Short circuit with power supply line…….2355
      Failure code [DW7EKA] Slow brake solenoid valve: Disconnection…….2356
      Failure code [DW7EKB] Slow brake solenoid valve: Short circuit…….2360
      Failure code [DW7EKY] Slow brake solenoid valve: Short circuit with power supply line…….2362
      Failure code [DWN5KA] Fan EPC solenoid valve: Disconnection…….2364
      Failure code [DWN5KB] Fan EPC solenoid valve: Short circuit…….2366
      Failure code [DWN5KY] Fan EPC solenoid valve: Short circuit with power supply line…….2368
      Failure code [DXA4KA] LF HST pump EPC solenoid valve: Disconnection…….2370
      Failure code [DXA4KB] LF HST pump EPC solenoid valve: Short circuit…….2372
      Failure code [DXA4KY] LF HST pump EPC solenoid valve: Short circuit with power supply line…….2374
      Failure code [DXA5KA] LR HST pump EPC solenoid valve: Disconnection…….2376
      Failure code [DXA5KB] LR HST pump EPC solenoid valve: Short circuit…….2378
      Failure code [DXA5KY] LR HST pump EPC solenoid valve: Short circuit with power supply line…….2380
      Failure code [DXA6KA] RF HST pump EPC solenoid valve: Disconnection…….2382
      Failure code [DXA6KB] RF HST pump EPC solenoid valve: Short circuit…….2384
      Failure code [DXA6KY] RF HST pump EPC solenoid valve: Short circuit with power supply line…….2385
      Failure code [DXA7KA] RR HST pump EPC solenoid valve: Disconnection…….2386
      Failure code [DXA7KB] RR HST pump EPC solenoid valve: Short circuit…….2388
      Failure code [DXA7KY] RR HST pump EPC solenoid valve: Short circuit with power supply line…….2390
      Failure code [DXK1KA] Left HST motor EPC solenoid valve: Disconnection…….2391
      Failure code [DXK1KB] Left HST motor EPC solenoid valve: Short circuit…….2392
      Failure code [DXK1KY] Left HST motor EPC solenoid valve: Short circuit with power supply line…….2393
      Failure code [DXK2KA] Right HST motor EPC solenoid valve: Disconnection…….2394
      Failure code [DXK2KB] Right HST motor EPC solenoid valve: Short circuit…….2395
      Failure code [DXK2KY] Right HST motor EPC solenoid valve: Short circuit with power supply line…….2396
    400 Troubleshooting of electrical system (E-mode)…….2399
      E-1 Engine does not start (Starting motor does not rotate)…….2402
      E-2 Engine is not preheated…….2405
      E-3 When starting switch is turned ON, any item does not light up…….2408
      E-4 Charge level caution flashes while engine is running…….2410
      E-5 Emergency warning items flash while engine is running…….2412
      E-6 Preheating pilot lamp does not light up during preheating operation…….2418
      E-7 The coolant temperature gauge does not indicate correctly……..2420
      E-8 The HST oil temperature gauge does not indicate correctly……..2421
      E-9 Fuel level gauge does not indicate properly…….2422
      E-10 Gear speed, set travel speed, and shift mode indicator does not display normally…….2424
      E-11 Multi-information unit does not display normally…….2424
      E-12 Caution lamp does not flash or does not go off…….2425
      E-13 Caution buzzer does not sound or does not stop…….2426
      E-14 Reverse travel speed setting switch does not function…….2428
      E-15 Shift mode switch does not function…….2430
      E-16 Buzzer cancel switch does not function…….2432
      E-17 Information switch does not function…….2434
      E-18 The fan cleaning does not operate or cannot be reset…….2436
      E-19 Backup alarm does not sound…….2438
      E-20 The horn does not sound or does not stop…….2439
      E-21 Work equipment does not move…….2440
      E-22 Headlamp or rear lamp does not light up…….2442
      E-23 Foot heater does not operate…….2445
      E-24 Air conditioner does not operate…….2448
      E-25 Windshield wiper and window washer do not operate…….2453
      E-26 KOMTRAX system does not operate normally…….2466
    500 Troubleshooting of hydraulic and mechanical system (H-mode)…….2469
      Information in troubleshooting table…….2471
      H-1 Right and left travel systems do not operate forward and in reverse (No travel systems operate)…….2472
      H-2 Right or left travel system does not operate forward and in reverse (Only right or left travel system does not operate)…….2474
      H-3 Right or left travel system does not operate forward or in reverse (Only 1 system does not operate)…….2475
      H-4 Speed or power of travel is low…….2476
      H-5 Gear is not shifted…….2477
      H-6 Large shocks are made when machine starts and stops travel…….2478
      H-7 Machine deviates largely during travel…….2479
      H-8 Hydraulic drift of travel is large…….2480
      H-9 Engine stalls or engine speed lowers extremely during travel…….2481
      H-10 Abnormal sound comes out from around HST pump and motor…….2482
      H-11 Work equipment dose not operate at all…….2483
      H-12 Speed or power of whole work equipment is low…….2484
      H-13 Speed or power of lifting blade is low…….2485
      H-14 Speed or power of tilting blade is low…….2486
      H-15 Speed or power of angling blade is low…….2487
      H-16 Time lag in lifting blade is large…….2488
      H-17 Hydraulic drift of lifting blade is large…….2488
      H-18 Hydraulic drift of tilting blade is large…….2488
      H-19 Abnormal sound comes out from around work equipment pump and control valve…….2489
      H-20 HST oil temperature (Hydraulic oil temperature) rises too high…….2490
      H-21 Fan speed is abnormal (High, low, or 0 rpm)…….2492
      H-22 Abnormal sound is heard from around fan…….2493
    600 Troubleshooting of engine (S-mode)…….2495
      Troubleshooting of engine (S-mode)…….2497
      S-1 Starting performance is poor…….2500
      S-2 Engine does not start…….2501
      S-3 Engine does not pick up smoothly…….2504
      S-4 Engine stops during operations…….2505
      S-5 Engine does not rotate smoothly…….2506
      S-6 Engine lacks output (or lacks power)…….2507
      S-7 Exhaust smoke is black (incomplete combustion)…….2508
      S-8 Oil consumption is excessive (or exhaust smoke is blue)…….2509
      S-9 Oil becomes contaminated quickly…….2510
      S-10 Fuel consumption is excessive…….2511
      S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)…….2512
      S-12 Oil pressure drops…….2513
      S-13 Oil level rises (Entry of coolant or fuel)…….2514
      S-14 Coolant temperature becomes too high (overheating)…….2515
      S-15 Abnormal noise is made…….2516
      S-16 Vibration is excessive…….2517
50 Disassembly and assembly…….0
    100 General information on disassembly and assembly…….2519
      How to read this manual…….2520
      Coating materials list…….2522
      Special tools list…….2525
      Sketches of special tools…….2528
    200 Engine and cooling system…….2533
      Removal and installation of fuel supply pump assembly…….2534
      Removal and installation of fuel injector assembly…….2537
      Removal and installation of front seal assembly…….2540
      Removal and installation of rear seal assembly…….2542
      Removal and installation of cylinder head assembly…….2545
      Removal and installation of engine and HST pump assembly…….2552
      Removal and installation of front guard assembly…….2556
      Removal and installation of radiator assembly…….2558
      Removal and installation of hydraulic oil cooler assembly…….2560
      Removal and installation of aftercooler assembly…….2562
      Removal and installation of cooling fan and motor assembly…….2564
      Removal and installation of cooling fan drive motor assembly…….2566
      Removal and installation of fuel tank assembly…….2568
    300 Power train…….2571
      Removal and installation of HST pump assembly…….2572
      Removal and installation of HST motor and final drive assembly…….2574
      Disassembly and assembly of final drive assembly…….2576
    400 Undercarriage and frame…….2587
      Spreading and installation of track shoe assembly…….2588
      Removal and installation of idler and recoil spring assembly…….2590
      Disassembly and assembly of idler assembly…….2591
      Disassembly and assembly of recoil spring assembly…….2594
      Disassembly and assembly of track roller assembly…….2598
      Disassembly and assembly of carrier roller assembly…….2602
    500 Hydraulic system…….2607
      Removal and installation of hydraulic tank assembly…….2608
      Removal and installation of control valve assembly…….2610
      Disassembly and assembly of control valve assembly…….2611
      Disassembly and assembly of hydraulic cylinder assembly…….2613
    600 Work equipment…….2619
      Removal and installation of work equipment assembly…….2620
    700 Cab and its attachments…….2625
      Removal and installation of ROPS canopy and operator seat frame assembly…….2626
      Removal and installation of ROPS cab and operator seat frame assembly…….2629
      Removal and installation of operator’s cab glass (Stuck glass)…….2633
    800 Electrical system…….2641
      Removal and installation of HST controller assembly…….2642
      Removal and installation of KOMTRAX terminal assembly…….2643
90 Diagrams and drawings…….0
    100 Hydraulic diagrams and drawings…….2645
      Work equipment hydraulic circuit diagram…….2647
    200 Electrical diagrams and drawings…….2652
      Electrical circuit diagram…….2654
      Cab electrical circuit diagram…….2659
      Air conditioner circuit diagram…….2663
      Connector list and stereogram…….2665
SEN06061-03 – Bulldozer D37EX-23, D37PX-23, D39EX-23, D39PX-23 Shop Manual (SN80001&up)…….2668
COVER…….2668
00 Index and foreword …….2670
    Index …….2671
    Foreword, safety and general information …….2683
      Important safety notice …….2683
      How to read the shop manual …….2690
      Explanation of terms for maintenance standard …….2692
      Handling equipment of fuel system devices …….2694
      Handling of intake system parts …….2695
      Handling of hydraulic equipment …….2696
      Method of disconnecting and connecting of push-pull type coupler …….2698
      Handling of electrical equipment …….2701
      How to read electric wire code …….2709
      Precautions when performing operation …….2712
      Practical use of KOMTRAX …….2717
      Standard tightening torque table …….2718
      List of abbreviation …….2724
      Conversion table …….2729
01 Specification …….2734
    Table of contents …….2735
    Specifications …….2736
      Specification drawing …….2736
      Specifications …….2740
      Weight table …….2760
      Table of fuel, coolant, and lubricants …….2768
10 Structure and function …….2770
    Table of contents …….2771
    Engine and cooling system …….2772
      Engine related parts …….2772
      VFT …….2774
      EGR system piping drawing …….2778
      EGR system circuit diagram …….2780
      EGR valve …….2781
      EGR cooler …….2783
      KCCV layout drawing …….2785
      KCCV ventilator …….2787
      KDOC muffler …….2791
      Cooling system …….2793
      Cooling fan motor …….2795
      Oil cooler bypass and HST charge safety valve …….2803
    Power train …….2810
      Power train system …….2810
      Damper …….2813
      Hydraulic component layout of HST …….2814
      Steering and brake control …….2815
      HST pump …….2817
      HST motor …….2831
      Charge pump …….2847
      Solenoid valve …….2848
      Final drive …….2858
    Undercarriage and frame …….2862
      Main frame …….2862
      Track frame and idler cushion …….2863
    Hydraulic system …….2865
      Hydraulic component layout …….2865
      Work equipment control system …….2867
      Hydraulic tank …….2869
      CLSS …….2871
      Work equipment and cooling fan pump …….2874
      Control valve …….2885
      Ripper PPC valve …….2902
      Angle control EPC valve …….2907
      Accumulator …….2912
    Work equipment …….2914
      Blade …….2914
      Ripper …….2915
      Piston valve …….2916
    Cab and its attachments …….2917
      ROPS cab …….2917
      Cab mount …….2919
    Electrical system …….2920
      Electrical control system …….2920
      Machine monitor system …….2942
      KOMTRAX system …….2964
      System component parts …….2967
      Sensor …….2984
20 Standard value tables …….3000
    Table of contents …….3001
    Standard service value table …….3002
      Standard value table for engine …….3002
      Standard value table for machine …….3003
      Standard value table for electrical system …….3016
30 Testing and adjusting …….3024
    Table of contents …….3025
    Related information on testing and adjusting …….3027
      Tools for testing and adjusting …….3027
      Sketch of tools for testing and adjusting …….3030
    Engine and cooling system …….3031
      Testing engine speed …….3031
      Testing exhaust gas color …….3033
      Testing and adjusting valve clearance …….3035
      Testing compression pressure …….3037
      Testing blowby pressure …….3040
      Testing engine oil pressure …….3041
      Testing fuel pressure …….3042
      Testing fuel return rate and leakage …….3043
      Bleeding air from fuel system …….3046
      Testing fuel circuit for leakage …….3047
      Handling cylinder cutout mode operation …….3048
      Handling no-injection cranking operation …….3049
      Testing of installed condition of cylinder heads and manifolds …….3050
      Testing engine piping for damage and looseness …….3051
      Replacing belt for alternator and air conditioner compressor …….3052
      Writing compensation values at replacement of injector and engine controller …….3053
    Power train …….3057
      Testing and adjusting HST oil pressure …….3057
      Testing outlet pressure of solenoid valve …….3062
      Testing if machine travels straight …….3066
      Simple test procedure for brake performance …….3067
      Adjusting deceleration/brake pedal …….3068
      Adjusting parking brake lever …….3071
      Move disabled machine urgently …….3073
    Undercarriage and frame …….3076
      Adjusting idler clearance …….3076
      Checking sprocket wear …….3077
      Testing and adjusting track tension …….3078
    Hydraulic system …….3079
      Releasing remaining pressure in work equipment cylinder …….3079
      Testing and adjusting work equipment oil pressure …….3080
      Testing source pressure of control circuit …….3082
      Testing outlet pressure of work equipment EPC valve and fan EPC valve …….3083
      Isolating the parts causing hydraulic drift in blade and ripper …….3085
      Testing internal oil leakage of work equipment cylinder …….3086
      Testing fan speed …….3088
      Testing fan circuit oil pressure …….3089
      Bleeding air from hydraulic circuit …….3090
    Work equipment …….3091
      Adjusting work equipment lock lever …….3091
      Adjusting play of blade center ball …….3093
    Electrical system …….3094
      Special functions of machine monitor …….3094
      Adjustment method when HST controller has been replaced …….3166
      Adjustment method when electric or hydraulic device has been replaced …….3169
      Adjusting rearview camera angle …….3170
      Testing windshield wiper operation …….3171
      Replacing windshield wiper blade …….3172
      Handling voltage circuit of engine controller …….3173
      Handling battery disconnect switch …….3174
      Testing diodes …….3175
    Pm clinic …….3176
      Pm Clinic service …….3176
      Pm Clinic service (D39EX-23,D39PX-23) …….3178
      Pm Clinic check sheet …….3180
      Pm Clinic check sheet (D39EX-23,D39PX-23) …….3189
40 Troubleshooting …….3198
    Table of contents …….3199
    Related information on troubleshooting …….3206
      Troubleshooting points …….3206
      Sequence of events in troubleshooting …….3208
      Checks before troubleshooting …….3210
      Inspection procedure before troubleshooting …….3212
      Preparation for troubleshooting of electrical system …….3230
      Classification and procedures for troubleshooting …….3233
      Symptom and troubleshooting numbers …….3235
      Information in troubleshooting table …….3237
      Troubleshooting method for open circuit in wiring harness of pressure sensor system …….3239
      Connector list and layout …….3241
      Connector contact identification …….3252
      T-branch box and T-branch adapter table …….3290
      Fuse location table …….3295
      Failure codes table …….3300
    Troubleshooting by failure code (Display of code) …….3309
      Failure code [6091NX] HST Oil Filter Clogging …….3309
      Failure code [989L00] Engine Controller Lock Caution 1 …….3311
      Failure code [989M00] Engine Controller Lock Caution 2 …….3312
      Failure code [989N00] Engine Controller Lock Caution 3 …….3313
      Failure code [AA10NX] Air Cleaner Clogging …….3314
      Failure code [AB00KE] Charge Voltage Low …….3316
      Failure code [B@BAZG] Eng Oil Press Low …….3318
      Failure code [B@BCNS] Eng Water Overheat …….3319
      Failure code [B@CRNS] HST Oil Overheat …….3320
      Failure code [B@CRZG] HST Charge Press Low …….3321
      Failure code [CA115] Eng Ne and Bkup Speed Sens Error …….3322
      Failure code [CA122] Chg Air Press Sensor High Error …….3323
      Failure code [CA123] Chg Air Press Sensor Low Error …….3325
      Failure code [CA131] Throttle Sensor High Error …….3327
      Failure code [CA132] Throttle Sensor Low Error …….3329
      Failure code [CA144] Coolant Temp Sens High Error …….3331
      Failure code [CA145] Coolant Temp Sens Low Error …….3333
      Failure code [CA153] Chg Air Temp Sensor High Error …….3335
      Failure code [CA154] Chg Air Temp Sensor Low Error …….3337
      Failure code [CA187] Sensor 2 Supply Volt Low Error …….3339
      Failure code [CA221] Ambient Press Sensor High Error …….3341
      Failure code [CA222] Ambient Press Sensor Low Error …….3343
      Failure code [CA227] Sensor 2 Supply Volt High Error …….3345
      Failure code [CA234] Eng Overspeed …….3346
      Failure code [CA238] Ne Speed Sensor Supply Volt Error …….3347
      Failure code [CA239] Ne Speed Sens Supply Volt High Error …….3348
      Failure code [CA271] IMV/PCV1 Short Error …….3349
      Failure code [CA272] IMV/PCV1 Open Error …….3350
      Failure code [CA322] Inj #1(L#1) Open/Short Error …….3351
      Failure code [CA324] Inj #3(L#3) Open/Short Error …….3353
      Failure code [CA331] Inj #2(L#2) Open/Short Error …….3355
      Failure code [CA332] Inj #4(L#4) Open/Short Error …….3357
      Failure code [CA343] ECM Critical Internal Failure …….3359
      Failure code [CA351] Injectors Drive Circuit Error …….3360
      Failure code [CA352] Sensor 1 Supply Volt Low Error …….3361
      Failure code [CA356] Mass Air Flow Sensor High Error …….3363
      Failure code [CA357] Mass Air Flow Sensor Low Error …….3365
      Failure code [CA386] Sensor 1 Supply Volt High Error …….3367
      Failure code [CA435] Eng Oil Press Sw Error …….3368
      Failure code [CA441] Battery Voltage Low Error …….3369
      Failure code [CA442] Battery Voltage High Error …….3371
      Failure code [CA449] Rail Press Very High Error …….3372
      Failure code [CA451] Rail Press Sensor High Error …….3373
      Failure code [CA452] Rail Press Sensor Low Error …….3375
      Failure code [CA466] KVGT Motor Driver Position Error …….3377
      Failure code [CA515] Rail Press Sens Sup Volt High Error …….3379
      Failure code [CA516] Rail Press Sens Sup Volt Low Error …….3381
      Failure code [CA553] Rail Press High Error …….3383
      Failure code [CA555] Crankcase Press High Error 1 …….3384
      Failure code [CA556] Crankcase Press High Error 2 …….3385
      Failure code [CA559] Rail Press Low Error …….3386
      Failure code [CA689] Eng Ne Speed Sensor Error …….3389
      Failure code [CA691] Intake Air Temp Sens High Error …….3391
      Failure code [CA692] Intake Air Temp Sens Low Error …….3393
      Failure code [CA697] ECM Internal Temp Sensor High Error …….3395
      Failure code [CA698] ECM Int Temp Sensor Low Error …….3396
      Failure code [CA731] Eng Bkup Speed Sens Phase Error …….3397
      Failure code [CA778] Eng Bkup Speed Sensor Error …….3400
      Failure code [CA1117] Persistent Data Lost Error …….3404
      Failure code [CA1695] Sensor 5 Supply Volt High Error …….3405
      Failure code [CA1696] Sensor 5 Supply Volt Low Error …….3406
      Failure code [CA1843] Crankcase Press Sens High Error …….3407
      Failure code [CA1844] Crankcase Press Sens Low Error …….3409
      Failure code [CA1896] EGR Valve Stuck Error …….3411
      Failure code [CA1942] Crankcase Press Sens In Range Error …….3412
      Failure code [CA1961] EGR_Motor Driver IC Over Temp Error …….3413
      Failure code [CA2185] Throt Sensor Sup Volt High Error …….3414
      Failure code [CA2186] Throt Sensor Sup Volt Low Error …….3415
      Failure code [CA2249] Rail Press Very Low Error …….3416
      Failure code [CA2272] EGR Valve Pos Sens Low Error …….3417
      Failure code [CA2311] IMV Solenoid Error …….3419
      Failure code [CA2349] EGR Valve Solenoid Open Error …….3420
      Failure code [CA2353] EGR Valve Solenoid Short Error …….3422
      Failure code [CA2357] EGR Valve Servo Error …….3424
      Failure code [CA2555] Grid Htr Relay Volt Low Error …….3425
      Failure code [CA2556] Grid Htr Relay Volt High Error …….3427
      Failure code [CA2765] Inj Trim Data Error …….3429
      Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error …….3430
      Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error …….3432
      Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error …….3434
      Failure code [CA3918] KVGT Stuck Error …….3436
      Failure code [CA3919] KVGT Motor Driver IC Over Temp Error …….3437
      Failure code [CA3921] KVGT Servo Error 2 …….3438
      Failure code [CA3922] KVGT Motor Driver Open Error …….3439
      Failure code [CA3923] KVGT Motor Driver Short Error …….3441
      Failure code [D130KA] Neutral relay Open …….3443
      Failure code [D130KB] Neutral relay Short circuit …….3445
      Failure code [D130KY] Neutral relay: Hot Short …….3447
      Failure code [D19JKZ] Personal Code Relay Abnormality …….3449
      Failure code [D811MC] KOMTRAX Error …….3452
      Failure code [D862KA] GPS Antenna Open Circuit …….3453
      Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) …….3454
      Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) …….3456
      Failure code [D8AQKR] CAN2 Discon (KOMTRAX) …….3457
      Failure code [DAF0MB] Monitor ROM Abnormality …….3459
      Failure code [DAF0MC] Monitor Error …….3460
      Failure code [DAF8KB] Camera Power Supply Short Circuit …….3461
      Failure code [DAF9KQ] Model Selection Abnormality …….3462
      Failure code [DAFGMC] GPS Module Error …….3463
      Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) …….3464
      Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) …….3466
      Failure code [DAFQKR] CAN2 Discon (Monitor) …….3467
      Failure code [DAJ000] HST controller: Abnormality in controller …….3468
      Failure code [DAJ0KQ] HST controller: Type select signal …….3469
      Failure code [DAJ0KT] HST controller: Abnormality in controller …….3470
      Failure code [DAJ0MC] HST Con Error …….3471
      Failure code [DAJ1KK] HST controller: Source voltage low …….3472
      Failure code [DAJ2KK] HST controller: Output voltage low …….3474
      Failure code [DAJ5KK] HST: Sensor volt 5V (0) Out of normal range …….3476
      Failure code [DAJ6KK] HST: Sensor volt 5V (1) Out of normal range …….3478
      Failure code [DAJLKA] Operating Lamp Open Circuit (HST Con) …….3480
      Failure code [DAJLKB] Operating Lamp Short Circuit (HST Con) …….3482
      Failure code [DAJPMA] Inconsistency of Option Selection (HST) …….3483
      Failure code [DAJQKR] CAN2 Discon (HST Con) …….3484
      Failure code [DAJRKR] CAN1 Discon (HST Con) …….3485
      Failure code [DB2QKR] CAN2 Discon (Engine Con) …….3486
      Failure code [DB2RKR] CAN1 Discon (Engine Con) …….3490
      Failure code [DD12KA] Shift up SW: Open …….3494
      Failure code [DD12KB] Shift up SW: Short Circuit …….3496
      Failure code [DD13KA] Shift down SW: Open …….3498
      Failure code [DD13KB] Shift down SW: Short Circuit …….3500
      Failure code [DD14KA] Parking lever SW: Open …….3502
      Failure code [DD14KB] Parking lever SW: Short circuit …….3504
      Failure code [DDKAKA] Blade float Sw: Open …….3506
      Failure code [DDKAKB] Blade float Sw: Short circuit …….3508
      Failure code [DDKFL4] Left Angle Sw: Signal mismatch …….3510
      Failure code [DDKGL4] Right Angle Sw: Signal mismatch …….3512
      Failure code [DDKHKA] iB Sw: Open …….3514
      Failure code [DDKHKB] iB Sw: Short circuit …….3516
      Failure code [DDNLKA] Weq lock Sw: Open …….3518
      Failure code [DDNLKB] Weq lock Sw: Short circuit …….3520
      Failure code [DDP6KA] Brake Pressure Sensor: Open …….3522
      Failure code [DDP6KB] Brake Pressure Sensor: Hot Short …….3524
      Failure code [DDP6MA] Brake pressure sensor: Malfunction …….3526
      Failure code [DDU1FS] Parking lever Switch 2: Signal mismatch …….3528
      Failure code [DDU1KA] Parking lever Sw2:Open …….3530
      Failure code [DDU1KY] Parking lever Sw2:Hot Short …….3532
      Failure code [DFA4KX] Blade lift lever: Main and Sub Error …….3534
      Failure code [DFA4KZ] Blade lift lever: Main and Sub Error …….3535
      Failure code [DFA4L8] Blade lift lever: Signal mismatch …….3536
      Failure code [DFA5KA] Blade lift lever1: Open …….3537
      Failure code [DFA5KB] Blade lift lever1: Hot Short …….3540
      Failure code [DFA6KA] Blade lift lever2: Open …….3542
      Failure code [DFA6KB] Blade lift lever2: Hot Short …….3544
      Failure code [DFA7KX] Blade tilt lever: Main and Sub Error …….3546
      Failure code [DFA7KZ] Blade tilt lever: Main and Sub Error …….3547
      Failure code [DFA7L8] Blade tilt lever: Signal mismatch …….3548
      Failure code [DFA8KA] Blade tilt lever1: Open …….3549
      Failure code [DFA8KB] Blade tilt lever1: Hot Short …….3552
      Failure code [DFA9KA] Blade tilt lever2: Open …….3554
      Failure code [DFA9KB] Blade tilt lever2: Hot Short …….3557
      Failure code [DGS1KA] HST oil temp sensor: Open …….3559
      Failure code [DGS1KX] HST oil temp sensor:Out of normal range …….3561
      Failure code [DH21KA] Weq pressure sensor: Open …….3562
      Failure code [DH21KB] Weq pressure sensor: Hot Short …….3564
      Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit …….3566
      Failure code [DHH7KA] LF HST Pressure Sensor: Open …….3568
      Failure code [DHH7KB] LF HST Pressure Sensor: Hot Short …….3570
      Failure code [DHH8KA] RF HST Pressure Sensor: Open …….3572
      Failure code [DHH8KB] RF HST Pressure Sensor: Hot Short …….3574
      Failure code [DHH9KA] LR HST Pressure Sensor: Open …….3576
      Failure code [DHH9KB] LR HST Pressure Sensor: Hot Short …….3578
      Failure code [DHHAKA] RR HST Pressure Sensor: Open …….3580
      Failure code [DHHAKB] RR HST Pressure Sensor: Hot Short …….3582
      Failure code [DK30KA] ST lever1: Open …….3584
      Failure code [DK30KB] ST lever1: Hot Short …….3586
      Failure code [DK30KX] ST lever: Main and Sub Error …….3588
      Failure code [DK30KZ] ST lever: Main and Sub Error …….3589
      Failure code [DK30L8] ST lever: Signal mismatch …….3590
      Failure code [DK31KA] ST lever2: Open …….3591
      Failure code [DK31KB] ST lever2: Hot Short …….3593
      Failure code [DK40KA] Decel/Brake potentiometer: Open …….3595
      Failure code [DK40KB] Decel/Brake potentiometer: Hot Short …….3598
      Failure code [DK55KX] FR lever: Main and Sub Error …….3600
      Failure code [DK55KZ] FR lever: Main and Sub Error …….3601
      Failure code [DK55L8] FR lever: Signal mismatch …….3602
      Failure code [DK56KA] FR lever1: Open …….3603
      Failure code [DK56KB] FR lever1: Hot Short …….3605
      Failure code [DK57KA] FR lever2: Open …….3607
      Failure code [DK57KB] FR lever2: Hot Short …….3609
      Failure code [DLM0KX] HST Motor Speed Sensor: Left/Right Error …….3611
      Failure code [DLM1KA] Left HST motor speed sensor: Open …….3612
      Failure code [DLM1KB] Left HST motor speed sensor: Short circuit …….3614
      Failure code [DLM1MA] Left HST motor speed sensor: Malfunction …….3616
      Failure code [DLM2KA] Right HST motor speed sensor: Open …….3617
      Failure code [DLM2KB] Right HST motor speed sensor: Short circuit …….3619
      Failure code [DLM2MA] Right HST motor speed sensor: Malfunction …….3621
      Failure code [DLM3KA] Fan Speed Sensor Open Circuit …….3622
      Failure code [DLM3KB] Fan Speed Sensor Short Circuit …….3624
      Failure code [DLM3MB] Fan control: Mismatch …….3626
      Failure code [DN21FS] Decel/Brake pedal SW: Signal mismatch …….3627
      Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality …….3629
      Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality …….3630
      Failure code [DV20KB] Back-up alarm : Short circuit …….3631
      Failure code [DW4BKA] Parking brake solenoid: Open …….3633
      Failure code [DW4BKB] Parking brake solenoid: Short circuit …….3635
      Failure code [DW4BKY] Parking brake solenoid: Hot Short …….3637
      Failure code [DW7BKA] Fan reverse solenoid: Open …….3639
      Failure code [DW7BKB] Fan reverse solenoid: Short circuit …….3641
      Failure code [DW7EKA] Slow brake solenoid: Open …….3642
      Failure code [DW7EKB] Slow brake solenoid: Short circuit …….3644
      Failure code [DW7EKY] Slow brake solenoid: Hot Short …….3646
      Failure code [DWN5KA] Fan EPC: Open …….3648
      Failure code [DWN5KB] Fan EPC: Short circuit …….3650
      Failure code [DWN5KY] Fan EPC: Hot Short …….3651
      Failure code [DXA4KA] LF HST pump EPC: Open …….3653
      Failure code [DXA4KB] LF HST pump EPC: Short circuit …….3655
      Failure code [DXA4KY] LF HST pump EPC: Hot Short …….3656
      Failure code [DXA5KA] LR HST pump EPC:Open …….3658
      Failure code [DXA5KB] LR HST pump EPC:Short circuit …….3660
      Failure code [DXA5KY] LR HST pump EPC: Hot Short …….3662
      Failure code [DXA6KA] RF HST pump EPC: Open …….3664
      Failure code [DXA6KB] RF HST pump EPC: Short circuit …….3666
      Failure code [DXA6KY] RF HST pump EPC: Hot Short …….3667
      Failure code [DXA7KA] RR HST pump EPC: Open …….3669
      Failure code [DXA7KB] RR HST pump EPC: Short circuit …….3671
      Failure code [DXA7KY] RR HST pump EPC: Hot Short …….3672
      Failure code [DXHRKA] Blade lift up EPC: Open …….3674
      Failure code [DXHRKB] Blade lift up EPC: Short circuit …….3676
      Failure code [DXHRKY] Blade lift up EPC: Hot short …….3677
      Failure code [DXHSKA] Blade lift down EPC: Open …….3679
      Failure code [DXHSKB] Blade lift down EPC: Short circuit …….3681
      Failure code [DXHSKY] Blade lift down EPC: Hot short …….3682
      Failure code [DXHTKA] Blade tilt left EPC: Open …….3684
      Failure code [DXHTKB] Blade tilt left EPC: Short circuit …….3686
      Failure code [DXHTKY] Blade tilt left EPC: Hot short …….3687
      Failure code [DXHUKA] Blade tilt right EPC: Open …….3689
      Failure code [DXHUKB] Blade tilt right EPC: Short circuit …….3691
      Failure code [DXHUKY] Blade tilt right EPC: Hot short …….3692
      Failure code [DXJ4KA] Weq lock Sol.: Open …….3694
      Failure code [DXJ4KB] Weq lock Sol.: Short circuit …….3696
      Failure code [DXJCKA] Blade angle left EPC: Open …….3698
      Failure code [DXJCKB] Blade angle left EPC: Short circuit …….3699
      Failure code [DXJCKY] Blade angle left EPC: Hot short …….3700
      Failure code [DXJDKA] Blade angle right EPC: Open …….3702
      Failure code [DXJDKB] Blade angle right EPC: Short circuit …….3703
      Failure code [DXJDKY] Blade angle right EPC: Hot short …….3704
      Failure code [DXK1KA] Left HST motor EPC: Open …….3706
      Failure code [DXK1KB] Left HST motor EPC: Short circuit …….3708
      Failure code [DXK1KY] Left HST motor EPC: Hot Short …….3709
      Failure code [DXK2KA] Right HST motor EPC: Open …….3711
      Failure code [DXK2KB] Right HST motor EPC: Short circuit …….3713
      Failure code [DXK2KY] Right HST motor EPC: Hot Short …….3714
    Troubleshooting of electrical system (E-mode) …….3716
      E-1 Engine does not start (Engine does not crank) …….3716
      E-2 Manual preheating system does not work …….3722
      E-3 Automatic preheating system does not work …….3725
      E-4 While preheating is working, preheating monitor does not light up …….3727
      E-5 When starting switch is turned to ON position, machine monitor displays nothing …….3729
      E-6 When starting switch is turned to ON position (with engine stopped), basic check monitor lights up …….3732
      E-7 Air cleaner clogging monitor lights up in yellow while engine is running …….3733
      E-8 Charge level monitor lights up in red while engine is running …….3734
      E-9 Engine coolant temperature monitor lights up in red while engine is running …….3735
      E-10 Engine oil pressure monitor lights up in red while engine is running …….3736
      E-11 HST charge pressure monitor lights up in red while engine is running …….3737
      E-12 Hydraulic oil temperature monitor lights up in red while engine is running …….3738
      E-13 HST oil filter clogging monitor lights up in red while engine is running …….3739
      E-14 Fuel level gauge does not indicate correct level …….3740
      E-15 Engine coolant temperature gauge does not indicate correct temperature …….3743
      E-16 Hydraulic oil temperature gauge does not indicate correct temperature …….3744
      E-17 Operation mode does not change …….3745
      E-18 Service mode cannot be selected …….3746
      E-19 Operating customize switch does not display customize screen …….3747
      E-20 Modifying setting on customize screen does not change setting of machine …….3748
      E-21 Service meter is not displayed, while starting switch is in OFF position …….3749
      E-22 Work equipment does not operate …….3750
      E-23 Foot heater does not operate …….3752
      E-24 Horn does not sound …….3757
      E-25 Horn does not stop sounding …….3759
      E-26 Backup alarm does not sound …….3760
      E-27 Backup alarm does not stop sounding …….3761
      E-28 Headlamp does not light up …….3762
      E-29 Rear lamp does not light up …….3765
      E-30 No wiper operates continuously or intermittently …….3768
      E-31 Front wiper does not operate …….3770
      E-32 Rear wiper does not operate …….3772
      E-33 Left door wiper does not operate (failed in both continuous and intermittent operations) …….3774
      E-34 Right door wiper does not operate (failed in both continuous and intermittent operations) …….3778
      E-35 Front washer does not operate …….3782
      E-36 Rear washer does not operate …….3784
      E-37 Left door washer does not operate …….3786
      E-38 Right door washer does not operate …….3788
      E-39 KOMTRAX system does not operate normally …….3790
    Troubleshooting of hydraulic and mechanical system (H-mode) …….3792
      Information described in troubleshooting table (H-mode) …….3792
      System chart of hydraulic and mechanical systems …….3793
      Failure mode and cause table …….3795
      H-1 Neither RH nor LH of tracks does not travel forward nor reverse (None of the travel system operates) …….3799
      H-2 Either RH or LH of track does not travel forward nor reverse (Only RH or LH of travel system operates) …….3801
      H-3 Either RH or LH of track travel only forward or reverse (Only forward or reverse of RH or LH of travel system does not operate) …….3802
      H-4 Travel speed or power is low …….3804
      H-5 Travel speed range does not change …….3805
      H-6 Shock is large when machine starts or stops …….3806
      H-7 Machine deviates largely …….3807
      H-8 Machine drift on a slope is large …….3809
      H-9 Engine stalls during travel or engine speed drops significantly …….3810
      H-10 Unusual noise is heard from around HST pump or motor …….3811
      H-11 All work equipment do not operate …….3812
      H-12 All work equipment operates slowly or lacks power …….3814
      H-13 Blade lift speed or power is low …….3816
      H-14 Blade tilt speed or power is low …….3817
      H-15 Blade angle speed or power is low …….3818
      H-16 Time lag of blade lift is large …….3819
      H-17 Hydraulic drift of lifted blade is large …….3820
      H-18 Hydraulic drift of tilted blade is large …….3821
      H-19 Unusual noise is heard from around work equipment pump or control valve …….3822
      H-20 HST oil temperature (hydraulic oil temperature) rises too high …….3823
      H-21 Fan speed is abnormal (too high or low, or fan doe not rotate) …….3825
      H-22 Unusual noise is heard from around fan …….3827
    Troubleshooting of engine (S-mode) …….3828
      Information described in troubleshooting table (S mode) …….3828
      S-1 Engine does not crank when starting switch is turned to START position …….3829
      S-2 Engine cranks but no exhaust smoke comes out …….3830
      S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) …….3831
      S-4 Engine startability is poor …….3832
      S-5 Engine does not pick up smoothly …….3834
      S-6 Engine stops during operation …….3836
      S-7 Engine runs rough or is unstable …….3838
      S-8 Engine lacks power …….3839
      S-9 Exhaust smoke is black …….3841
      S-10 Engine oil consumption is excessive …….3843
      S-11 Oil becomes contaminated quickly …….3844
      S-12 Fuel consumption is excessive …….3845
      S-13 Oil is in coolant (or coolant spurts or coolant level goes down) …….3846
      S-14 Oil pressure drops …….3847
      S-15 Fuel mixes into engine oil …….3848
      S-16 Water mixes into engine oil (milky) …….3849
      S-17 Coolant temperature rises too high (overheating) …….3850
      S-18 Unusual noise is heard …….3851
      S-19 Vibration is excessive …….3852
      S-20 Air cannot be bled from fuel circuit …….3853
50 Disassembly and assembly …….3854
    Table of contents …….3855
    Related information on disassembly and assembly …….3857
      How to read this manual …….3857
      Coating materials list …….3859
      Special tools list …….3863
      Sketches of special tools …….3871
    Engine and cooling system …….3885
      Removal and installation of supply pump assembly …….3885
      Removal and installation of fuel injector assembly …….3888
      Removal and installation of cylinder head assembly …….3893
      Removal and installation of radiator assembly …….3903
      Removal and installation of aftercooler assembly …….3906
      Removal and installation of hydraulic oil cooler assembly …….3909
      Removal and installation of cooling fan drive assembly …….3911
      Removal and installation of cooling fan motor assembly …….3913
      Removal and installation of engine and HST pump assembly …….3915
      Disassembly and assembly of damper assembly …….3919
      Removal and installation of engine front oil seal …….3920
      Removal and installation of engine rear oil seal …….3922
      Removal and installation of engine hood assembly …….3924
      Removal and installation of fuel tank assembly …….3927
      Removal and installation of KCCV assembly …….3929
      Removal and installation of VFT assembly …….3930
      Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly …….3931
      Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly …….3933
      Removal and installation of starting motor assembly …….3934
      Removal and installation of belt for alternator and air conditioner compressor …….3935
      Removal and installation of air cleaner assembly …….3937
    Power train …….3939
      Removal and installation of HST motor and final drive assembly …….3939
      Disassembly and assembly of final drive …….3941
    Undercarriage and frame …….3949
      Removal and installation of idler and recoil spring assembly …….3949
      Disassembly and assembly of idler …….3950
      Disassembly and assembly of recoil spring …….3953
      Disassembly and assembly of track roller assembly …….3957
      Disassembly and assembly of carrier roller assembly …….3961
      Separation and connection of track shoe assembly (Standard type track shoe) …….3963
      Separation and connection of track shoe assembly (PLUS type track shoe) …….3965
      Overall disassembly and assembly of track shoe assembly (Standard type track shoe) …….3966
      Overall disassembly and assembly of track shoe assembly (PLUS type track shoe) …….3979
      Disassembly and assembly of one track link assembly in field (Standard type track shoe) …….3992
      Disassembly and assembly of one track link assembly in field (PLUS type track shoe) …….3999
    Hydraulic system …….4004
      Removal and installation of hydraulic tank assembly …….4004
      Removal and installation of control valve assembly …….4006
      Removal and installation of HST pump assembly …….4008
      Disassembly and assembly of hydraulic cylinder assembly …….4010
    Work equipment …….4014
      Removal and installation of work equipment assembly …….4014
      Removal and installation of blade assembly …….4016
      Removal and installation of U-frame assembly …….4018
    Cab and its attachments …….4020
      Removal and installation of ROPS cab assembly …….4020
      Removal and installation of wiper arm …….4024
      Removal and installation of operator's cab glass (adhesion glass) …….4026
      Removal and installation of operator's seat …….4032
      Removal and installation of seat belt …….4033
      Removal and installation of foot heater assembly …….4034
      Disassembly and assembly of foot heater assembly …….4036
      Removal and installation of air conditioner unit assembly …….4037
      Removal and installation of air conditioner compressor assembly …….4042
    Electrical system …….4044
      Removal and installation of machine monitor assembly …….4044
      Removal and installation of engine controller assembly …….4045
      Removal and installation of HST controller assembly …….4046
      Removal and installation of mass air flow and temperature sensor …….4047
      Removal and installation of KOMTRAX terminal …….4048
60 Maintenance standard …….4050
    Table of contents …….4051
    Engine and cooling system …….4052
      Engine mount …….4052
      Cooling fan motor …….4053
      Oil cooler bypass and HST charge safety valve …….4055
    Power train …….4056
      Damper …….4056
      HST pump …….4057
      HST motor …….4059
      Charge pump …….4060
      Solenoid valve …….4061
      Final drive …….4062
      Sprocket …….4063
      Full-scale drawing of sprocket tooth profile …….4069
    Undercarriage and frame …….4074
      Track frame and idler cushion …….4074
      Idler …….4077
      Track roller …….4085
      Carrier roller …….4093
      Track shoe …….4097
    Hydraulic system …….4109
      Hydraulic tank …….4109
      Work equipment and cooling fan pump …….4110
      Control valve …….4113
      Ripper PPC valve …….4120
    Work equipment …….4122
      Blade …….4122
      Cutting edge and end bit …….4125
      Ripper …….4126
      Lift cylinder …….4128
      Tilt cylinder …….4129
      Angle cylinder …….4130
      Ripper cylinder …….4131
    Cab and its attachments …….4132
      Cab mount …….4132
    Electrical system …….4133
      System component parts …….4133
80 Appendix …….4134
    Table of contents …….4135
    Air conditioner components …….4136
      Precautions for refrigerant …….4136
      Air conditioner component …….4137
      Configuration and function of refrigeration cycle …….4140
      Outline of refrigeration cycle …….4141
      Air conditioner unit …….4143
      Dual pressure switch …….4147
      Pressure switch …….4148
      Compressor …….4149
      Condenser …….4150
      Receiver drier …….4152
      Procedure for testing and troubleshooting …….4153
      Electrical circuit diagram …….4156
      System diagram …….4157
      Parts and connectors layout …….4159
      Testing relays …….4164
      Troubleshooting chart 1 …….4166
      Troubleshooting chart 2 …….4167
      Information described in troubleshooting table …….4169
      A-1 Troubleshooting for condenser fan …….4170
      A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) …….4173
      A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) …….4177
      A-4 Troubleshooting for temperature control …….4179
      Troubleshooting with gauge pressure …….4182
      Connection of service tool …….4185
      Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit …….4187
      Handling of compressor oil …….4189
90 Diagrams and drawings …….4192
    Table of contents …….4193
    Hydraulic circuit diagram …….4194
      Symbols in hydraulic circuit diagram …….4194
      Hydraulic circuit diagram…….4198
    Electric circuit diagram …….4199
      Symbols in electric circuit diagram …….4199
      Electrical circuit diagram…….4203
INDEX…….4213

Komatsu Bulldozers D31EX,PX & D37EX,PX & D39EX,PX Repair Service Manuals

INSTANT DOWNLOAD

Posted on June 5, 2025 by admin

Komatsu Bulldozers D31A, D31E, D31P, D31PL, D31PLL, D31S, D31Q, D37E, D37P Repair Service Manuals

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Complete service repair manuals for Komatsu Bulldozers D31A, D31E, D31P, D31PL, D31PLL, D31S, D31Q, D37E, D37P, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Bulldozers D31A, D31E, D31P, D31PL, D31PLL, D31S, D31Q, D37E, D37P 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.

SEBM0114B01 – Bulldozer D31A-16, D31P-16 Shop Manual (SN25001&up).pdf
SEBM0114C04 – Bulldozer D31A,E,P,PL,PLL-17, D31P-17A,B Shop Manual (SN32001&up).pdf
SEBM001007 – Bulldozer D31E,P,PL,PLL,S,Q-20, D31P-20A, D37E-5, D37P-5A Shop Manual.pdf
SEBM01141805 – Bulldozer D31E,P,PL,PLL,S,Q-18, D31P-18A, D37E,P-2 Shop Manual.pdf
SRBM001007K – Бульдозер D31E,P,PL,PLL,S,Q-20 & D31P-20A & D37E-5 & D37P-5A Заводская инструкция.pdf

PRODUCT DETAILS:
Total Pages: 2,653 pages
File Format: PDF
Language: English

MAIN SECTIONS
01 GENERAL
10 STRUCTURE AND FUNCTION
20 TESTING AND ADJUSTING
30 DISASSEMBLY AND ASSEMBLY
40 MAINTENANCE STANDARD
90 OTHERS

TABLE OF CONTENTS
10 ENGINE
20 POWER TRAIN
30 UNDERCARRIAGE
60 HYDRAULIC SYSTEM
70 WORK EQUIPMENT
80 ELECTRICAL SYSTEM

SEBM001007 – Bulldozer D31E,P,PL,PLL,S,Q-20, D31P-20A, D37E-5, D37P-5A Shop Manual….2
CONTENTS….3
01 GENERAL ….26
SPECIFICATION DRAWINGS….27
SPECIFICATIONS….39
WEIGHT TABLE….63
LIST OF LUBRICANT AND WATER….75
10 STRUCTURE AND FUNCTION ….80
POWER TRAIN SYSTEM ….81
POWER TRAIN SKELETON ….82
POWER TRAIN HYDRAULIC PIPING ….85
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM ….87
POWER TRAIN HYDRAULIC SYSTEM ….88
DAMPER AND UNIVERSAL JOINT ….89
TRANSMISSION CONTROL….90
TRANSMISSION PUMP ….95
HYDROSHIFT TRANSMISSION….97
TRANSMISSION CONTROL VALVE ….106
STEERING CONTROL….114
STEERING CYLINDER ….118
BRAKE CYLINDER….119
PPC VALVE ….120
BEVEL GEAR SHAFT AND STEERING CLUTCH ….132
STEERING BRAKE….134
FINAL DRIVE ….136
TRACK FRAME ….137
MAIN FRAME AND SUSPENSION ….139
HYDRAULIC PIPING ….141
HYDRAULIC CIRCUIT DIAGRAM ….148
HYDRAULIC CIRCUIT SYSTEM ….149
HYDRAULIC CONTROL ….156
HYDRAULIC TANK AND FILTER ….158
HYDRAULIC CONTROL VALVE ….160
ANGLE SELECTOR VALVE ….166
SUCTION SAFETY VALVE ….169
WORK EQUIPMENT ….170
ELECTRICAL CIRCUIT DIAGRAM….173
ENGINE CONTROL….176
MONITOR SYSTEM ….177
SENSORS ….178
20 TESTING AND ADJUSTING ….181
STANDARD VALUE TABLE FOR ENGINE ….182
STANDARD VALUE TABLE FOR CHASSIS ….184
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM ….193
TABLE OF TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING ….194
MEASURlNG ENGINE SPEED ….196
MEASURING EXHAUST COLOR ….198
ADJUSTING VALVE CLEARANCE ….199
MEASURING COMPRESSION PRESSURE ….202
MEASURING BLOW-BY PRESSURE ….204
TESTING AND ADJUSTING FUEL INJECTION TIMING ….206
BLEEDING AIR FROM FUEL CIRCUIT ….210
MEASURING ENGINE OIL PRESSURE ….211
TESTING AND ADJUSTING FAN BELT TENSION ….214
MEASURING POWER TRAIN OIL PRESSURE ….215
ADJUSTING PPC VALVE ….216
BLEEDING AIR FROM STEERING CIRCUIT ….217
MEASURING AND ADJUSTING WORK EQUIPMENT MAIN RELIEF PRESSURE ….218
BLEEDING AIR FROM HYDRAULIC CYLINDERS ….220
BLEEDING AIR FROM ANGLE CYLINDER CIRCUIT ….221
ADJUSTING FUEL CONTROL CABLE ….222
ADJUSTING FUEL CONTROL LEVER ….223
PROCEDURE FOR ADJUSTING ENGINE STOP MOTOR CABLE ….224
ADJUSTING ENGINE STOP SOLENOID LINKAGE ….226
ADJUSTING TRANSMISSION CONTROL LINKAGE ….228
ADJUSTING TRAVEL OF INCHING PEDAL ….234
ADJUSTING BRAKE PEDAL, STEERING BRAKE CYLINDER ….235
ADJUSTING BRAKE LINING CLEARANCE ….238
TROUBLESHOOTING….239
POINTS TO REMEMBER WHEN TROUBLESHOOTING ….240
SEQUENCE OF EVENTS IN TROUBLESHOOTING ….241
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE ….242
HANDLING CONNECTORS….249
CHECKS BEFORE TROUBLESHOOTING ….250
TROUBLESHOOTING OF ENGINE (S MODE)….251
METHOD OF USING TROUBLESHOOTING CHARTS ….252
D31E-20 Serial No.: 42001-42713, D31P-20A Serial No.: 45001-47616, D31P, PL-20 Serial No.: 45001-47616, D37E-5 Serial No.: 3….256
S-1 Starting performance is poor (Starting always takes time) ….256
S-2 Engine does not start ….257
S-3 Engine does not pick up smoothly (Follow-up is poor) ….260
S-4 Engine stops during operations ….261
S-5 Engine does not rotate smoothly ….262
S-6 Engine lacks output (no power) ….263
S-7 Exhaust gas is black (incomplete combustion) ….264
S-8 Oil consumption is excessive (or exhaust gas is blue)….265
S-9 Oil becomes contaminated quickly ….266
S-10 Fuel consumption is excessive ….267
S-11 Oil is in cooling water, or water spurts back, or water level goes down ….268
S-12 Oil pressure lamp lights up (drop in oil pressure) ….269
S-13 Oil level rises….270
S-14 Water temperature becomes too high (overheating) ….271
S-15 Abnormal noise is made….272
S-16 Vibration is excessive….273
D31E-20 Serial No.: 42714 and up, D31P-20A Serial No.: 47617 and up, D31P, PL-20 Serial No.: 47617 and up, D37E-5 Serial No.: 37….274
S-1 Starting performance is poor (starting always takes time) ….274
S-2 Engine does not start ….275
(1) Engine does not turn….275
(2) Engine turns but no exhaust smoke comes out (fuel is not being injected)….276
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected)….277
S-3 Engine does not pick up smoothly (follow-up is poor) ….278
S-4 Engine stops during operations ….279
S-5 Engine does not rotate smoothly (hunting) ….280
S-6 Engine lacks output (no power) ….281
S-7 Exhaust smoke is black (incomplete combustion) ….282
S-8 Oil consumption is excessive (or exhaust smoke is blue) ….283
S-9 Oil becomes contaminated quickly ….284
S-10 Fuel consumption is excessive ….285
S-11 Oil is in cooling water, or water spurts back, or water level goes down ….286
S-12 Oil pressure caution lamp lights up (drop in oil pressure) ….287
S-13 Oil level rises (water, fuel in oil) ….288
S-14 Water temperature becomes too high (overheating) ….289
S-15 Abnormal noise is made ….290
S-16 Vibration is excessive ….291
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)….293
METHOD OF USING TROUBLESHOOTING CHART….294
TABLE OF FAILURE MODES AND CAUSES….296
H-1. Machine does not start ….296
H-2. Drawbar pull is weak, travel speed is slow….297
H-3. Excessive time lag when starting or shifting gear checks before troubleshooting ….298
H-4. Steering does not work properly ….299
H-5. Machine moves when engine is started ….300
H-6. Excessive shock when starting or shifting gear ….300
H-7. Level of oil in transmission case or bevel gear case changes ….300
H-8. Lack of blade lifting force, speed ….301
H-9. Impossible to raise blade or push up chassis ….302
H-10. Excessive hydraulic drift of blade ….303
H-11. Blade moves up and down during leveling operations (control lever at HOLD) ….303
H-12. Blade goes down ….303
H-13. Blade tilt lacks power, speed, impossible to push up chassis with tilt ….304
H-14. Blade cannot be tilted ….305
H-15. Excessive hydraulic drift of blade tilt ….306
H-16. Blade angle lacks power, speed (applicable to power angle, power tilt dozer) ….307
H-17. Blade cannot be angled (applicable to power angle tiltdozer) ….308
H-18. When blade is angled, blade returns to straight position or shakes during operations (control lever at HOLD) ….309
H-19. Lift arm lacks lifting power, speed ….310
H-20. Impossible to raise lift arm, impossible to raise chassis ….311
H-21. Excessive hydraulic drift of lift arm ….312
H-22. Bucket tilt back lacks power, speed ….313
H-23. Impossible to tilt back bucket ….314
H-24. Impossible to dump bucket, impossible to raise chassis with dump cylinder ….315
H-25. Bucket dump speed is slow ….316
H-26. Excessive hydraulic drift of bucket dump circuit ….317
H-27. Bucket moves up and down along ground surface during leveling operations, but lift arm moves irregularly [control lever at….318
H-28. Lift arm goes down ….318
H-29. Bucket moves irregularly during leveling operations (control lever at HOLD) ….318
H-30. Bucket dumps ….318
H-31. When bucket is dumped to maximum, it is impossible to raise lift arm ….318
H-32. Work equipment control levers are heavy ….319
30 DISASSEMBLY AND ASSEMBLY ….321
METHOD OF USING MANUAL….323
PRECAUTIONS WHEN CARRYING OUT OPERATION….324
SPECIAL TOOL LIST….326
STARTING MOTOR….330
REMOVAL AND INSTALLATION….330
ALTERNATOR….332
REMOVAL AND INTALLATION….332
ENGINE OIL COOLER CORE….334
REMOVAL AND INSTALLATION….334
FUEL INJECTION PUMP….336
REMOVAL ….336
INSTALLATION ….337
WATER PUMP….344
REMOVAL AND INSTALLATION….344
THERMOSTAT….346
REMOVAL AND INSTALLATION….346
NOZZLE HOLDER….348
REMOVAL AND INSTALLATION….348
TURBOCHARGER….351
REMOVAL ….351
INSTALLATION….353
CYLINDER HEAD….354
REMOVAL ….354
INSTALLATION ….355
RADIATOR GUARD….366
REMOVAL ….366
INSTALLATION ….367
RADIATOR….368
REMOVAL….368
INSTALLATION ….369
RADIATOR, RADIATOR GUARD….370
REMOVAL….370
INSTALLATION….373
ENGINE….374
REMOVAL ….374
INSTALLATION….375
DAMPER….380
REMOVAL….380
INSTALLATION….381
HYDROSHIFT TRANSMISSION….386
REMOVAL….386
INSTALLATION….388
DISASSEMBLY….389
ASSEMBLY ….401
MODULATING VALVE AND PUMP….415
REMOVAL AND INSTALLATION….415
MODULATING VALVE….416
DISASSEMBLY….416
ASSEMBLY ….417
SELECTOR AND INCHING VALVE….418
REMOVAL AND INSTALLATION….418
DISASSEMBLY ….419
ASSEMBLY ….420
MAIN RELIEF VALVE….421
REMOVAL AND INSTALLATION….421
STEERING PPC VALVE….422
REMOVAL AND INSTALLATION….422
DISASSEMBLY AND ASSEMBLY….425
STEERING CLUTCH….430
REMOVAL ….430
INSTALLATION ….432
DISASSEMBLY ….433
ASSEMBLY ….435
BEVEL GEAR SHAFT AND BEVEL GEAR….438
REMOVAL ….438
INSTALLATION ….441
FINAL DRIVE FIRST PINION….445
REMOVAL AND INSTALLATION….445
FINAL DRIVE….447
DISASSEMBLY ….447
ASSEMBLY ….450
TRACK FRAME….455
REMOVAL AND INSTALLATION….455
RECOIL SPRING….459
DISASSEMBLY ….459
ASSEMBLY ….460
IDLER….461
REMOVAL AND INSTALLATION….461
DISASSEMBLY ….462
ASSEMBLY….464
CARRIER ROLLER….466
REMOVAL AND INSTALLATION….466
DISASSEMBLY….467
ASSEMBLY ….468
TRACK ROLLER….469
REMOVAL AND INSTALLATION….469
DISASSEMBLY ….470
ASSEMBLY ….471
TRACK SHOE….479
REMOVAL AND INSTALLATION….479
HYDRAULIC PUMP….480
REMOVAL AND INSTALLATION….480
HYDRAULIC CONTROL VALVE….483
REMOVAL AND INSTALLATION….483
DISASSEMBLY AND ASSEMBLY….486
BLADE LIFT CYLINDER ….500
REMOVAL AND INSTALLATION (D13E, P-20, D31P-20A, D37E-5, D37P-5A)….500
(D31PL, PLL-20)….501
BLADE TILT CYLINDER ….502
REMOVAL AND INSTALLATION (D31 E, P-20, D31 P-20A. D37E-5, D37P-5A)….502
(D31 PL, PLL-20)….503
BLADE ANGLE CYLINDER ….504
REMOVAL AND INSTALLATION (D31 E, P-20, D31 P-20A. D37E-5, D37P-5A)….504
BUCKET LIFT CYLINDER….505
REMOVAL AND INSTALLATION (D31S, Q-20)….505
BUCKET DUMP CYLINDER….506
(D31S, Q-20)….506
HYDRAULIC CYLINDER….507
DISASSEMBLY….507
ASSEMBLY ….508
WORK EQUIPMENT….510
REMOVAL AND INSTALLATION (D31 E, P-20, D31 P-20A, D37E-5, D37P-5A)….510
(D31PL, PLL-20)….511
BLADE….512
REMOVAL AND INSTALLATION (D31 E, P-20, D31 P-20A, D37E-5, D37P-5A)….512
(D31PL, PLL-20)….513
WORK EQUIPMENT….514
REMOVAL AND INSTALLATION (D31S. Q-20)….514
BUCKET….515
REMOVAL AND INSTALLATION (D31S, Q-20)….515
OPERATOR’S SEAT FRAME….516
REMOVAL ….516
INSTALLATlON….517
40 MAINTENANCE STANDARD ….519
DAMPER AND UNIVERSAL JOINT ….520
HYDROSHIFT TRANSMISSION ….522
TRANSMISSION CONTROL VALVE ….524
TRANSMISSION AND STEERING PUMP ….526
PPC VALVE ….527
STEERING CYLINDER ….530
BEVEL GEAR SHAFT ….531
STEERING CLUTCH ….532
STEERING BRAKE ….534
FINAL DRIVE ….536
TRACK FRAME ….538
IDLER CUSHION ….540
IDLER ….542
TRACK ROLLER ….544
CARRIER ROLLER ….547
TRACK (LUBRICATED TRACK LINK) D31E, P, PL, PLL-20, D31P-20A, D37E-5, D37P-5A….548
TRACK (DRY TYPE TRACK LINK) D31E, P, PL, PLL-20, D31P-20A, D37E-5, D37P-5A….550
TRACK (LUBRICATED TRACK LINK) D31S, Q-20….556
TRACK (DRY TYPE TRACK LINK) D31S, Q-20….558
HYDRAULIC PUMP….560
HYDRAULIC CONTROL VALVE ….562
HYDRAULIC CYLINDER….568
WORK EQUIPMENT ….574
90 OTHERS ….581
TRIMMING DOZER….583
CONTENTS ….584
GENERAL ….585
SPECIFICATION DRAWING….585
SPECIFICATIONS ….588
WEIGHT TABLE ….592
TABLE OF FUEL, COOLANT AND LUBRICANTS ….594
STRUCTURE AND FUNCTION ….596
POWER TRAIN HYDRAULIC PIPING ….596
TRANSMISSION CONTROL….598
STEERING CONTROL ….602
PPC VALVE ….604
TRACK FRAME ….616
HYDRAULIC PIPING ….618
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM ….620
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM ….621
WORK EQUIPMENT CONTROL ….622
WORK EQUIPMENT CONTROL VALVE ….624
TRIMMING DOZER….628
ELECTRICAL WIRING DIAGRAM….631
ENGINE CONTROL….632
MAINTENANCE STANDARD ….634
PPC VALVE ….634
TRACK FRAME ….636
IDLER CUSHION ….638
IDLER ….640
TRACK ROLLER ….644
CARRIER ROLLER ….646
TRACK….648
WORK EQUIPMENT CONTROL VALVE ….660
HYDRAULIC CYLINDER ….664
TRIMMING DOZER….666
SEBM01141805 – Bulldozer D31E,P,PL,PLL,S,Q-18, D31P-18A, D37E,P-2 Shop Manual….673
COVER….673
CONTENTS….674
10 ENGINE….693
12 TESTING AND ADJUSTING….693
TESTING AND ADJUSTING DATA….694
TOOL LIST FOR TESTING AND ADJUSTING….696
ADJUSTING VALVE CLEARANCE….697
MEASURING EXHAUST GAS COLOR….698
MEASURING COMPRESSION PRESSURE….699
MEASURING BLOW-BY PRESSURE….700
ADJUSTING FUEL INJECTION TIMING….701
TESTING AND ADJUSTING FAN BELT TENSION….702
BLEEDING AIR FROM FUEL CIRCUIT….702
ADJUSTING FUEL CONTROL LEVER….703
13 DISASSEMBLY AND ASSEMBLY….704
STARTING MOTOR….705
REMOVAL AND INSTALLATION….705
ALTERNATOR….705
REMOVAL AND INSTALLATION….705
WATER PUMP….705
REMOVAL AND INSTALLATION….705
FUEL INJECTION PUMP….707
REMOVAL AND INSTALLATION….707
NOZZLE HOLDER….707
REMOVAL AND INSTALLATION….707
CYLINDER HEAD….709
REMOVAL….709
INSTALLATION….711
RADIATOR GUARD….715
REMOVAL AND INSTALLATION….715
RADIATOR….717
REMOVAL AND INSTALLATION….717
THERMOSTAT….717
REMOVAL AND INSTALLATION….717
ENGINE….719
REMOVAL….719
INSTALLATION….721
20 POWER TRAIN….723
21 STRUCTURE AND FUNCTION….723
GENERAL….724
POWER TRAIN HYDRAULIC SYSTEM (D31E, P, PL, PLL-18, D31P-18A, D37E, P-2)….726
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM (D31E, P, PL, PLL-18, D31P-18A, D37E,P-2)….727
POWER TRAIN HYDRAULIC SYSTEM (D31S, Q-18)….729
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM (D31S, Q-18)….730
DAMPER AND UNIVERSAL JOINT….731
HYDROSHIFT TRANSMISSION….732
TRANSMISSION CONTROL….739
HYDROSHIFT TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM….740
TRANSMISSION CONTROL VALVE….742
TRANSMISSION PUMP….749
BEVEL GEAR SHAFT AND STEERING CLUTCH….750
STEERING CONTROL (D31E, P, PL, PLL-18, D31P-18A, D37E,P-2)….752
STEERING CONTROL (D31S, Q-18)….753
STEERING HYDRAULIC PIPING….754
STEERING HYDRAULIC SYSTEM (D31E, P, PL, PLL-18, D31P-18A, D37E,P-2)….757
STEERING HYDRAULIC CIRCUIT DIAGRAM (D31E, P, PL, PLL-18, D31P-18A, D37E,P-2)….757
STEERING HYDRAULIC SYSTEM (D37E, P-2)….758
STEERING HYDRAULIC CIRCUIT DIAGRAM (D37E, P-2)….758
STEERING HYDRAULIC SYSTEM (D31S, Q-18)….759
STEERING HYDRAULIC CIRCUIT DIAGRAM (D31S, Q-18)….759
STEERING CONTROL VALVE (D31E, P, PL, PLL-18, D31P-18A, D37E, P-2)….760
STEERING CONTROL VALVE (D31S, Q-18)….761
STEERING BOOSTER CYLINDER….766
STEERING BRAKE….768
FINAL DRIVE….770
22 TESTING AND ADJUSTING….771
STANDARD FOR TESTING AND ADJUSTING….772
TESTING AND ADJUSTING TOOL LIST….773
MEASURING OIL TEMPERATURE….774
MEASURING OIL PRESSURE….775
ADJUSTING LINKAGE….777
ADJUSTING GEAR SHIFT LEVER CONTROL LINKAGE….777
ADJUSTING INCHING CONTROL LINKAGE….778
ADJUSTING STEERING CONTROL LINKAGE….779
TROUBLESHOOTING….783
1. MACHINE DOES NOT MOVE OFF….784
2. DRAWBAR-PULL IS SMALL OR TRAVEL SPEED IS LOW….785
3. TIME LAG IS EXCESSIVE WHEN MOVING OFF OR GEARSHIFTING….786
4. WHEN ENGINE IS STARTED, MACHINE MOVES….787
5. MACHINE SHOCK IS EXCESSIVE WHEN MOVING OFF OR GEARSHIFTING….787
6. OIL QUANTITY IN TRANSMISSION AND BEVEL GEAR CASE FLUCTUATES….787
23 DISASSEMBLY AND ASSEBMLY….788
DAMPER….789
REMOVAL AND INSTALLATION….789
HYDROSHIFT TRANSMISSION….791
REMOVAL….791
INSTALLATION….793
DISASSEMBLY….795
ASSEMBLY….809
MODULATING VALVE….823
REMOVAL AND INSTALLATION….823
DISASSEMBLY AND ASSEMBLY….825
SELECTOR AND INCHING VALVE….823
REMOVAL AND INSTALLATION….823
DISASSEMBLY AND ASSEMBLY….827
STEERING VALVE….829
REMOVAL AND INSTALLATION….829
DISASSEMBLY AND ASSEMBLY….829
STEERING CLUTCH….831
REMOVAL….831
INSTALLATION….833
DISASSEMBLY….837
ASSEMBLY….839
BEVEL GEAR SHAFT AND BEVEL GEAR….843
REMOVAL….843
INSTALLATION….845
FINAL DRIVE FIRST PINION….849
REMOVAL AND INSTALLATION….849
FINAL DRIVE….851
DISASSEMBLY….851
ASSEMBLY….855
SPROCKET….859
REMOVAL AND INSTALLATION….859
24 MAINTENANCE STANDARD….861
DAMPER AND UNIVERSAL JOINT….862
TRANSMISSION AND STEERING PUMP….863
HYDROSHIFT TRANSMISSION….864
TRANSMISSION CONTROL VALVE….866
BEVEL GEAR SHAFT….868
STEERING CLUTCH….869
STEERING CONTROL VALVE (D31E, P, PL, PLL-18, D31P-18A, D37E, P-2)….871
STEERING CONTROL VALVE (D31S, Q-18)….872
STEERING BOOSTER CYLINDER….873
STEERING BRAKE….875
FINAL DRIVE….876
30 UNDERCARRIAGE….878
31 STRUCTURE AND FUNCTION….878
TRACK (DRY TYPE TRACK LINK) (D31E, P, PL, PLL-18, D31P-18A, D37E, P-2)….879
TRACK (LUBRICATED TRACK LINK) (D31E, P, PL, PLL-18, D31P-18A, D37E, P-2)….880
TRACK (DRY TYPE TRACK LINK) (D31S, Q-18)….881
TRACK (LUBRICATED TRACK LINK) (D31S, Q-18)….882
TRACK GROUP….883
IDLER….886
IDLER CUSHION….887
TRACK ROLLER….889
CARRIER ROLLER….889
MAIN FRAME AND SUSPENSION….890
33 DISASSEMBLY AND ASSEMBLY….892
TRACK FRAME….893
REMOVAL AND INSTALLATION….893
RECOIL SPRING….893
REMOVAL AND INSTALLATION….893
DISASSEMBLY AND ASSEMBLY….895
IDLER….897
REMOVAL AND INSTALLATION….897
CARRIER ROLLER….897
REMOVAL AND INSTALLATION….897
TRACK ROLLER….899
REMOVAL AND INSTALLATION….899
TRACK SHOE….899
REMOVAL AND INSTALLATION….899
34 MAINTENANCE STANDARD….901
TRACK (DRY TYPE TRACK LINK) (D31E, P, PL, PLL-18, D31P-18A, D37E, P-2)….902
TRACK (LUBRICATED TRACK LINK) (D31E, P, PL, PLL-18, D31P-18A, D37E, P-2)….904
TRACK (DRY TYPE TRACK LINK) (D31S, Q-18)….906
TRACK (LUBRICATED TRACK LINK) (D31S, Q-18)….908
TRACK FRAME….910
IDLER CUSHION….912
IDLER….914
TRACK ROLLER….916
CARRIER ROLLER….917
60 HYDRAULIC SYSTEM….918
61 STRUCTURE AND FUNCTION….918
HYDRAULIC PIPING (D31E-18, D31P-18A, D37E, P-2)….919
HYDRAULIC CONTROL (D31E-18, D31P-18A, D37E, P-2)….920
HYDRAULIC CIRCUIT SYSTEM (D31E-18, D31P-18A, D37E, P-2)….921
HYDRAULIC CIRCUIT DIAGRAM (D31E-18, D31P-18A, D37E, P-2)….922
HYDRAULIC PIPING (D31P, PL, PLL-18)….923
HYDRAULIC CONTROL (D31P, PL, PLL-18)….924
HYDRAULIC CIRCUIT SYSTEM (D31P, PL, PLL-18)….925
HYDRAULIC CIRCUIT DIAGRAM (D31P, PL, PLL-18)….926
HYDRAULIC PIPING (D31S, Q-18)….927
HYDRAULIC CONTROL (D31S, Q-18)….928
HYDRAULIC CIRCUIT SYSTEM (D31S, Q-18)….929
HYDRAULIC CIRCUIT DIAGRAM (D31S, Q-18)….930
HYDRAULIC TANK AND FILTER….931
HYDRAULIC PUMP….932
HYDRAULIC CONTROL VALVE (D31E-18, D31P-18A, D37E, P-2)….933
HYDRAULIC CONTROL VALVE (D31P, PL, PLL-18)….935
HYDRAULIC CONTROL VALVE (D31S, Q-18)….937
HYDRAULIC LEVER OPERATION (D31E, P, PL-18, D31P-18A, D37E, P-2)….942
HYDRAULIC LEVER OPERATION (D31S, Q-18)….948
HYDRAULIC CYLINDER (D31E-18, D31P-18A, D37E, P-2)….952
HYDRAULIC CYLINDER (D31P, PL, PLL-18)….954
HYDRAULIC CYLINDER (D31S, Q-18)….956
62 TESTING AND ADJUSTING….958
STANDARD FOR TESTING AND ADJUSTING….959
TESTING AND ADJUSTING TOOL LIST….962
MEASURING AND ADJUSTING OIL PRESSURE….963
MEASURING OIL TEMPERATURE….964
BLEEDING AIR FROM ANGLE CYLINDER CIRCUIT….965
TROUBLESHOOTING….966
1. BLADE LACKS LIFTING POWER AND LIFTING SPEED IS SLOW….967
2. BLADE DOES NOT RISE, THE FRONT OF MACHINE CANNOT BE RAISED OFF GROUND WHEN LOWERING THE BLADE….968
3. HYDRAULIC DRIFT OF BLADE LIFT CYLINDER IS EXCESSIVE….969
4. BLADE MOVES UNSTEADILY WHEN LEVELING THE GROUND. (CONTROL LEVER AT HOLD)….970
5. BLADE LOWERS UNDER THE FOLLOWING CONDITIONS….970
6. BLADE LACKS TILTING POWER, BLADE TILTING SPEED IS SLOW. THE MACHINE CANNOT BE RAISED OFF GROUND BY BLADE TILTING POWER….971
7. BLADE TILT CYLINDER DOES NOT MOVE (TILTING IS IMPOSSIBLE)….972
8. HYDRAULIC DRIFT OF BLADE TILT CYLINDER IS EXCESSIVE….973
9. BLADE LACKS ANGLING POWER, BLADE ANGLING SPEED IS SLOW (FOR POWER ANGLE AND TILTDOZER)….974
10. BLADE ANGLE CYLINDER DOES NOT MOVE (ANGLING IS IMPOSSIBLE) (FOR POWER ANGLE AND TILTDOZER)….975
11. BLADE RETURNS STRAIGHTLY OR MOVES UNSTEADILY WHEN LOADING BY ANGLING (CONTROL LEVER AT HOLD) (FOR POWER ANGLE AND TILTDOZER)….976
12. LIFT ARM LACKS LIFTING POWER AND LIFTING SPEED IS SLOW….977
13. LIFT ARM DOES NOT RISE, THE FRONT OF MACHINE CANNOT BE RAISED OFF GROUND WHEN LOWERING THE BUCKET….978
14. HYDRAULIC DRIFT OF BUCKET LIFT CYLINDER IS EXCESSIVE….979
15. BUCKET LACKS TILT BACK POWER AND BUCKET TILT SPEED IS SLOW….980
16. BUCKET DUMP CYLINDER DOES NOT MOVE (BUCKET TILT BACK IS IMPOSSIBLE)….981
17. BUCKET DUMP CYLINDER DOES NOT MOVE (DUMPING IS IMPOSSIBLE), MACHINE CANNOT BE RAISED OFF GROUND BY THE DUMP CYLINDER….982
18. BUCKET DUMP SPEED IS SLOW….983
19. HYDRAULIC DRIFT OF BUCKET DUMP CYLINDER IS EXCESSIVE….984
20. BUCKET MOVES UP AND DOWN ALONG GROUND AND LIFT ARM MOVES UNSTEADILY WHEN LEVELING THE GROUND. (CONTROL LEVER AT HOLD)….985
21. LIFT ARM LOWERS UNDER THE FOLLOWING CONDITIONS….985
22. BUCKET MOVES UNSTEADILY WHEN LEVELING THE GROUND WITH MACHINE TRAVELING IN REVERSE.(CONTROL LEVER AT HOLD)….985
23. BUCKET DUMPS….985
24. LIFT ARM CANNOT BE RAISED WHEN BUCKET DUMPS FULLY….985
25. OPERATING FORCE OF WORK EQUIPMENT CONTROL LEVER IS HEAVY….986
63 DISASSEMBLY AND ASSEMBLY….987
HYDRAULIC PUMP….988
REMOVAL AND INSTALLATION….988
MAIN RELIEF VALVE….988
REMOVAL AND INSTALLATION….988
HYDRAULIC CONTROL VALVE….988
REMOVAL AND INSTALLATION….988
DISASSEMBLY (D31E-18, D31P-18A, D37E, P-2)….990
ASSEMBLY (D31E-18, D31P-18A, D37E, P-2)….992
DISASSEMBLY (D31P, PL, PLL-18)….994
ASSEMBLY (D31P, PL, PLL-18)….996
DISASSEMBLY (D31S, Q-18)….998
ASSEMBLY (D31S, Q-18)….1000
BLADE LIFT CYLINDER….1002
REMOVAL AND INSTALLATION….1002
BLADE TIFT CYLINDER….1002
REMOVAL AND INSTALLATION….1002
BLADE ANGLE CYLINDER….1004
REMOVAL AND INSTALLATION….1004
BUCKET LIFT CYLINDER….1004
REMOVAL AND INSTALLATION….1004
BUCKET DUMP CYLINDER….1004
REMOVAL AND INSTALLATION….1004
HYDRAULIC CYLINDER….1006
DISASSEMBLY….1006
ASSEMBLY….1006
64 MAINTENANCE STANDARD….1008
HYDRAULIC CONTROL VALVE (3-SPOOL) (D31E-18, D31P-18A, D37E, P-2)….1009
HYDRAULIC CONTROL VALVE (D31P, PL, PLL-18)….1011
HYDRAULIC CONTROL VALVE (D31S, Q-18)….1013
HYDRAULIC CYLINDER (D31P, PL, PLL-18)….1015
HYDRAULIC CYLINDER (D31E-18, D31P-18A, D37E, P-2)….1017
HYDRAULIC CYLINDER (D31S, Q-18)….1019
HYDRAULIC PUMP….1020
70 WORK EQUIPMENT….1021
71 STRUCTURE AND FUNCTION….1021
POWER ANGLE AND TILTDOZER (D31E-18, D31P-18A, D37E, P-2)….1022
STRAIGHT TILTDOZER (D31P, PL, PLL-18)….1024
BUCKET AND LINK (D31S, Q-18)….1026
73 DISASSEMBLY AND ASSEMBLY….1028
WORK EQUIPMENT….1029
REMOVAL AND INSTALLATION….1029
BLADE….1031
REMOVAL AND INSTALLATION….1031
WORK EQUIPMENT….1033
REMOVAL AND INSTALLATION….1033
BUCKET….1033
REMOVAL AND INSTALLATION….1033
74 MAINTENANCE STANDARD….1035
POWER ANGLE AND TILTDOZER (D31E-18, D31P-18A, D37E, P-2)….1036
STRAIGHT TILTDOZER (D31P, PL, PLL-18)….1038
BUCKET LINK (D31S, Q-18)….1040
80 ELECTRICAL SYSTEM….1042
81 STRUCTURE AND FUNCTION….1042
WIRING DIAGRAM….1043
SEBM0114B01 – Bulldozer D31A-16, D31P-16 Shop Manual (SN25001&up)….1044
SEBM0114C04 – Bulldozer D31A,E,P,PL,PLL-17, D31P-17A,B Shop Manual (SN32001&up)….1596
SRBM001007K – Бульдозер D31E,P,PL,PLL,S,Q-20 & D31P-20A & D37E-5 & D37P-5A Заводская инструкция….2000

Komatsu Bulldozers D31A, D31E, D31P, D31PL, D31PLL, D31S, D31Q, D37E, D37P Repair Service Manuals

INSTANT DOWNLOAD

Posted on June 5, 2025 by admin

Komatsu Bulldozer D20- & D21- series Operation Maintenance Manuals

INSTANT DOWNLOAD

Complete operator’s manual for Komatsu Bulldozer D20- & D21- series, with all the shop information to maintain & operate.

SEAM101D00 – Bulldozer D20A,P,PL-5 Operation & Maintenance Manual (SN45001&up).pdf
SEAM101D01 – Bulldozer D20A,P,PL,PLL-5 & D20P-5A Operation & Maintenance Manual (SN50001&up).pdf
SEAM000902 – Bulldozer D20AG,PL,PLL-7 & D20P,PG-7A & D21A,AG-7 & D21PG-7A Operation & Maintenance Manual.pdf
SEAM000904 – Bulldozer D20A,PL,PLL-7 & D20P-7A & D21A-7 & D21P-7A Operation & Maintenance Manual.pdf
SEAM000905 – Bulldozer D20A,PL,PLL-7 & D20-7A & D21A-7 & D21P-7A Operation & Maintenance Manual.pdf
SEAM000909T – Bulldozer D20A,PL,PLL-7 & D20P-7A & D21A-7 & D21P-7A Operation & Maintenance Manual.pdf
SEAM025800P – Bulldozer D20A,PL,PLL-7 & D20-7A & D21A-7 & D21P-7A Operation & Maintenance Manual.pdf
SEAM01010601 – Bulldozer D20A,P,PL,PLL-6 & D20P-6A & D21A,E,P,PL-6 & D21P-6A,6B Operation & Maintenance Manual.pdf
SEAM01010603 – Bulldozer D20A,P,PL,PLL-6 & D20P-6A & D21A,E,P,PL-6 & D21P-6A,6B Operation & Maintenance Manual.pdf
SEAM01020603 – Dozer Shovel D20S,Q-6 & D21S,Q-6 & D21S-6A Operation & Maintenance Manual.pdf
TEN00016-01 – Bulldozer GALEO D21A-8 & D21P-8 Operation & Maintenance Manual (SN83001&up).pdf
TEN00269-03 – Bulldozer D21A-8E0 & D21P-8E0 Operation & Maintenance Manual (SN90001&up).pdf
TEN00496-01 – Bulldozer D21A-8E0 & D21P-8E0 Operation & Maintenance Manual (SN90219&up).pdf

Total Pages: 1,021 pages
File Format: PDF
Language: English

SEAM000902 – Bulldozer D20AG,PL,PLL-7 & D20P,PG-7A & D21A,AG-7 & D21PG-7A Operation & Maintenance Manual…2
COVER…2
1. FOREWORD…3
2. SAFETY INFORMATION…4
3. INTRODUCTION…5
4. LOCATION OF PLATES,TABLE TO ENTER SERIAL NO.AND DISTRIBUTOR…6
5. CONTENTS…7
SAFETY…10
    6. GENERAL PRECAUTIONS…11
    7. PRECAUTIONS DURING OPERATION…16
      7.1 BEFORE STARTING ENGINE…16
      7.2 OPERATING MACHINE…18
      7.3 TRANSPORTATION…21
      7.4 BATTERY…22
      7.5 TOWING…24
    8. PRECAUTIONS FOR MAINTENANCE…25
      8.1 BEFORE CARRYING OUT MAINTENANCE…25
      8.2 DURING MAINTENANCE…27
    9. POSITION FOR ATTACHING SAFETY LABELS…32
OPERATION…34
    10. GENERAL VIEW…35
      10.1 GENERAL VIEW OF MACHINE…35
      10.2 GENERAL VIEW OF CONTROLS AND GAUGES…36
    11. EXPLANATION OF COMPONENTS…38
      11.1 METERS AND LAMPS…38
      11.2 SWITCHES…40
      11.3 CONTROL LEVERS AND PEDALS…42
      11.4 FUSE BOX…48
    12. OPERATION…49
      12.1 CHECK BEFORE STARTING ENGINE…49
      12A.OPERATION…58
        12A.1.4 OPERATIONS AND CHECKS BEFOR STARTING ENGINE…59
        12A.2 STARTING ENGINE…61
        12A.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…65
        12A.4 MOVING MACHINE OFF…66
        12A.5 STEERING MACHINE…68
        12A.6 STOPPING MACHINE…70
        12A.7 SHIFTING GEAR,SHIFTING BETWEEN FORWARD AND REVERSE…71
        12A.8 PRECAUTIONS FOR OPERATION…73
        12A.9 WORK POSSIBLE USING BULLDOZER…74
        12A.10 PARKING MACHINE…75
        12A.11 CHECK AFTER FINISHING WORK…76
        12A.12 STOPPING ENGINE…77
        12A.13 CHECK AFTER STOPPING ENGINE…78
        12A.14 LOCKING…78
      12B.OPERATION…79
        12B1.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE…80
        12B.2 STARTING ENGINE…82
        12B.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…85
        12B.4 MOVING MACHINE OFF…86
        12B.5 SHIFTING GEAR…87
        12B.6 SHIFTING BETWEEN FORWARD AND REVERSE…88
        12B.7 STEERING MACHINE…89
        12B.8 STOPPING MACHINE…91
        12B.9 PRECAUTIONS FOR OPERATION…92
        12B.10 WORK POSSIBLE USING BULLDOZER…93
        12B.11 PARKING MACHINE…94
        12B.12 CHECK AFTER FINISHING WORK…95
        12B.13 STOPPING ENGINE…96
        12B.14 CHECK AFTER STOPPING ENGINE…97
        12B.15 LOCKING…97
      12.16 TIPS FOR LONGER UNDERCARRIAGE LIFE (STEEL SHOES ONLY)…98
      12.17 HANDLING RUBBER SHOES (RUBBER SHOES ONLY)…101
    13. TRANSPORTATION…107
      13.1 LOADING,UNLOADING WORK…107
      13.2 PRECAUTIONS FOR LOADING…108
      13.3 PRECAUTIONS FOR TRANSPORTATION…109
    14. COLD WEATHER OPERATION…110
      14.1 PRECAUTIONS FOR LOW TEMPERATURE…110
      14.2 PRECAUTIONS AFTER COMPLETION OF WORK…112
      14.3 AFTER COLD WEATHER…112
    15. LONG-TERM STORAGE…113
      15.1 BEFORE STORAGE…113
      15.2 DURING STORAGE…113
      15.3 AFTER STORAGE…114
    16. TROUBLESHOOTING…115
      16.1 AFTER RUNNING OUT OF FUEL…115
      16.2 IF BATTERY IS DISCHARGED…116
      16.3 OTHER TROUBLE…120
MAINTENANCE…123
    17. GUIDES TO MAINTENANCE…124
    18. OUTLINES OF SERVICE…127
      18.1 OUTLINE OF OIL,FUEL,COOLANT…127
      18.2 RELATING TO ELECTRIC SYSTEM…130
    19. WEAR PARTS LIST…131
    20. USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…132
    21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…136
      21.1 INTRODUCTION OF NECESSARY TOOLS…136
      21.2 TORQUE LIST…137
    22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…138
    23. MAINTENACE SCHEDULE CHART…140
    24. SERVICE PROCEDURE…143
      24.1 INITIAL 250 HOURS SERVICE…143
      24.2 WHEN REQUIRED…144
      24.3 CHECK BEFORE STARTING…166
      24.4 EVERY 50 HOURS SERVICE…172
      24.5 EVERY 250 HOURS SERVICE…173
      24.6 EVERY 500 HOURS SERVICE…178
      24.7 EVERY 1000 HOURS SERVICE…183
      24.8 EVERY 2000 HOURS SERVICE…191
      24.9 EVERY 4000 HOURS SERVICE…192
SPECIFICATIONS…193
    25. SPECIFICATIONS…194
OPTIONS,ATTACHMENTS…201
    26. GENERAL PRECAUTIONS…202
      26.1 PRECAUTIONS RELATED TO SAFETY…202
    27. USING SEAT BELT…203
      27.1 SEAT BELT (FOR FIXED TYPE)…203
      27.2 SEAT BELT (FOR SUSPENSION TYPE)…205
    28. HANDLING SUSPENSION SEAT…207
SEAM000904 – Bulldozer D20A,PL,PLL-7 & D20P-7A & D21A-7 & D21P-7A Operation & Maintenance Manual…208
COVER…208
1.FOREWORD…209
2.SAFETY INFORMATION…210
3.INTRODUCTION…211
4.LOCATION OF PLATES,TABLE TO ENTER SERIAL NO.AND DISTRIBUTOR…212
5.CONTENTS…213
SAFETY…216
    6.GENERAL PRECAUTIONS…217
    7.PRECAUTIONS DURING OPERATION…222
      7.1 BEFORE STARTING ENGINE…222
      7.2 OPERATING MACHINE…224
      7.3 TRANSPORTATION…227
      7.4 BATTERY…228
      7.5 TOWING…230
    8.PRECAUTIONS FOR MAINTENANCE…231
      8.1 BEFORE CARRYING OUT MAINTENANCE…231
      8.2 DURING MAINTENANCE…233
    9.POSITION FOR ATTACHING SAFETY LABELS…238
OPERATION…240
    10.GENERAL VIEW…241
      10.1 GENERAL VIEW OF MACHINE…241
      10.2 GENERAL VIEW OF CONTROLS AND GAUGES…242
    11.EXPLANATION OF COMPONENTS…244
      11.1 METERS AND LAMPS…244
      11.2 SWITCHES…247
      11.3 CONTROL LEVERS AND PEDALS…249
      11.4 FUSE BOX…255
    12. OPERATION…256
      12.1 CHECK BEFORE STARTING ENGINE…256
      12A.OPERATION…265
        12A.1.4 OPERATIONS AND CHECKS BEFOR STARTING ENGINE…266
        12A.2 STARTING ENGINE…268
        12A.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…272
        12A.4 MOVING MACHINE OFF…273
        12A.5 STEERING MACHINE…275
        12A.6 STOPPING MACHINE…277
        12A.7 SHIFTING GEAR,SHIFTING BETWEEN FORWARD AND REVERSE…278
        12A.8 PRECAUTIONS FOR OPERATION…280
        12A.9 WORK POSSIBLE USING BULLDOZER…281
        12A.10 PARKING MACHINE…282
        12A.11 CHECK AFTER FINISHING WORK…283
        12A.12 STOPPING ENGINE…284
        12A.13 CHECK AFTER STOPPING ENGINE…284
        12A.14 LOCKING…285
      12B.OPERATION…286
        12B1.4 OPERATIONS AND CHECKS BEFORE STATING ENGINE…287
        12B.2 STARTING ENGINE…289
        12B.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…292
        12B.4 MOVING MACHINE OFF…293
        12B.5 SHIFTING GEAR…294
        12B.6 SHIFTING BETWEEN FORWARD AND REVERSE…295
        12B.7 STEERING MACHINE…296
        12B.8 STOPPING MACHINE…298
        12B.9 PRECAUTIONS FOR OPERATION…299
        12B.10 WORK POSSIBLE USING BULLDOZER…300
        12B.11 PARKING MACHINE…301
        12B.12 CHECK AFTER FINISHING WORK…302
        12B.13 STOPPING ENGINE…303
        12B.14 CHECK AFTER STOPPING ENGINE…303
        12B.15 LOCKING…304
        12.16 TIPS FOR LONGER UNDERCARRIAGE LIFE (STEEL SHOES ONLY)…305
        12.17 HANDLING RUBBER SHOES (RUBBER SHOES ONLY)…308
    13.TRANSPORTATION…314
      13.1 LOADING,UNLOADING WORK…314
      13.2 PRECAUTIONS FOR LOADING…315
      13.3 LIFTING MACHINE…316
      13.4 PRECAUTIONS FOR TRANSPORTATION…319
    14.COLD WEATHER OPERATION…320
      14.1 PRECAUTIONS FOR LOW TEMPERATURE…320
      14.2 PRECAUTIONS AFTER COMPLETION OF WORK…322
      14.3 AFTER COLD WEATHER…322
    15.LONG-TERM STORAGE…323
      15.1 BEFORE STORAGE…323
      15.2 DURING STORAGE…323
      15.3 AFTER STORAGE…324
    16.TROUBLESHOOTING…325
      16.1 AFTER RUNNING OUT OF FUEL…325
      16.2 IF BATTERY IS DISCHARGED…326
      16.3 OTHER TROUBLE…330
MAINTENANCE…333
    17.GUIDES TO MAINTENANCE…334
    18.OUTLINES OF SERVICE…337
      18.1 OUTLINE OF OIL,FUEL,COOLANT…337
      18.2 RELATING TO ELECTRIC SYSTEM…340
    19.WEAR PARTS LIST…341
    20.USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…342
    21.STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…346
      21.1 INTRODUCTION OF NECESSARY TOOLS…346
      21.2 TORQUE LIST…347
    22.PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…348
    23.MAINTENACE SCHEDULE CHART…350
    24.SERVICE PROCEDURE…353
      24.1 INITIAL 250 HOURS SERVICE…353
      24.2 WHEN REQUIRED…354
      24.3 CHECK BEFORE STARTING…376
      24.4 EVERY 50 HOURS SERVICE…382
      24.5 EVERY 250 HOURS SERVICE…383
      24.6 EVERY 500 HOURS SERVICE…388
      24.7 EVERY 1000 HOURS SERVICE…393
      24.8 EVERY 2000 HOURS SERVICE…401
      24.9 EVERY 4000 HOURS SERVICE…402
SPECIFICATIONS…403
    25.SPECIFICATIONS…404
OPTIONS,ATTACHMENTS…411
    26.GENERAL PRECAUTIONS…412
      26.1 PRECAUTIONS RELATED TO SAFETY…412
    27.USING SEAT BELT…413
      27.1 SEAT BELT (FOR FIXED TYPE)…413
      27.2 SEAT BELT (FOR SUSPENSION TYPE)…415
    28.HANDLING SUSPENSION SEAT…417
SEAM000905 – Bulldozer D20A,PL,PLL-7 & D20-7A & D21A-7 & D21P-7A Operation & Maintenance Manual…418
1. FOREWORD…419
2. SAFETY INFORMATION…420
3. INTRODUCTION…421
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…422
5. CONTENTS…423
SAFETY…426
    6. GENERAL PRECAUTIONS …427
    7. PRECAUTIONS DURING OPERATION …433
      7.1 BEFORE STARTING ENGINE …433
      7.2 AFTER STARTING ENGINE…435
      7.3 TRANSPORTATION …442
      7.4 BATTERY …443
      7.5 TOWING …445
    8. PRECAUTIONS FOR MAINTENANCE …446
      8.1 BEFORE CARRYING OUT MAINTENANCE …446
      8.2 DURING MAINTENANCE …451
    9. POSITION FOR ATTACHING SAFETY LABELS …458
      9.1 POSITION FOR ATTACHING SAFETY LABELS …458
OPERATION…460
    10. GENERAL VIEW…461
      10.1 GENERAL VIEW OF MACHINE…461
      10.2 GENERAL VIEW OF CONTROLS AND GAUGES…462
    11. EXPLANATION OF COMPONENTS…464
      11.1 METERS AND LAMPS…464
      11.2 SWITCHES…467
      11.3 CONTROL LEVERS AND PEDALS…469
      11.4 FUSE BOX …475
      11.5 MANUAL POCKET …475
    12. OPERATION…476
      12.1 CHECK BEFORE STARTING ENGINE…476
      12A. OPERATION (ONLY THOSE USING D20A, PL, PLL-7/D20P-7A NEED READ THIS SECTION)…487
        12A.1.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE…488
        12A.2 STARTING ENGINE…490
        12A.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…494
        12A.4 MOVING MACHINE OFF …495
        12A.5 STEERING MACHINE…497
        12A.6 STOPPING MACHINE…499
        12A.7 SHIFTING GEAR, SHIFTING BETWEEN FORWARD AND REVERSE …500
        12A.8 PRECAUTIONS FOR OPERATION …502
        12A.9 WORK POSSIBLE USING BULLDOZER …503
        12A.10 PARKING MACHINE…504
        12A.11 CHECK AFTER FINISHING WORK …505
        12A.12 STOPPING ENGINE …506
        12A.13 CHECK AFTER STOPPING ENGINE …506
        12A.14 LOCKING …507
      12B. OPERATION (ONLY THOSE USING D21A-7/D21P-7A NEED READ THIS SECTION)…508
        12B.1.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE…509
        12B.2 STARTING ENGINE …511
        12B.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE …514
        12B.4 MOVING MACHINE OFF …515
        12B.5 SHIFTING GEAR …516
        12B.6 SHIFTING BETWEEN FORWARD AND REVERSE…517
        12B.7 STEERING MACHINE …518
        12B.8 STOPPING MACHINE …521
        12B.9 PRECAUTIONS FOR OPERATION …522
        12B.10 WORK POSSIBLE USING BULLDOZER …523
        12B.11 PARKING MACHINE …524
        12B.12 CHECK AFTER FINISHING WORK …525
        12B.13 STOPPING ENGINE …526
        12B.14 CHECK AFTER STOPPING ENGINE …526
        12B.15 LOCKING …527
      12.16 TIPS FOR LONGER UNDERCARRIAGE LIFE (STEEL SHOES ONLY) …528
      12.17 HANDLING RUBBER SHOES (RUBBER SHOES ONLY) …531
    13. TRANSPORTATION…537
      13.1 LOADING, UNLOADING WORK …537
      13.2 PRECAUTIONS FOR LOADING …538
      13.3 LIFTING MACHINE…539
      13.4 PRECAUTIONS FOR TRANSPORTATION…542
    14. COLD WEATHER OPERATION…543
      14.1 PRECAUTIONS FOR LOW TEMPERATURE …543
      14.2 PRECAUTIONS AFTER COMPLETION OF WORK …545
      14.3 AFTER COLD WEATHER …545
    15. LONG-TERM STORAGE…546
      15.1 BEFORE STORAGE …546
      15.2 DURING STORAGE …546
      15.3 AFTER STORAGE …547
    16. TROUBLESHOOTING …548
      16.1 AFTER RUNNING OUT OF FUEL …548
      16.2 IF BATTERY IS DISCHARGED…549
      16.3 OTHER TROUBLE …553
MAINTENANCE…556
    17. GUIDES TO MAINTENANCE …557
    18. OUTLINES OF SERVICE …560
      18.1 OUTLINE OF OIL, FUEL, COOLANT …560
      18.2 RELATING TO ELECTRIC SYSTEM …563
    19. WEAR PARTS LIST …564
    20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE …565
    21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…569
      21.1 INTRODUCTION OF NECESSARY TOOLS …569
      21.2 TORQUE LIST …570
    22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS …571
    23. MAINTENANCE SCHEDULE CHART …573
    24. SERVICE PROCEDURE …577
      24.1 INITIAL 250 HOURS SERVICE …577
      24.2 WHEN REQUIRED …578
      24.3 CHECK BEFORE STARTING …600
      24.4 EVERY 50 HOURS SERVICE …608
      24.5 EVERY 250 HOURS SERVICE …609
      24.6 EVERY 500 HOURS SERVICE …614
      24.7 EVERY 1000 HOURS SERVICE …619
      24.8 EVERY 2000 HOURS SERVICE …627
      24.9 EVERY 4000 HOURS SERVICE …628
SPECIFICATIONS…629
    25. SPECIFICATIONS …630
OPTIONS, ATTACHMENTS…637
    26. GENERAL PRECAUTIONS …638
      26.1 PRECAUTIONS RELATED TO SAFETY …638
    27. USING SEAT BELT …639
      27.1 SEAT BELT (For fixed type)…639
      27.2 SEAT BELT (For suspension type)…641
    28. HANDLING SUSPENSION SEAT …643
SEAM000909T – Bulldozer D20A,PL,PLL-7 & D20P-7A & D21A-7 & D21P-7A Operation & Maintenance Manual…646
COVER…646
1. FOREWORD…647
2. SAFETY INFORMATION…650
3. INTRODUCTION…651
4. LOCATION OF PLATES,TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…652
5. CONTENTS…653
SAFETY…656
    6. GENERAL PRECAUTIONS…657
    7. PRECAUTIONS DURING OPERATION…663
      7.1 BEFORE STARTING ENGINE…663
      7.2 AFTER STARTING ENGINE…665
      7.3 TRANSPORTATION…672
      7.4 BATTERY…673
      7.5 TOWING…675
    8. PRECAUTIONS FOR MAINTENANCE …676
      8.1 BEFORE CARRYING OUT MAINTENANCE…676
      8.2 DURING MAINTENANCE…681
    9. POSITION FOR ATTACHING SAFETY LABELS…688
      9.1 POSITION FOR ATTACHING SAFETY LABELS…688
OPERATION…692
    10. GENERAL VIEW…693
      10.1 GENERAL VIEW OF MACHINE…693
      10.2 GENERAL VIEW OF CONTROLS AND GAUGES…694
    11. EXPLANATION OF COMPONENTS…696
      11.1 METERS AND LAMPS…696
      11.2 SWITCHES…699
      11.3 CONTROL LEVERS AND PEDALS…701
      11.4 FUSE BOX…707
      11.5 MANUAL POCKET…707
    12. OPERATION…708
      12.1 CHECK BEFORE STARTING ENGINE…708
      12A. OPERATION (D20A,PL,PLL-7/D20P-7A)…719
        12A.1.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE…720
        12A.2 STARTING ENGINE…722
        12A.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…726
        12A.4 MOVING MACHINE OFF…727
        12A.5 STEERING MACHINE…729
        12A.6 STOPPING MACHINE…731
        12A.7 SHIFTING GEAR,SHIFTING BETWEEN FORWARD AND REVERSE…732
        12A.8 PRECAUTIONS FOR OPERATION…734
        12A.9 WORK POSSIBLE USING BULLDOZER…735
        12A.10 PARKING MACHINE…736
        12A.11 CHECK AFTER FINISHING WORK…737
        12A.12 STOPPING ENGINE…738
        12A.13 CHECK AFTER STOPPING ENGINE…738
        12A.14 LOCKING…739
      12B. OPERATION (D21A-7/D21P-7A)…740
        12B.1.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE…741
        12B.2 STARTING ENGINE…743
        12B.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…746
        12B.4 MOVING MACHINE OFF…747
        12B.5 SHIFTING GEAR…748
        12B.6 SHIFTING BETWEEN FORWARD AND REVERSE…749
        12B.7 STEERING MACHINE…750
        12B.8 STOPPING MACHINE…753
        12B.9 PRECAUTIONS FOR OPERATION…754
        12B.10 WORK POSSIBLE USING BULLDOZER…755
        12B.11 PARKING MACHINE…756
        12B.12 CHECK AFTER FINISHING WORK…757
        12B.13 STOPPING ENGINE…758
        12B.14 CHECK AFTER STOPPING ENGINE…758
        12B.15 LOCKING…759
      12.16 TIPS FOR LONGER UNDERCARRIAGE LIFE (STEEL SHOES ONLY)…760
      12.17 HANDLING RUBBER SHOES (RUBBER SHOES ONLY)…763
    13. TRANSPORTATION…769
      13.1 LOADING,UNLOADING WORK…769
      13.2 PRECAUTIONS FOR LOADING…770
      13.3 LIFTING MACHINE…771
      13.4 PRECAUTIONS FOR TRANSPORTATION…774
    14. COLD WEATHER OPERATION…775
      14.1 PRECAUTIONS FOR LOW TEMPERATURE…775
      14.2 PRECAUTIONS AFTER COMPLETION OF WORK…777
      14.3 AFTER COLD WEATHER…777
    15. LONG-TERM STORAGE…778
      15.1 BEFORE STORAGE…778
      15.2 DURING STORAGE…778
      15.3 AFTER STORAGE…779
    16. TROUBLESHOOTING…780
      16.1 AFTER RUNNING OUT OF FUEL…780
      16.2 IF BATTERY IS DISCHARGED…781
      16.3 OTHER TROUBLE…785
MAINTENANCE…788
    17. GUIDES TO MAINTENANCE…789
    18. OUTLINES OF SERVICE…792
      18.1 OUTLINE OF OIL,FUEL,COOLANT…792
      18.2 RELATING TO ELECTRIC SYSTEM…795
    19. WEAR PARTS LIST…796
    20. USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…797
    21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…801
      21.1 INTRODUCTION OF NECESSARY TOOLS…801
      21.2 TORQUE LIST…802
    22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…803
    23. MAINTENANCE SCHEDULE CHART…805
    24. SERVICE PROCEDURE…809
      24.1 INITIAL 250 HOURS SERVICE…809
      24.2 WHEN REQUIRED…810
      24.3 CHECK BEFORE STARTING…832
      24.4 EVERY 50 HOURS SERVICE…840
      24.5 EVERY 250 HOURS SERVICE…841
      24.6 EVERY 500 HOURS SERVICE…846
      24.7 EVERY 1000 HOURS SERVICE…851
      24.8 EVERY 2000 HOURS SERVICE…859
      24.9 EVERY 4000 HOURS SERVICE…860
SPECIFICATIONS…861
    25. SPECIFICATIONS…862
OPTIONS,ATTACHMENTS…869
    26. GENERAL PRECAUTIONS…870
      26.1 PRECAUTIONS RELATED TO SAFETY…870
    27. USING SEAT BELT…871
      27.1 SEAT BELT (FOR FIXED TYPE)…871
      27.2 SEAT BELT (FOR SUSPENSION TYPE)…873
    28. HANDLING SUSPENSION SEAT…875
    29. DECELERATION PEDAL…876
SEAM01010601 – Bulldozer D20A,P,PL,PLL-6 & D20P-6A & D21A,E,P,PL-6 & D21P-6A,6B Operation & Maintenance Manual…878
COVER…878
FOREWORD…879
BREAKING IN YOUR NEW MACHINE…880
CONTENTS…881
GENERAL LOCATIONS AND SPECIFICATIONS…882
INSTRUMENTS AND CONTROLS…883
CHECK BEFORE STARTING…897
OPERATING YOUR MACHINE…902
COLD WEATHER OPERATION…925
TIPS FOR LONGER UNDERCARRIAGE LIFE…930
PERIODIC MAINTENANCE…931
    MAINTENANCE TABLE…932
    OIL FILLER AND LEVEL GAUGE POSITIONS…935
    EVERY 50 HOURS SERVICE…936
    INITIAL 250 HOURS SERVICE…937
    EVERY 250 HOURS SERVICE…937
    EVERY 500 HOURS SERVICE…945
    EVERY 1000 HOURS SERVICE…949
    EVERY 2000 HOURS SERVICE…954
    EVERY 4000 HOURS SERVICE…955
    WHEN REQUIRED…956
ADJUSTMENT…962
TROUBLE SHOOTING GUIDE…969
SERVICE METER…972
MACHINE AND ENGINE SERIAL NUMBERS…973
FUEL,COOLANT AND LUBRICANTS…974
SAFETY AND OPERATION…976
    CONTENTS…977
    SAFETY HINTS…978
    PRECAUTIONS FOR MAINTENANCE…985
    BULLDOZER'S WORK…989
    LOCKING CAP…990
    HANDLING OF BATTERY…991
    TRANSPORTATION…994
    STORAGE…995
    COOLANT AND LUBRICANTS…997
SEAM01010603 – Bulldozer D20A,P,PL,PLL-6 & D20P-6A & D21A,E,P,PL-6 & D21P-6A,6B Operation & Maintenance Manual…999
COVER…999
FOREWORD…1000
BREAKING IN YOUR NEW MACHINE…1001
CONTENTS…1002
GENERAL LOCATIONS AND SPECIFICATIONS…1003
INSTRUMENTS AND CONTROLS…1004
CHECK BEFORE STARTING…1019
OPERATING YOUR MACHINE…1024
COLD WEATHER OPERATION…1047
BULLDOZER'S WORK…1052
TIPS FOR LONGER UNDERCARRIAGE LIFE…1053
PERIODIC MAINTENANCE…1054
    MAINTENANCE TABLE…1055
    OIL FILLER AND LEVEL GAUGE POSITIONS…1058
    EVERY 50 HOURS SERVICE…1059
    INITIAL 250 HOURS SERVICE…1060
    EVERY 250 HOURS SERVICE…1060
    EVERY 500 HOURS SERVICE…1068
    EVERY 1000 HOURS SERVICE…1072
    EVERY 2000 HOURS SERVICE…1077
    EVERY 4000 HOURS SERVICE…1078
    WHEN REQUIRED…1079
ADJUSTMENT…1085
TROUBLE SHOOTING GUIDE…1092
SERVICE METER…1095
MACHINE AND ENGINE SERIAL NUMBERS…1096
FUEL,COOLANT AND LUBRICANTS…1097
SAFETY AND OPERATION…1099
    CONTENTS…1100
    SAFETY HINTS…1101
    PRECAUTIONS FOR MAINTENANCE…1114
    HANDLING OF BATTERY…1121
    TRANSPORTATION…1124
    STORAGE…1125
    COOLANT AND LUBRICANTS…1127
SEAM01020603 – Dozer Shovel D20S,Q-6 & D21S,Q-6 & D21S-6A Operation & Maintenance Manual…1129
COVER…1129
FOREWORD…1130
BREAKING IN YOUR NEW MACHINE…1131
CONTENTS…1132
SAFETY HINTS…1133
GENERAL LOCATIONS AND SPECIFICATIONS…1140
INSTRUMENTS AND CONTROLS…1141
CHECK BEFORE STARTING…1156
OPERATING YOUR MACHINE…1161
COLD WEATHER OPERATION…1184
BUCKET OPERATION…1189
HOW TO USE INCHING PEDAL (D21S,Q-6)…1192
HOW TO USE INCHING PEDAL (D21S-6A)…1196
TIPS FOR LONGER UNDERCARRIAGE LIFE…1200
HANDLING OF BATTERY…1201
TRANSPORTATION…1204
PERIODIC MAINTENANCE…1205
    PRECAUTIONS FOR MAINTENANCE…1206
    MAINTENANCE TABLE…1210
    OIL FILLER AND LEVEL GAUGE POSITIONS…1213
    EVERY 50 HOURS SERVICE…1214
    INITIAL 250 HOURS SERVICE…1215
    EVERY 250 HOURS SERVICE…1215
    EVERY 500 HOURS SERVICE…1222
    EVERY 1000 HOURS SERVICE…1226
    EVERY 2000 HOURS SERVICE…1231
    EVERY 4000 HOURS SERVICE…1232
    WHEN REQUIRED…1233
ADJUSTMENT…1239
TROUBLE SHOOTING GUIDE…1245
STORAGE…1248
SERVICE METER…1250
MACHINE AND ENGINE SERIAL NUMBERS…1251
FUEL,COOLANT AND LUBRICANTS…1252
SEAM025800P – Bulldozer D20A,PL,PLL-7 & D20-7A & D21A-7 & D21P-7A Operation & Maintenance Manual…1257
COVER…1257
1. FOREWORD…1258
2. SAFETY INFORMATION…1259
3. INTRODUCTION…1260
4. LOCATION OF PLATES,TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…1261
5. CONTENTS…1262
SAFETY…1265
    6. GENERAL PRECAUTIONS…1266
    7. PRECAUTIONS DURING OPERATION…1272
      7.1 BEFORE STARTING ENGINE…1272
      7.2 AFTER STARTING ENGINE…1274
      7.3 TRANSPORTATION…1281
      7.4 BATTERY…1282
      7.5 TOWING…1284
    8. PRECAUTIONS FOR MAINTENANCE …1285
      8.1 BEFORE CARRYING OUT MAINTENANCE…1285
      8.2 DURING MAINTENANCE…1290
    9. POSITION FOR ATTACHING SAFETY LABELS…1297
      9.1 POSITION FOR ATTACHING SAFETY LABELS…1297
OPERATION…1301
    10. GENERAL VIEW…1302
      10.1 GENERAL VIEW OF MACHINE…1302
      10.2 GENERAL VIEW OF CONTROLS AND GAUGES…1303
    11. EXPLANATION OF COMPONENTS…1305
      11.1 METERS AND LAMPS…1305
      11.2 SWITCHES…1308
      11.3 CONTROL LEVERS AND PEDALS…1310
      11.4 FUSE BOX…1316
      11.5 MANUAL POCKET…1316
    12. OPERATION…1317
      12.1 CHECK BEFORE STARTING ENGINE…1317
      12A. OPERATION (D20A,PL,PLL-7/D20P-7A)…1328
        12A.1.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE…1329
        12A.2 STARTING ENGINE…1331
        12A.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…1335
        12A.4 MOVING MACHINE OFF…1336
        12A.5 STEERING MACHINE…1338
        12A.6 STOPPING MACHINE…1340
        12A.7 SHIFTING GEAR,SHIFTING BETWEEN FORWARD AND REVERSE…1341
        12A.8 PRECAUTIONS FOR OPERATION…1343
        12A.9 WORK POSSIBLE USING BULLDOZER…1344
        12A.10 PARKING MACHINE…1345
        12A.11 CHECK AFTER FINISHING WORK…1346
        12A.12 STOPPING ENGINE…1347
        12A.13 CHECK AFTER STOPPING ENGINE…1347
        12A.14 LOCKING…1348
      12B. OPERATION (D21A-7/D21P-7A)…1349
        12B.1.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE…1350
        12B.2 STARTING ENGINE…1352
        12B.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…1355
        12B.4 MOVING MACHINE OFF…1356
        12B.5 SHIFTING GEAR…1357
        12B.6 SHIFTING BETWEEN FORWARD AND REVERSE…1358
        12B.7 STEERING MACHINE…1359
        12B.8 STOPPING MACHINE…1362
        12B.9 PRECAUTIONS FOR OPERATION…1363
        12B.10 WORK POSSIBLE USING BULLDOZER…1364
        12B.11 PARKING MACHINE…1365
        12B.12 CHECK AFTER FINISHING WORK…1366
        12B.13 STOPPING ENGINE…1367
        12B.14 CHECK AFTER STOPPING ENGINE…1367
        12B.15 LOCKING…1368
      12.16 TIPS FOR LONGER UNDERCARRIAGE LIFE (STEEL SHOES ONLY)…1369
      12.17 HANDLING RUBBER SHOES (RUBBER SHOES ONLY)…1372
    13. TRANSPORTATION…1378
      13.1 LOADING,UNLOADING WORK…1378
      13.2 PRECAUTIONS FOR LOADING…1379
      13.3 LIFTING MACHINE…1380
      13.4 PRECAUTIONS FOR TRANSPORTATION…1383
    14. COLD WEATHER OPERATION…1384
      14.1 PRECAUTIONS FOR LOW TEMPERATURE…1384
      14.2 PRECAUTIONS AFTER COMPLETION OF WORK…1386
      14.3 AFTER COLD WEATHER…1386
    15. LONG-TERM STORAGE…1387
      15.1 BEFORE STORAGE…1387
      15.2 DURING STORAGE…1387
      15.3 AFTER STORAGE…1388
    16. TROUBLESHOOTING…1389
      16.1 AFTER RUNNING OUT OF FUEL…1389
      16.2 IF BATTERY IS DISCHARGED…1390
      16.3 OTHER TROUBLE…1394
MAINTENANCE…1397
    17. GUIDES TO MAINTENANCE…1398
    18. OUTLINES OF SERVICE…1401
      18.1 OUTLINE OF OIL,FUEL,COOLANT…1401
      18.2 RELATING TO ELECTRIC SYSTEM…1404
    19. WEAR PARTS LIST…1405
    20. USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…1406
    21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…1410
      21.1 INTRODUCTION OF NECESSARY TOOLS…1410
      21.2 TORQUE LIST…1411
    22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…1412
    23. MAINTENANCE SCHEDULE CHART…1414
    24. SERVICE PROCEDURE…1418
      24.1 INITIAL 250 HOURS SERVICE…1418
      24.2 WHEN REQUIRED…1419
      24.3 CHECK BEFORE STARTING…1441
      24.4 EVERY 50 HOURS SERVICE…1449
      24.5 EVERY 250 HOURS SERVICE…1450
      24.6 EVERY 500 HOURS SERVICE…1455
      24.7 EVERY 1000 HOURS SERVICE…1460
      24.8 EVERY 2000 HOURS SERVICE…1468
      24.9 EVERY 4000 HOURS SERVICE…1469
SPECIFICATIONS…1470
    25. SPECIFICATIONS…1471
OPTIONS,ATTACHMENTS…1478
    26. GENERAL PRECAUTIONS…1479
      26.1 PRECAUTIONS RELATED TO SAFETY…1479
    27. USING SEAT BELT…1480
      27.1 SEAT BELT (FOR FIXED TYPE)…1480
      27.2 SEAT BELT (FOR SUSPENSION TYPE)…1482
    28. HANDLING SUSPENSION SEAT…1484
SEAM101D00 – Bulldozer D20A,P,PL-5 Operation & Maintenance Manual (SN45001&up)…1486
COVER…1486
FOREWORD…1487
BREAKING IN YOUR NEW MACHINE…1488
CONTENTS…1489
GENERAL LOCATIONS…1490
SAFETY HINTS…1492
OPERATOR'S COMPARTMENT…1505
INSTRUMENTS AND CONTROLS…1507
CHECK BEFORE STARTING…1515
OPERATING YOUR MACHINE…1519
COLD WEATHER OPERATION…1527
BULLDOZER'S WORK…1531
TIPS FOR LONGER UNDERCARRIAGE LIFE…1533
REVERSING AND REPLACEMENT OF CUTTING EDGE AND END BIT…1534
TRANSPORTATION…1535
MAINTENANCE…1537
    PERIODIC MAINTENANCE…1538
      PRECAUTIONS FOR MAINTENANCE…1539
      MAINTENANCE TABLE…1545
      EVERY 50 HOURS SERVICE…1549
      EVERY 250 HOURS SERVICE…1550
      EVERY 500 HOURS SERVICE…1557
      EVERY 1000 HOURS SERVICE…1560
      EVERY 2000 HOURS SERVICE…1564
      WHEN REQUIRED…1565
    ADJUSTMENT…1567
    TROUBLE SHOOTING GUIDE…1576
    STORAGE…1579
    SERVICE METER…1581
    MACHINE AND ENGINE SERIAL NUMBERS…1582
    WEAR PARTS…1583
    SPECIFICATIONS…1584
    FUEL AND LUBRICANTS…1588
SEAM101D01 – Bulldozer D20A,P,PL,PLL-5 & D20P-5A Operation & Maintenance Manual (SN50001&up)…1591
COVER…1591
FOREWORD…1592
BREAKING IN YOUR NEW MACHINE…1593
CONTENTS…1594
SAFETY HINTS…1595
GENERAL LOCATIONS…1608
OPERATOR'S COMPARTMENT…1610
INSTRUMENTS AND CONTROLS…1612
CHECK BEFORE STARTING…1621
OPERATING YOUR MACHINE…1625
COLD WEATHER OPERATION…1633
BULLDOZER'S WORK…1637
TIPS FOR LONGER UNDERCARRIAGE LIFE…1639
REVERSING AND REPLACEMENT OF CUTTING EDGE AND END BIT…1640
HANDLING OF BATTERY…1641
TRANSPORTATION…1644
MAINTENANCE…1646
    PERIODIC MAINTENANCE…1647
      PRECAUTIONS FOR MAINTENANCE…1648
      MAINTENANCE TABLE…1654
      EVERY 50 HOURS SERVICE…1658
      EVERY 250 HOURS SERVICE…1659
      EVERY 500 HOURS SERVICE…1667
      EVERY 1000 HOURS SERVICE…1670
      EVERY 2000 HOURS SERVICE…1674
      WHEN REQUIRED…1675
    ADJUSTMENT…1677
    TROUBLE SHOOTING GUIDE…1686
    STORAGE…1689
    SERVICE METER…1691
    MACHINE AND ENGINE SERIAL NUMBERS…1692
    WEAR PARTS…1693
    SPECIFICATIONS…1694
    FUEL AND LUBRICANTS…1698
TEN00016-01 – Bulldozer GALEO D21A-8 & D21P-8 Operation & Maintenance Manual (SN83001&up)…1701
COVER…1701
FOREWORD…1702
    FOREWORD…1703
    SAFETY INFORMATION…1706
    INTRODUCTION…1708
      FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE…1708
    NECESSARY INFORMATION…1709
      PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…1709
      ENGINE SERIAL NO. PLATE…1709
      EMISSION CONTROL INFORMATION LABEL…1710
      POSITION OF SERVICE METER…1710
      TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR…1711
CONTENTS…1712
SAFETY…1716
    SAFETY…1717
    SAFETY LABELS…1719
      POSITIONS OF SAFETY PICTOGRAMS…1719
      SAFETY LABELS…1720
    GENERAL PRECAUTIONS…1723
      SAFETY RULES…1723
      IF PROBLEMS ARE FOUND…1723
      CLOTHING AND PERSONAL PROTECTIVE ITEMS…1723
      FIRE EXTINGUISHER AND FIRST AID KIT…1723
      SAFETY FEATURES…1723
      KEEP MACHINE CLEAN…1724
      INSIDE OPERATOR'S COMPARTMENT…1724
      ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT…1724
      HANDRAILS AND STEPS…1725
      MOUNTING AND DISMOUNTING…1726
      NO PEOPLE ON ATTACHMENTS…1726
      CRUSHING OR CUTTING PREVENTION…1726
      PREVENTION OF BURNS…1726
      FIRE PREVENTION…1727
      ACTION IF FIRE OCCURS…1728
      WINDOW WASHER LIQUID…1728
      PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)…1728
      PRECAUTIONS FOR ATTACHMENTS…1728
      UNAUTHORIZED MODIFICATION…1728
      SAFETY AT WORKSITE…1729
      WORKING ON LOOSE GROUND…1729
      DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES…1729
      ENSURE GOOD VISIBILITY…1730
      VENTILATION FOR ENCLOSED AREAS…1730
      CHECKING SIGNALMAN'S SIGNALS AND SIGNS…1730
      EMERGENCY EXIT FROM OPERATOR'S CAB…1730
      BE CAREFUL ABOUT ASBESTOS DUST…1730
    PRECAUTIONS FOR OPERATION…1731
      STARTING ENGINE…1731
        CHECKS BEFORE STARTING ENGINE…1731
        PRECAUTIONS WHEN STARTING…1731
        PRECAUTIONS IN COLD AREAS…1732
      OPERATION…1733
        CHECKS BEFORE OPERATION…1733
        PRECAUTIONS FOR MOVING MACHINE FORWARD OR IN REVERSE…1733
        PRECAUTIONS WHEN TRAVELING…1733
        TRAVELING ON SLOPES…1734
        USING BRAKES…1734
        OPERATE CAREFULLY ON SNOW…1735
        PARKING MACHINE…1735
      TRANSPORTATION…1737
        LOADING AND UNLOADING…1737
        SHIPPING…1737
      BATTERY…1738
        BATTERY HAZARD PREVENTION…1738
        STARTING WITH BOOSTER CABLE…1739
      TOWING…1740
        WHEN TOWING…1740
    PRECAUTIONS FOR MAINTENANCE…1741
      WARNING TAG…1741
      KEEP WORK PLACE CLEAN AND TIDY…1741
      APPOINT LEADER WHEN WORKING WITH OTHERS…1741
      STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE…1742
      TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…1743
      PROPER TOOLS…1744
      NO UNAUTHORIZED PERSONNEL INTO AREA…1744
      ATTACHMENTS…1744
      WORK UNDER THE MACHINE…1744
      NOISE…1744
      PRECAUTIONS WHEN USING HAMMER…1745
      REPAIR WELDING…1745
      REMOVING BATTERY TERMINAL…1745
      PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…1745
      DO NOT DISASSEMBLE RECOIL SPRING…1745
      PRECAUTION WITH HIGH-PRESSURE OIL…1746
      HANDLING HIGH-PRESSURE HOSES…1746
      WASTE MATERIAL…1746
      MAINTENANCE FOR AIR CONDITIONER…1746
      COMPRESSED AIR…1747
      PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…1747
OPERATION…1748
    GENERAL VIEW…1749
      GENERAL VIEW OF MACHINE…1749
      GENERAL VIEW OF CONTROLS AND GAUGES…1750
    EXPLANATION OF COMPONENTS…1751
      FRONT PANEL…1751
      SWITCHES…1757
      CONTROL LEVERS AND PEDALS…1759
      FUSE…1765
      FUSIBLE LINK…1765
      DOOR POCKET…1766
    OPERATION…1767
      CHECK BEFORE STARTING ENGINE, ADJUST…1767
      STARTING ENGINE…1779
      OPERATIONS AND CHECKS AFTER STARTING ENGINE…1782
      STOPPING ENGINE…1784
      MACHINE OPERATION…1785
      SHIFTING GEARS…1789
      SHIFTING BETWEEN FORWARD AND REVERSE…1790
      STEERING MACHINE…1791
      PRECAUTIONS FOR OPERATION…1795
      WORK POSSIBLE USING BULLDOZER…1796
      PARKING MACHINE…1798
      CHECK AFTER FINISHING WORK…1800
      LOCKING…1800
      TIPS FOR LONGER UNDERCARRIAGE LIFE…1801
      HANDLING RUBBER SHOES (RUBBER SHOES ONLY)…1804
    TRANSPORTATION…1809
      TRANSPORTATION MEANS…1809
      LOADING, UNLOADING WORK…1809
      LIFTING MACHINE…1812
    COLD WEATHER OPERATION…1813
      PRECAUTIONS FOR LOW TEMPERATURE…1813
      AFTER COMPLETION OF WORK…1815
      AFTER COLD WEATHER…1815
    LONG-TERM STORAGE…1816
      BEFORE STORAGE…1816
      DURING STORAGE…1816
      AFTER STORAGE…1816
    TROUBLESHOOTING…1817
      AFTER RUNNING OUT OF FUEL…1817
      MACHINE TOWING METHOD…1817
      IF BATTERY IS DISCHARGED…1818
      OTHER TROUBLE…1821
MAINTENANCE…1824
    GUIDE TO MAINTENANCE…1825
    OUTLINE OF SERVICE…1827
      OUTLINE OF OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…1827
      RELATING TO ELECTRIC SYSTEM…1829
    WEAR PARTS LIST…1830
      WEAR PARTS LIST…1830
    USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…1831
      PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS…1831
    STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…1835
      TORQUE LIST…1835
    PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…1836
      SAFETY CRITICAL PARTS…1836
    MAINTENANCE SCHEDULE CHART…1837
      MAINTENANCE SCHEDULE CHART…1837
    SERVICE PROCEDURE…1839
      INITIAL 250 HOURS SERVICE(ONLY AFTER THE FIRST 250 HOURS)…1839
      WHEN REQUIRED…1840
        CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…1840
        CLEAN INSIDE OF COOLING SYSTEM…1843
        CLEAN WATER SEPARATOR ELEMENT…1845
        CHECK AND ADJUST STEEL SHOE TENSION…1846
        CHECK AND TIGHTEN TRACK STEEL SHOE BOLTS…1848
        CHECK AND REPLACE RUBBER SHOES…1849
        CHECK AND ADJUST RUBBER SHOE TENSION…1851
        REPLACE RUBBER SHOES…1853
        REVERSE AND REPLACE END BITS AND CUTTING EDGES…1856
        BLEED AIR FROM HEAD END OF ANGLE CIRCUIT…1857
        ADJUST BRAKE PEDAL (TEST, ADJUST STEERING BRAKE)…1858
        ADJUST IDLER CLEARANCE…1860
      CHECK BEFORE STARTING…1861
      EVERY 50 HOURS SERVICE…1862
        DRAIN WATER, SEDIMENT FROM FUEL TANK…1862
      EVERY 250 HOURS SERVICE…1863
        LUBRICATING…1863
        CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…1865
        CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL…1865
        CHECK LEVEL OF BATTERY ELECTROLYTE…1866
        CHECK FAN BELT TENSION, ADJUST…1868
      EVERY 500 HOURS SERVICE…1869
        REPLACE FUEL FILTER CARTRIDGE…1869
        CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…1871
        CLEAN, CHECK RADIATOR FINS…1872
        CLEAN BREATHER…1872
      EVERY 1000 HOURS SERVICE…1873
        CHECK OIL LEVEL IN DAMPER CASE, ADD OIL…1873
        CHANGE OIL IN BEVEL GEAR CASE, TRANSFER CASE…1873
        CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER…1875
        CHANGE OIL IN FINAL DRIVE CASE…1876
        CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER CARTRIDGE…1877
        CHECK OIL IN UNDERCARRIAGE COMPONENTS…1877
        CHECK ENGINE VALVE CLEARANCE, ADJUST…1877
      EVERY 2000 HOURS SERVICE…1878
        CHECK ALTERNATOR, STARTING MOTOR…1878
      EVERY 4000 HOURS SERVICE…1879
        CHECK WATER PUMP…1879
SPECIFICATIONS…1880
    SPECIFICATIONS…1881
ATTACHMENTS, OPTIONS…1882
    GENERAL PRECAUTIONS…1883
      PRECAUTIONS RELATED TO SAFETY…1883
    DECELERATOR PEDAL…1884
    SUSPENSION SEAT…1885
      ADJUSTMENT…1885
      SEAT BELT…1885
    HANDLING TRIMMING DOZER…1887
      GENERAL VIEW…1887
      EXPLANATION OF COMPONENTS…1888
      OPERATION…1891
      MAINTENANCE…1893
      SPECIFICATIONS…1901
      WEAR PARTS LIST…1902
INDEX…1904
TEN00269-03 – Bulldozer D21A-8E0 & D21P-8E0 Operation & Maintenance Manual (SN90001&up)…1908
COVER…1908
FOREWORD…1909
    BEFORE READING THIS MANUAL…1910
    IMPORTANT SAFETY INFORMATION…1912
    INTENDED USE…1913
      USE OF MACHINE…1913
      GENERAL VIEW AND DIRECTIONS OF MACHINE…1913
      VISIBILITY FROM OPERATOR'S SEAT…1913
    LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…1914
      PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…1914
      ENGINE SERIAL NO. PLATE POSITION…1914
      ADDITIONAL EPA NAMEPLATE…1915
      SERVICE METER POSITION…1915
      TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…1916
    CONTENTS…1917
SAFETY…1921
    SAFETY…1922
    SAFETY LABELS…1925
      POSITIONS OF SAFETY PICTOGRAMS…1925
      SAFETY LABELS…1926
    GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…1930
      PRECAUTIONS BEFORE STARTING OPERATION…1930
      PREPARATIONS FOR SAFE OPERATION…1930
      FIRE PREVENTION…1932
      PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…1934
      DO NOT GET CAUGHT IN WORK EQUIPMENT…1936
      PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…1937
      UNAUTHORIZED MODIFICATION…1937
      PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…1937
      PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…1938
    PRECAUTIONS FOR OPERATION…1939
      PRECAUTIONS FOR JOBSITE…1939
      STARTING ENGINE…1941
      OPERATION…1944
      TRANSPORTATION…1948
      TOWING…1949
    PRECAUTIONS FOR MAINTENANCE…1950
      PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…1950
      PRECAUTIONS FOR INSPECTION AND MAINTENANCE…1954
OPERATION…1959
    GENERAL VIEW…1960
      GENERAL VIEW OF MACHINE…1960
      GENERAL VIEW OF CONTROLS AND GAUGES…1961
    EXPLANATION OF COMPONENTS…1962
      FRONT PANEL…1962
      SWITCHES…1968
      CONTROL LEVERS AND PEDALS…1970
      FUSE…1977
      FUSIBLE LINK…1977
      DOOR POCKET…1978
    OPERATION…1979
      CHECK BEFORE STARTING ENGINE, ADJUST…1979
      STARTING ENGINE…1991
      OPERATIONS AND CHECKS AFTER STARTING ENGINE…1994
      STOPPING ENGINE…1996
      MACHINE OPERATION…1997
      SHIFTING GEARS…2001
      SHIFTING BETWEEN FORWARD AND REVERSE…2002
      STEERING MACHINE…2003
      PRECAUTIONS FOR OPERATION…2007
      WORK POSSIBLE USING BULLDOZER…2008
      PARKING MACHINE…2010
      CHECK AFTER FINISHING WORK…2012
      LOCKING…2012
      TIPS FOR LONGER UNDERCARRIAGE LIFE…2013
      HANDLING RUBBER SHOES (RUBBER SHOES ONLY)…2016
    TRANSPORTATION…2021
      TRANSPORTATION MEANS…2021
      LOADING, UNLOADING WORK…2021
      LIFTING MACHINE…2024
    COLD WEATHER OPERATION…2025
      PRECAUTIONS FOR LOW TEMPERATURE…2025
      AFTER COMPLETION OF WORK…2026
      AFTER COLD WEATHER…2026
    LONG-TERM STORAGE…2027
      BEFORE STORAGE…2027
      DURING STORAGE…2027
      AFTER STORAGE…2027
    TROUBLESHOOTING…2028
      AFTER RUNNING OUT OF FUEL…2028
      MACHINE TOWING METHOD…2028
      IF BATTERY IS DISCHARGED…2029
      OTHER TROUBLE…2032
MAINTENANCE…2035
    GUIDE TO MAINTENANCE…2036
    OUTLINE OF SERVICE…2038
      HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…2038
      RELATING TO ELECTRIC SYSTEM…2041
    WEAR PARTS LIST…2042
      WEAR PARTS LIST…2042
    RECOMMENDED FUEL, COOLANT, AND LUBRICANT…2043
      USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…2044
      RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…2045
    STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…2046
      TORQUE LIST…2046
    PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…2047
      SAFETY CRITICAL PARTS…2047
    MAINTENANCE SCHEDULE CHART…2048
      MAINTENANCE SCHEDULE CHART…2048
    SERVICE PROCEDURE…2050
      INITIAL 250 HOURS SERVICE(ONLY AFTER THE FIRST 250 HOURS)…2050
      WHEN REQUIRED…2051
      CHECK BEFORE STARTING…2073
      EVERY 50 HOURS SERVICE…2074
      EVERY 250 HOURS SERVICE…2075
      EVERY 500 HOURS SERVICE…2080
      EVERY 1000 HOURS SERVICE…2084
      EVERY 1500 HOURS SERVICE…2089
      EVERY 2000 HOURS SERVICE…2090
      EVERY 4000 HOURS SERVICE…2091
SPECIFICATIONS…2093
    SPECIFICATIONS…2094
ATTACHMENTS, OPTIONS…2095
    GENERAL PRECAUTIONS…2096
      PRECAUTIONS RELATED TO SAFETY…2096
    DECELERATOR PEDAL…2097
    SUSPENSION SEAT…2098
      ADJUSTMENT…2098
      SEAT BELT…2098
    HANDLING MACHINES EQUIPPED WITH KOMTRAX…2100
      BASIC PRECAUTIONS…2100
INDEX…2101
TEN00496-01 – Bulldozer D21A-8E0 & D21P-8E0 Operation & Maintenance Manual (SN90219&up)…2105
COVER…2105
FOREWORD…2106
    BEFORE READING THIS MANUAL…2107
    IMPORTANT SAFETY INFORMATION…2109
    INTENDED USE…2110
      USE OF MACHINE…2110
      GENERAL VIEW AND DIRECTIONS OF MACHINE…2110
      VISIBILITY FROM OPERATOR'S SEAT…2110
    LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…2111
      PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…2111
      ENGINE SERIAL NO. PLATE POSITION…2111
      SERVICE METER POSITION…2112
      TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…2112
    CONTENTS…2113
SAFETY…2116
    SAFETY…2117
    SAFETY LABELS…2120
      POSITIONS OF SAFETY PICTOGRAMS…2120
      SAFETY LABELS…2121
    GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…2125
      PRECAUTIONS BEFORE STARTING OPERATION…2125
      PREPARATIONS FOR SAFE OPERATION…2125
      FIRE PREVENTION…2127
      PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…2128
      DO NOT GET CAUGHT IN WORK EQUIPMENT…2130
      PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…2131
      UNAUTHORIZED MODIFICATION…2131
      PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…2131
      PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…2132
    PRECAUTIONS FOR OPERATION…2133
      PRECAUTIONS FOR JOBSITE…2133
      STARTING ENGINE…2135
      OPERATION…2138
      TRANSPORTATION…2142
      TOWING…2143
    PRECAUTIONS FOR MAINTENANCE…2144
      PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…2144
      PRECAUTIONS FOR INSPECTION AND MAINTENANCE…2148
OPERATION…2154
    GENERAL VIEW…2155
      GENERAL VIEW OF MACHINE…2155
      GENERAL VIEW OF CONTROLS AND GAUGES…2156
    EXPLANATION OF COMPONENTS…2157
      FRONT PANEL…2157
      SWITCHES…2163
      CONTROL LEVERS AND PEDALS…2165
      FUSE…2172
      FUSIBLE LINK…2172
      DOOR POCKET…2173
    OPERATION…2174
      CHECK BEFORE STARTING ENGINE, ADJUST…2174
      STARTING ENGINE…2186
      OPERATIONS AND CHECKS AFTER STARTING ENGINE…2189
      STOPPING ENGINE…2191
      MACHINE OPERATION…2192
      SHIFTING GEARS…2196
      SHIFTING BETWEEN FORWARD AND REVERSE…2197
      STEERING MACHINE…2198
      PRECAUTIONS FOR OPERATION…2202
      WORK POSSIBLE USING BULLDOZER…2203
      PARKING MACHINE…2205
      CHECK AFTER FINISHING WORK…2207
      LOCKING…2207
      TIPS FOR LONGER UNDERCARRIAGE LIFE…2208
      HANDLING RUBBER SHOES (RUBBER SHOES ONLY)…2211
    TRANSPORTATION…2216
      TRANSPORTATION MEANS…2216
      LOADING, UNLOADING WORK…2216
      LIFTING MACHINE…2219
    COLD WEATHER OPERATION…2220
      PRECAUTIONS FOR LOW TEMPERATURE…2220
      AFTER COMPLETION OF WORK…2221
      AFTER COLD WEATHER…2221
    LONG-TERM STORAGE…2222
      BEFORE STORAGE…2222
      DURING STORAGE…2222
      AFTER STORAGE…2222
    TROUBLESHOOTING…2223
      AFTER RUNNING OUT OF FUEL…2223
      MACHINE TOWING METHOD…2223
      IF BATTERY IS DISCHARGED…2224
      OTHER TROUBLE…2227
MAINTENANCE…2230
    GUIDE TO MAINTENANCE…2231
    OUTLINE OF SERVICE…2233
      HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…2233
      RELATING TO ELECTRIC SYSTEM…2236
    WEAR PARTS LIST…2237
      WEAR PARTS LIST…2237
    RECOMMENDED FUEL, COOLANT, AND LUBRICANT…2238
      USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…2239
      RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…2240
    PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…2242
      SAFETY CRITICAL PARTS…2242
    MAINTENANCE SCHEDULE CHART…2243
    SERVICE PROCEDURE…2245
      INITIAL 250 HOURS SERVICE(ONLY AFTER THE FIRST 250 HOURS)…2245
      WHEN REQUIRED…2246
      CHECK BEFORE STARTING…2268
      EVERY 50 HOURS SERVICE…2269
      EVERY 250 HOURS SERVICE…2270
      EVERY 500 HOURS SERVICE…2275
      EVERY 1000 HOURS SERVICE…2279
      EVERY 1500 HOURS SERVICE…2284
      EVERY 2000 HOURS SERVICE…2285
      EVERY 4000 HOURS SERVICE…2286
SPECIFICATIONS…2288
    SPECIFICATIONS…2289
ATTACHMENTS, OPTIONS…2290
    GENERAL PRECAUTIONS…2291
      PRECAUTIONS RELATED TO SAFETY…2291
    DECELERATOR PEDAL…2292
    SUSPENSION SEAT…2293
      ADJUSTMENT…2293
      SEAT BELT…2293
    HANDLING MACHINES EQUIPPED WITH KOMTRAX…2295
      BASIC PRECAUTIONS…2295
INDEX…2296

TABLE OF CONTENTS
FOREWORD
FOREWORD
SAFETY INFORMATION
INTRODUCTION
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE
NECESSARY INFORMATION
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE
ENGINE SERIAL NO. PLATE
EMISSION CONTROL INFORMATION LABEL
POSITION OF SERVICE METER
TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR
SAFETY
SAFETY
SAFETY LABELS
POSITIONS OF SAFETY PICTOGRAMS
SAFETY LABELS
GENERAL PRECAUTIONS
PRECAUTIONS FOR OPERATION
STARTING ENGINE
OPERATION
TRANSPORTATION
BATTERY
TOWING
PRECAUTIONS FOR MAINTENANCE
OPERATION
GENERAL VIEW
GENERAL VIEW OF MACHINE
GENERAL VIEW OF CONTROLS AND GAUGES
EXPLANATION OF COMPONENTS
FRONT PANEL
SWITCHES
CONTROL LEVERS AND PEDALS
FUSE
FUSIBLE LINK
DOOR POCKET
OPERATION
CHECK BEFORE STARTING ENGINE, ADJUST
STARTING ENGINE
OPERATIONS AND CHECKS AFTER STARTING ENGINE
STOPPING ENGINE
MACHINE OPERATION
SHIFTING GEARS
SHIFTING BETWEEN FORWARD AND REVERSE
STEERING MACHINE
PRECAUTIONS FOR OPERATION
WORK POSSIBLE USING BULLDOZER
PARKING MACHINE
CHECK AFTER FINISHING WORK
LOCKING
TIPS FOR LONGER UNDERCARRIAGE LIFE
HANDLING RUBBER SHOES (RUBBER SHOES ONLY)
TRANSPORTATION
TRANSPORTATION MEANS
LOADING, UNLOADING WORK
LIFTING MACHINE
COLD WEATHER OPERATION
PRECAUTIONS FOR LOW TEMPERATURE
AFTER COMPLETION OF WORK
AFTER COLD WEATHER
LONG-TERM STORAGE
BEFORE STORAGE
DURING STORAGE
AFTER STORAGE
TROUBLESHOOTING
AFTER RUNNING OUT OF FUEL
MACHINE TOWING METHOD
IF BATTERY IS DISCHARGED
OTHER TROUBLE
MAINTENANCE
GUIDE TO MAINTENANCE
OUTLINE OF SERVICE
OUTLINE OF OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC
RELATING TO ELECTRIC SYSTEM
WEAR PARTS LIST
WEAR PARTS LIST
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS
TORQUE LIST
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
SAFETY CRITICAL PARTS
MAINTENANCE SCHEDULE CHART
MAINTENANCE SCHEDULE CHART
SERVICE PROCEDURE
INITIAL 250 HOURS SERVICE(ONLY AFTER THE FIRST 250 HOURS)
WHEN REQUIRED
CHECK BEFORE STARTING
EVERY 50 HOURS SERVICE
EVERY 250 HOURS SERVICE
EVERY 500 HOURS SERVICE
EVERY 1000 HOURS SERVICE
EVERY 2000 HOURS SERVICE
EVERY 4000 HOURS SERVICE
SPECIFICATIONS
SPECIFICATIONS
ATTACHMENTS, OPTIONS
GENERAL PRECAUTIONS
PRECAUTIONS RELATED TO SAFETY
DECELERATOR PEDAL
SUSPENSION SEAT
ADJUSTMENT
SEAT BELT
HANDLING TRIMMING DOZER
GENERAL VIEW
EXPLANATION OF COMPONENTS
OPERATION
MAINTENANCE
SPECIFICATIONS
WEAR PARTS LIST
INDEX

Komatsu Bulldozer D20- & D21- series Operation Maintenance Manuals

INSTANT DOWNLOAD

Posted on June 5, 2025 by admin

Komatsu Mobile Crusher GALEO BR380JG Operation & Maintenance Manuals

INSTANT DOWNLOAD

Complete Operation & Maintenance Manuals for Komatsu Mobile Crusher GALEO BR380JG, with all the service information to maintain & operate your crusher.

SEAM059001T – Mobile Crusher GALEO BR380JG-1 Operation & Maintenance Manual (SN1001&up).pdf
TEN00006-03 – Mobile Crusher GALEO BR380JG-1 Operation & Maintenance Manual (SN1201&up).pdf
TEN00168-03 – Mobile Crusher GALEO BR380JG-1E0 Operation & Maintenance Manual (SN2001&up).pdf
TEN00358-01 – Mobile Crusher GALEO BR380JG-1E0 Operation & Maintenance Manual (SN2609&up).pdf
TEN00476-01 – Mobile Crusher GALEO BR380JG-1E0 Operation & Maintenance Manual (SN2621&up).pdf

Total Pages: 1,857 pages
File Format: PDF
Language: English

TABLE OF CONTENTS
FOREWORD
BEFORE READING THIS MANUAL
SAFETY INFORMATION
INTRODUCTION
INTRODUCTION
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE
NECESSARY INFORMATION
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE
EPA REGULATIONS, ENGINE NUMBER PLATE
POSITION OF SERVICE METER
TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR
SAFETY
SAFETY
SAFETY LABELS
POSITIONS OF SAFETY PICTOGRAMS
SAFETY LABELS
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE
PRECAUTIONS BEFORE STARTING OPERATION
PREPARATIONS FOR SAFE OPERATION
FIRE PREVENTION
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE
DO NOT GET CAUGHT IN WORK EQUIPMENT
UNAUTHORIZED MODIFICATION
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING
PRECAUTIONS FOR OPERATION
PRECAUTIONS FOR JOBSITE
STARTING ENGINE
OPERATION
CRUSHING OPERATION
TRANSPORTATION
TOWING
MAGNETIC SEPARATOR
PRECAUTIONS FOR MAINTENANCE
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE
PRECAUTIONS FOR INSPECTION AND MAINTENANCE
OPERATION
GENERAL VIEW
GENERAL VIEW OF MACHINE
GENERAL VIEW OF CONTROLS AND GAUGES
EXPLANATION OF COMPONENTS
MACHINE MONITOR
SWITCHES
CONTROL LEVERS
OPTION-RELATED SWITCHES
CAP, COVER WITH LOCK
REVOLVING WARNING LAMP
ELECTRIC POWER TAKEOFF
FUSIBLE LINK
CONTROLLERS
FUSE
TOOL BOX
OPERATION
CHECK BEFORE STARTING ENGINE
STARTING ENGINE
OPERATIONS AND CHECKS AFTER STARTING ENGINE
STOPPING ENGINE
CHECK AFTER STOPPING ENGINE
MACHINE OPERATION
STEERING MACHINE
OPERATION OF WORK EQUIPMENT
CHECK AND CONFIRMATION OF JAW CRUSHER AFTER WORK
CHECK AFTER FINISHING WORK
LOCKING
RUN-IN OPERATION OF JAW CRUSHER
PRECAUTIONS WHEN OPERATING JAW CRUSHER
EFFICIENT USE OF JAW CRUSHER
SCOPE OF WORKS USING MOBILE CRUSHER
PROHIBITIONS FOR OPERATION
PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS
TRANSPORTATION
TRANSPORTATION PROCEDURE
LOADING, UNLOADING WORK
LIFTING MACHINE
COLD WEATHER OPERATION
PRECAUTIONS FOR LOW TEMPERATURE
AFTER COMPLETION OF WORK
AFTER COLD WEATHER
LONG-TERM STORAGE
BEFORE STORAGE
DURING STORAGE
AFTER STORAGE
STARTING MACHINE AFTER LONG-TERM STORAGE
TROUBLESHOOTING
AFTER RUNNING OUT OF FUEL
PHENOMENA THAT ARE NOT FAILURES
METHOD OF TOWING MACHINE
IF BATTERY IS DISCHARGED
OTHER TROUBLE
MAINTENANCE
GUIDE TO MAINTENANCE
OUTLINE OF SERVICE
HANDLING AND PERFORMANCE OF OIL CLINIC FOR OIL, FUEL, COOLANT
RELATING TO ELECTRIC SYSTEM
OUTLINE OF HYDRAULIC EQUIPMENT
AIR-BLEEDING FROM HYDRAULIC CIRCUIT
WEAR PARTS
WEAR PARTS LIST
JAW CRUSHER RELATED PARTS
PRIMARY CONVEYOR RELATED PARTS
RECOMMENDED FUEL, COOLANT AND LUBRICANTS
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN
KOMATSU GENUINE OIL
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS
TORQUE LIST
TOOLS TO USE CHECK AND MAINTENANCE CRUSHER
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
SAFETY CRITICAL PARTS
MAINTENANCE SCHEDULE CHART
MAINTENANCE SCHEDULE CHART
SERVICE PROCEDURE
INITIAL 250 HOURS SERVICE (FIRST MAINTENANCE FOR NEW MACHINE ONLY)
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)
WHEN REQUIRED
CHECK BEFORE STARTING
EVERY 10 HOURS SERVICE
EVERY 100 HOURS SERVICE
EVERY 250 HOURS SERVICE
EVERY 500 HOURS SERVICE
EVERY 1000 HOURS SERVICE
EVERY 2000 HOURS SERVICE
EVERY 4000 HOURS SERVICE
EVERY 5000 HOURS SERVICE
EVERY 8000 HOURS SERVICE
SPECIFICATIONS
SPECIFICATIONS
ATTACHMENTS, OPTIONS
GENERAL PRECAUTIONS
PRECAUTIONS RELATED TO SAFETY
ATTACHMENTS, OPTIONS
ATTACHMENTS, OPTIONS CHART
METHOD FOR CONNECTING HYDRAULIC HOSES FOR OPTIONS
RADIO CONTROL UNIT
ON USE OF RADIO CONTROL UNIT
DIRECTIONS FOR USE
RADIO CONTROL OPERATION
MUCK DISCHARGE CONVEYOR
PROCEDURE FOR RAISING (BENDING) MUCK DISCHARGE CONVEYOR
PROCEDURE FOR LOWERING (EXTEND) MUCK DISCHARGE CONVEYOR
GREASING MUCK DISCHARGE CONVEYOR
CHECK AND ADJUSTMENT OF MUCK DISCHARGE CONVEYOR
FAILURES AND CORRECTIVE ACTIONS
WEARING PARTS
SPECIFICATIONS
M-TYPE CHUTE
METHOD OF OPERATION
GRIZZLY BAR OPENING
HANDLING MACHINES EQUIPPED WITH KOMTRAX
BASIC PRECAUTIONS
MACHINES THAT CAN INSTALL ATTACHMENTS
NAMES OF CONTROL PANEL SWITCHES
HYDRAULIC POWER TAKEOFF PORT
ATTACHMENT PORT
PROCEDURE FOR CONNECTING OPTIONS
SPRINKLER
EXPLANATIONS FOR COMPONENT PARTS
HOW TO USE SPRINKLER
INSPECTION AND MAINTENANCE
ADDITIONAL SPRINKLER NOZZLE
INDEX

SEAM059001T – Mobile Crusher GALEO BR380JG-1 Operation & Maintenance Manual (SN1001&up)…2
COVER…2
FOREWORD…3
FOREWORD…4
SAFETY INFORMATION…7
INTRODUCTION…9
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE…9
NECESSARY INFORMATION…10
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…10
ENGINE SERIAL NO. PLATE AND POSITION…10
POSITION OF SERVICE METER…11
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…11
CONTENTS…12
SAFETY…16
SAFETY…17
SAFETY LABELS…20
POSITIONS OF SAFETY PICTOGRAMS…21
SAFETY LABELS…22
GENERAL PRECAUTIONS…31
SAFETY RULES…31
IF ABNORMALITIES ARE FOUND…31
CLOTHING AND PERSONAL PROTECTIVE ITEMS…31
FIRE EXTINGUISHER AND FIRST AID KIT…31
SAFETY FEATURES…31
KEEP MACHINE CLEAN…32
ON OPERATOR'S PLATFORM…32
ALWAYS APPLY LOCK WHEN LEAVING UPPER OPERATION DECK…32
HANDRAILS AND STEPS…33
MOUNTING AND DISMOUNTING…33
NO PEOPLE ON ATTACHMENTS…33
CRUSHING OR CUTTING PREVENTION…33
PREVENTION OF BURNS…34
FIRE PREVENTION…34
ACTION IF FIRE OCCURS…35
PRECAUTIONS FOR ATTACHMENTS…35
UNAUTHORIZED MODIFICATION…35
SAFETY AT WORKSITE…35
WORKING ON LOOSE GROUND…36
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES…36
ENSURE GOOD VISIBILITY…36
VENTILATION FOR ENCLOSED AREAS…37
CHECKING SIGNALMAN'S SIGNALS AND SIGNS…37
BE CAREFUL ABOUT ASBESTOS DUST…37
PRECAUTIONS FOR OPERATION…38
STARTING ENGINE…38
CHECKS BEFORE STARTING ENGINE…38
PRECAUTIONS WHEN STARTING…38
PRECAUTIONS IN COLD AREAS…39
OPERATION…40
CHECKS BEFORE OPERATION…40
PRECAUTIONS WHEN CHANGING DIRECTION…40
PRECAUTIONS WHEN TRAVELING…40
TRAVELING ON SLOPES…41
OPERATIONS ON SLOPES…41
PRECAUTIONS WHILE IN OPERATION…41
OPERATE CAREFULLY ON SNOW…41
PARKING MACHINE…42
CRUSHING OPERATION…43
CHECKS AROUND MACHINE…43
TURN MODE SELECTOR SWITCH TO WORK POSITION…43
ENSURE SAFETY WHILE OPERATING IN TANDEM WITH HYDRAULIC EXCAVATOR…44
CHECKS OF CRUSHER BEFORE STARTING OPERATION…44
PRECAUTIONS FOR CRUSHING WORK…44
EMERGENCY STOP TO WARD OFF DANGERS WHILE IN CRUSHING WORK…45
REMOVE FOREIGN MATERIAL FROM INSIDE CRUSHER…45
MAGNETIC SEPARATOR…46
HYDRAULIC MAGNETIC SEPARATOR (HANGING TYPE)…46
TRANSPORTATION…47
LOADING AND UNLOADING…47
SHIPPING…47
BATTERY…48
BATTERY HAZARD PREVENTION…48
STARTING WITH BOOSTER CABLE…49
TOWING…50
WHEN TOWING…50
PRECAUTIONS FOR MAINTENANCE…51
WARNING TAG…51
KEEP WORK PLACE CLEAN AND TIDY…51
APPOINT LEADER WHEN WORKING WITH OTHERS…51
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…51
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…52
PRECAUTIONS FOR CONVEYOR MAINTENANCE…52
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE OF FEEDER, CRUSHER…53
PROPER TOOLS…53
PERSONNEL…53
PRECAUTIONS WHEN MOUNTING, DISMANTLING AND STORING ATTACHMENTS…53
PRECAUTIONS FOR WORK UNDER MACHINE…53
NOISE…54
PRECAUTIONS WHEN USING HAMMER…54
REPAIR WELDING…54
REMOVING BATTERY TERMINAL…54
PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…54
DO NOT DISASSEMBLE RECOIL SPRING…55
PRECAUTIONS WITH HIGH-PRESSURE OIL…55
HANDLING HIGH-PRESSURE HOSES…55
WASTE MATERIAL…55
COMPRESSED AIR…56
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…56
OPERATION…57
GENERAL VIEW…58
GENERAL VIEW OF MACHINE…58
GENERAL VIEW OF CONTROLS AND GAUGES…59
EXPLANATION OF COMPONENTS…63
MACHINE MONITOR…63
SWITCHES…87
CONTROL LEVERS…96
OPTION-RELATED SWITCHES…97
CAP, COVER WITH LOCK…99
REVOLVING WARNING LAMP…101
ELECTRIC POWER TAKEOFF…102
FUSIBLE LINK…104
CONTROLLERS…104
FUSE…104
TOOL BOX…105
OPERATION…106
CHECK BEFORE STARTING ENGINE…106
STARTING ENGINE…124
OPERATIONS AND CHECKS AFTER STARTING ENGINE…128
STOPPING ENGINE…133
CHECK AFTER STOPPING ENGINE…133
MACHINE OPERATION…134
STEERING MACHINE…140
OPERATION OF WORK EQUIPMENT…142
CHECK AND CONFIRMATION OF JAW CRUSHER AFTER WORK…151
CHECK AFTER FINISHING WORK…151
LOCKING…152
RUN-IN OPERATION OF JAW CRUSHER…153
PRECAUTIONS WHEN OPERATING JAW CRUSHER…155
SCOPE OF WORKS USING MOBILE CRUSHER…163
PROHIBITIONS FOR OPERATION…171
PRECAUTIONS WHEN TRAVELING UP OR DOWNHILLS…173
TRANSPORTATION…174
TRANSPORTATION PROCEDURE…174
LOADING, UNLOADING WORK…174
LIFTING MACHINE…180
COLD WEATHER OPERATION…181
PRECAUTIONS FOR LOW TEMPERATURE…181
AFTER COMPLETION OF WORK…183
AFTER COLD WEATHER…184
LONG-TERM STORAGE…185
BEFORE STORAGE…185
DURING STORAGE…185
AFTER STORAGE…185
STARTING MACHINE AFTER LONG-TERM STORAGE…185
TROUBLESHOOTING…186
AFTER RUNNING OUT OF FUEL…186
PHENOMENA THAT ARE NOT FAILURES…186
METHOD OF TOWING MACHINE…186
IF BATTERY IS DISCHARGED…187
OTHER TROUBLE…190
MAINTENANCE…199
GUIDES TO MAINTENANCE…200
OUTLINE OF SERVICE…202
HANDLING AND PERFORMANCE OF OIL CLINIC FOR OIL, FUEL, COOLANT…202
RELATING TO ELECTRIC SYSTEM…205
OUTLINE OF HYDRAULIC EQUIPMENT…205
AIR-BLEEDING FROM HYDRAULIC CIRCUIT…206
WEAR PARTS…207
WEAR PARTS LIST…207
JAW CRUSHER RELATED PARTS…208
PRIMARY CONVEYOR RELATED PARTS…210
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…211
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…215
CRUSHER ACCESSORY TOOLS…215
TORQUE LIST…217
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…218
SAFETY CRITICAL PARTS…218
MAINTENANCE SCHEDULE CHART…219
MAINTENANCE SCHEDULE CHART…219
SERVICE PROCEDURE…221
INITIAL 250 HOURS SERVICE (FIRST MAINTENANCE FOR NEW MACHINE ONLY)…221
INITIAL 1000 HOURS SERVICE (FIRST MAINTENANCE FOR NEW MACHINE ONLY)…221
WHEN REQUIRED…222
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…222
CLEAN INSIDE OF COOLING SYSTEM…227
CHECK AND TIGHTEN TRACK SHOE BOLT…229
CHECK AND ADJUST TRACK TENSION…230
INSPECTION OF ELECTRIC HEATER…232
CHECK AND ADJUSTMENT OF JAW CRUSHER…233
CHECK AND ADJUSTMENT OF PRIMARY CONVEYOR…254
INSPECTION AND MAINTENANCE OF MAGNETIC SEPARATOR…259
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT…261
CHECK BEFORE STARTING…263
EVERY 100 HOURS SERVICE…264
GREASING CRUSHER BEARING SEAT…264
GREASING PRIMARY CONVEYOR…265
EVERY 250 HOURS SERVICE…266
CHECK LEVEL OF BATTERY ELECTROLYTE…266
CHECK AND ADJUSTMENT OF JAW CRUSHER V-BELT…268
CHECK OF OIL LEVEL IN CRUSHER MOTOR BEARING CASE AND ADDING OIL…268
EVERY 500 HOURS SERVICE…269
REPLACE FUEL FILTER CARTRIDGE…269
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…270
CLEAN, INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS…271
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…272
REPLACE HYDRAULIC TANK BREATHER ELEMENT…273
GREASE CRUSHER LINK…273
EVERY 1000 HOURS SERVICE…274
CHANGE OF OIL IN CRUSHER MOTOR BEARING CASE…274
CHANGE OF OIL IN GRIZZLY FEEDER VIBRATOR CASE…274
CHANGE OIL IN DAMPER CASE…275
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…275
CHECK PLAY OF TURBOCHARGER ROTOR…275
CHECK AND REPLACE OF FAN BELT TENSION…275
REPLACE HYDRAULIC FILTER ELEMENT…276
EVERY 2000 HOURS SERVICE…277
CHANGE OIL IN FINAL DRIVE CASE…277
CLEAN HYDRAULIC TANK STRAINER…278
CLEAN, CHECK TURBOCHARGER…278
CHECK ALTERNATOR, STARTING MOTOR…278
CHECK ENGINE VALVE CLEARANCE, ADJUST…278
CHECK VIBRATION DAMPER…278
EVERY 4000 HOURS SERVICE…279
CHECK WATER PUMP…279
EVERY 5000 HOURS SERVICE…280
CHANGE OIL IN HYDRAULIC TANK AND CLEAN STRAINER…280
SPECIFICATIONS…281
SPECIFICATIONS…282
ATTACHMENTS, OPTIONS…284
GENERAL PRECAUTIONS…285
PRECAUTIONS RELATED TO SAFETY…285
ATTACHMENTS, OPTIONS…286
ATTACHMENTS, OPTIONS CHART…286
METHOD FOR CONNECTING HYDRAULIC HOSES FOR OPTIONS…286
RADIO CONTROL UNIT…287
ON USE OF RADIO CONTROL UNIT…287
DIRECTIONS FOR USE…290
REMOTE CONTROL OPERATION…294
MUCK DISCHARGE CONVEYOR…303
PROCEDURE FOR RAISING (BENDING) MUCK DISCHARGE CONVEYOR…303
PROCEDURE FOR LOWERING MUCK DISCHARGE CONVEYOR…305
GREASING MUCK DISCHARGE CONVEYOR…306
CHECK AND ADJUSTMENT OF MUCK DISCHARGE CONVEYOR…307
FAILURES AND CORRECTIVE ACTIONS…309
WEARING PARTS…311
SPECIFICATIONS…312
M-TYPE CHUTE…313
METHOD OF OPERATION…313
BELT CONVEYOR PROTECTIVE PLATE…314
GRIZZLY BAR OPENING…316
MACHINES THAT CAN INSTALL ATTACHMENTS…317
NAMES OF CONTROL PANEL SWITCHES…317
HYDRAULIC POWER TAKEOFF PORT…317
PROCEDURE FOR CONNECTING OPTIONS…318
HYDRAULIC VIBRATORY SIEVE…319
SPECIFICATION…319
GENERAL VIEW…319
CAUTIONS TO BE NOTED FOR SAFETY…320
CONNECTING METHOD TO MACHINE BODY…320
PRECAUTIONS DURING OPERATION…320
HYDRAULIC SECONDARY CONVEYOR…321
SPECIFICATIONS…321
GENERAL VIEW…321
INCLINED LEG CONNECTING METHOD…323
LIFTING METHOD…324
CONNECTING METHOD TO MACHINE BODY…324
PRECAUTIONS ON OPERATION…324
INSPECTION, MAINTENANCE AND ADJUSTMENT…325
TROUBLES AND CORRECTIVE ACTIONS…327
CONSUMABLE PARTS OF HYDRAULIC SECONDARY CONVEYOR…329
INDEX…331
TEN00006-03 – Mobile Crusher GALEO BR380JG-1 Operation & Maintenance Manual (SN1201&up)…335
COVER…335
FOREWORD…336
FOREWORD…337
SAFETY INFORMATION…340
INTRODUCTION…342
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE…342
BREAKING IN THE NEW MACHINE…342
NECESSARY INFORMATION…343
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…343
ENGINE SERIAL NO. PLATE AND POSITION…343
POSITION OF SERVICE METER…344
TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR…344
CONTENTS…345
SAFETY…349
SAFETY…350
SAFETY LABELS…353
POSITIONS OF SAFETY PICTOGRAMS…354
SAFETY LABELS…355
GENERAL PRECAUTIONS…363
SAFETY RULES…363
IF ABNORMALITIES ARE FOUND…363
CLOTHING AND PERSONAL PROTECTIVE ITEMS…363
FIRE EXTINGUISHER AND FIRST AID KIT…363
SAFETY FEATURES…363
KEEP MACHINE CLEAN…364
ON OPERATOR'S PLATFORM…364
ALWAYS APPLY LOCK WHEN LEAVING UPPER OPERATOR'S PLATFORM…364
HANDRAILS AND STEPS…365
PRECAUTIONS WHEN WORKING IN HIGH PLACES…365
MOUNTING AND DISMOUNTING…365
NO PEOPLE ON ATTACHMENTS…365
CRUSHING OR CUTTING PREVENTION…365
PREVENTION OF BURNS…366
FIRE PREVENTION…366
ACTION IF FIRE OCCURS…367
PRECAUTIONS FOR ATTACHMENTS…367
UNAUTHORIZED MODIFICATION…367
SAFETY AT WORKSITE…367
WORKING ON LOOSE GROUND…368
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES…368
ENSURE GOOD VISIBILITY…368
VENTILATION FOR ENCLOSED AREAS…369
CHECKING SIGNALMAN'S SIGNALS AND SIGNS…369
BE CAREFUL ABOUT ASBESTOS DUST…369
MAGNETIC SEPARATOR…370
PRECAUTIONS FOR OPERATION…371
STARTING ENGINE…371
CHECKS BEFORE STARTING ENGINE…371
PRECAUTIONS WHEN STARTING…371
PRECAUTIONS IN COLD AREAS…371
OPERATION…373
CHECK BEFORE OPERATION…373
PRECAUTIONS WHEN CHANGING DIRECTION…373
PRECAUTIONS WHEN TRAVELING…373
TRAVELING ON SLOPES…374
OPERATIONS ON SLOPES…374
PRECAUTIONS WHILE IN OPERATION…374
OPERATE CAREFULLY ON SNOW…374
PARKING MACHINE…375
CRUSHING OPERATION…376
CHECKS AROUND MACHINE…376
TURN MODE SELECTOR SWITCH TO WORK POSITION…376
ENSURE SAFETY WHILE OPERATING IN TANDEM WITH HYDRAULIC EXCAVATOR…377
CHECKS OF CRUSHER BEFORE STARTING OPERATION…377
PRECAUTIONS FOR CRUSHING WORK…377
EMERGENCY STOP TO WARD OFF DANGERS WHILE IN CRUSHING WORK…378
REMOVE FOREIGN MATERIAL FROM INSIDE CRUSHER…378
TRANSPORTATION…379
LOADING AND UNLOADING…379
SHIPPING…379
BATTERY…380
BATTERY HAZARD PREVENTION…380
STARTING WITH BOOSTER CABLE…381
TOWING…382
WHEN TOWING…382
PRECAUTIONS FOR MAINTENANCE…383
WARNING TAG…383
KEEP WORK PLACE CLEAN AND TIDY…383
APPOINT LEADER WHEN WORKING WITH OTHERS…383
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE…383
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…384
PRECAUTIONS FOR CONVEYOR MAINTENANCE…384
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE OF FEEDER, CRUSHER…385
PROPER TOOLS…385
PERSONNEL…385
PRECAUTIONS WHEN MOUNTING, DISMANTLING AND STORING ATTACHMENTS…385
PRECAUTIONS FOR WORK UNDER MACHINE…385
NOISE…386
PRECAUTIONS WHEN USING HAMMER…386
REPAIR WELDING…386
REMOVING BATTERY TERMINAL…386
PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…386
DO NOT DISASSEMBLE RECOIL SPRING…387
PRECAUTIONS WITH HIGH-PRESSURE OIL…388
HANDLING HIGH-PRESSURE HOSES…388
WASTE MATERIAL…388
COMPRESSED AIR…388
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…389
OPERATION…390
GENERAL VIEW…391
GENERAL VIEW OF MACHINE…391
GENERAL VIEW OF CONTROLS AND GAUGES…392
EXPLANATION OF COMPONENTS…396
MACHINE MONITOR…396
SWITCHES…421
CONTROL LEVERS…430
OPTION-RELATED SWITCHES…431
CAP, COVER WITH LOCK…433
REVOLVING WARNING LAMP…435
ELECTRIC POWER TAKEOFF…436
FUSIBLE LINK…438
CONTROLLERS…438
FUSE…438
TOOL BOX…439
OPERATION…440
CHECK BEFORE STARTING ENGINE…440
STARTING ENGINE…459
OPERATIONS AND CHECKS AFTER STARTING ENGINE…463
STOPPING ENGINE…468
CHECK AFTER STOPPING ENGINE…468
MACHINE OPERATION…469
STEERING MACHINE…475
OPERATION OF WORK EQUIPMENT…477
CHECK AND CONFIRMATION OF JAW CRUSHER AFTER WORK…486
CHECK AFTER FINISHING WORK…486
LOCKING…487
RUN-IN OPERATION OF JAW CRUSHER…488
PRECAUTIONS WHEN OPERATING JAW CRUSHER…490
EFFICIENT USE OF JAW CRUSHER…494
SCOPE OF WORKS USING MOBILE CRUSHER…500
PROHIBITIONS FOR OPERATION…508
PRECAUTIONS WHEN TRAVELING UP OR DOWNHILLS…510
TRANSPORTATION…511
TRANSPORTATION PROCEDURE…511
LOADING, UNLOADING WORK…511
LIFTING MACHINE…517
COLD WEATHER OPERATION…518
PRECAUTIONS FOR LOW TEMPERATURE…518
AFTER COMPLETION OF WORK…520
AFTER COLD WEATHER…520
LONG-TERM STORAGE…521
BEFORE STORAGE…521
DURING STORAGE…521
AFTER STORAGE…521
STARTING MACHINE AFTER LONG-TERM STORAGE…521
TROUBLESHOOTING…522
AFTER RUNNING OUT OF FUEL…522
PHENOMENA THAT ARE NOT FAILURES…522
METHOD OF TOWING MACHINE…523
IF BATTERY IS DISCHARGED…524
OTHER TROUBLE…527
MAINTENANCE…536
GUIDE TO MAINTENANCE…537
OUTLINE OF SERVICE…539
HANDLING AND PERFORMANCE OF OIL CLINIC FOR OIL, FUEL, COOLANT…539
RELATING TO ELECTRIC SYSTEM…542
OUTLINE OF HYDRAULIC EQUIPMENT…542
AIR-BLEEDING FROM HYDRAULIC CIRCUIT…543
WEAR PARTS…544
WEAR PARTS LIST…544
JAW CRUSHER RELATED PARTS…545
PRIMARY CONVEYOR RELATED PARTS…547
RECOMMENDED FUEL, COOLANT AND LUBRICANTS…548
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN…550
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…551
CRUSHER ACCESSORY TOOLS…551
TORQUE LIST…553
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…554
SAFETY CRITICAL PARTS…554
MAINTENANCE SCHEDULE CHART…555
MAINTENANCE SCHEDULE CHART…555
SERVICE PROCEDURE…557
INITIAL 250 HOURS SERVICE (FIRST MAINTENANCE FOR NEW MACHINE ONLY)…557
INITIAL 1000 HOURS SERVICE (FIRST MAINTENANCE FOR NEW MACHINE ONLY)…557
WHEN REQUIRED…558
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…558
CLEAN INSIDE OF COOLING SYSTEM…563
CHECK AND TIGHTEN TRACK SHOE BOLT…566
CHECK AND ADJUST TRACK TENSION…567
INSPECTION OF ELECTRIC HEATER…569
CHECK AND ADJUSTMENT OF JAW CRUSHER…570
CHECK AND ADJUSTMENT OF PRIMARY CONVEYOR…592
INSPECTION AND MAINTENANCE OF MAGNETIC SEPARATOR…596
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT…599
CHECK BEFORE STARTING…601
EVERY 10 HOURS SERVICE…602
GREASING CRUSHER BEARING SEAT…602
GREASING CRUSHER LINK…602
EVERY 100 HOURS SERVICE…603
GREASING CRUSHER LOCK CYLINDER SECURING POINT…603
GREASING PRIMARY CONVEYOR…604
EVERY 250 HOURS SERVICE…605
CHECK LEVEL OF BATTERY ELECTROLYTE…605
CHECK AND ADJUSTMENT OF JAW CRUSHER V-BELT…608
CHECK OF OIL LEVEL IN CRUSHER MOTOR BEARING CASE AND ADDING OIL…608
EVERY 500 HOURS SERVICE…609
REPLACE FUEL FILTER CARTRIDGE…609
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…610
CLEAN, INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS…611
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…612
REPLACE HYDRAULIC TANK BREATHER ELEMENT…613
EVERY 1000 HOURS SERVICE…614
CHANGE OF OIL IN CRUSHER MOTOR BEARING CASE…614
CHANGE OF OIL IN GRIZZLY FEEDER VIBRATOR CASE…615
CHANGE OIL IN DAMPER CASE…616
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…616
CHECK PLAY OF TURBOCHARGER ROTOR…616
CHECK AND REPLACE OF FAN BELT TENSION…616
REPLACE HYDRAULIC FILTER ELEMENT…617
EVERY 2000 HOURS SERVICE…618
CHANGE OIL IN FINAL DRIVE CASE…618
CLEAN HYDRAULIC TANK STRAINER…619
CLEAN, CHECK TURBOCHARGER…619
CHECK ALTERNATOR, STARTING MOTOR…619
CHECK ENGINE VALVE CLEARANCE, ADJUST…619
CHECK VIBRATION DAMPER…619
EVERY 4000 HOURS SERVICE…620
CHECK WATER PUMP…620
EVERY 5000 HOURS SERVICE…621
CHANGE OIL IN HYDRAULIC TANK AND CLEAN STRAINER…621
SPECIFICATIONS…622
SPECIFICATIONS…623
ATTACHMENTS, OPTIONS…625
GENERAL PRECAUTIONS…626
PRECAUTIONS RELATED TO SAFETY…626
ATTACHMENTS, OPTIONS…627
ATTACHMENTS, OPTIONS CHART…627
METHOD FOR CONNECTING HYDRAULIC HOSES FOR OPTIONS…627
RADIO CONTROL UNIT…628
ON USE OF RADIO CONTROL UNIT…628
DIRECTIONS FOR USE…631
REMOTE CONTROL OPERATION…635
MUCK DISCHARGE CONVEYOR…643
PROCEDURE FOR RAISING (BENDING) MUCK DISCHARGE CONVEYOR…643
PROCEDURE FOR LOWERING MUCK DISCHARGE CONVEYOR…644
GREASING MUCK DISCHARGE CONVEYOR…647
CHECK AND ADJUSTMENT OF MUCK DISCHARGE CONVEYOR…648
FAILURES AND CORRECTIVE ACTIONS…650
WEARING PARTS…652
SPECIFICATIONS…653
M-TYPE CHUTE…654
METHOD OF OPERATION…654
BELT CONVEYOR PROTECTIVE PLATE…655
GRIZZLY BAR OPENING…657
HANDLING MACHINES EQUIPPED WITH KOMTRAX…658
BASIC PRECAUTIONS…658
MACHINES THAT CAN INSTALL ATTACHMENTS…659
NAMES OF CONTROL PANEL SWITCHES…659
HYDRAULIC POWER TAKEOFF PORT…659
ATTACHMENT PORT…660
PROCEDURE FOR CONNECTING OPTIONS…661
HYDRAULIC VIBRATORY SIEVE…663
SPECIFICATION…663
GENERAL VIEW…663
CAUTIONS TO BE NOTED FOR SAFETY…664
CONNECTING METHOD TO MACHINE BODY…664
PRECAUTIONS DURING OPERATION…664
HYDRAULIC SECONDARY CONVEYOR…665
SPECIFICATIONS…665
GENERAL VIEW…665
INCLINED LEG CONNECTING METHOD…667
LIFTING METHOD…668
CONNECTING METHOD TO MACHINE BODY…668
PRECAUTIONS ON OPERATION…668
INSPECTION, MAINTENANCE AND ADJUSTMENT…669
TROUBLES AND CORRECTIVE ACTIONS…671
CONSUMABLE PARTS OF HYDRAULIC SECONDARY CONVEYOR…673
SPRINKLER…675
EXPLANATIONS FOR COMPONENT PARTS…675
HOW TO USE SPRINKLER…676
INSPECTION AND MAINTENANCE…679
INDEX…681
TEN00168-03 – Mobile Crusher GALEO BR380JG-1E0 Operation & Maintenance Manual (SN2001&up)…685
COVER…685
FOREWORD…686
BEFORE READING THIS MA…687
SAFETY INFORMATION…688
INTRODUCTION…689
INTRODUCTION…689
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE…689
NECESSARY INFORMATION…690
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…690
EPA REGULATIONS, ENGINE NUMBER PLATE…690
POSITION OF SERVICE METER…691
TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR…691
CONTENTS…692
SAFETY…696
SAFETY…697
SAFETY LABELS…700
POSITIONS OF SAFETY PICTOGRAMS…701
SAFETY LABELS…702
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…712
PRECAUTIONS BEFORE STARTING OPERATION…712
PREPARATIONS FOR SAFE OPERATION…712
FIRE PREVENTION…714
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…715
DO NOT GET CAUGHT IN WORK EQUIPMENT…717
UNAUTHORIZED MODIFICATION…717
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…717
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…717
PRECAUTIONS FOR OPERATION…718
PRECAUTIONS FOR JOBSITE…718
STARTING ENGINE…720
OPERATION…723
CRUSHING OPERATION…726
TRANSPORTATION…729
TOWING…730
MAGNETIC SEPARATOR…731
PRECAUTIONS FOR MAINTENANCE…732
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…732
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…736
OPERATION…742
GENERAL VIEW…743
GENERAL VIEW OF MACHINE…743
GENERAL VIEW OF CONTROLS AND GAUGES…744
EXPLANATION OF COMPONENTS…748
MACHINE MONITOR…748
SWITCHES…775
CONTROL LEVERS…787
OPTION-RELATED SWITCHES…788
CAP, COVER WITH LOCK…789
REVOLVING WARNING LAMP…791
ELECTRIC POWER TAKEOFF…792
FUSIBLE LINK…794
CONTROLLERS…794
FUSE…794
TOOL BOX…795
OPERATION…796
CHECK BEFORE STARTING ENGINE…796
STARTING ENGINE…821
OPERATIONS AND CHECKS AFTER STARTING ENGINE…823
STOPPING ENGINE…829
CHECK AFTER STOPPING ENGINE…829
MACHINE OPERATION…830
STEERING MACHINE…835
OPERATION OF WORK EQUIPMENT…837
CHECK AND CONFIRMATION OF JAW CRUSHER AFTER WORK…845
CHECK AFTER FINISHING WORK…845
LOCKING…846
RUN-IN OPERATION OF JAW CRUSHER…847
PRECAUTIONS WHEN OPERATING JAW CRUSHER…849
EFFICIENT USE OF JAW CRUSHER…853
SCOPE OF WORKS USING MOBILE CRUSHER…860
PROHIBITIONS FOR OPERATION…868
PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS…871
TRANSPORTATION…872
TRANSPORTATION PROCEDURE…872
LOADING, UNLOADING WORK…873
LIFTING MACHINE…880
COLD WEATHER OPERATION…881
PRECAUTIONS FOR LOW TEMPERATURE…881
AFTER COMPLETION OF WORK…883
AFTER COLD WEATHER…883
LONG-TERM STORAGE…884
BEFORE STORAGE…884
DURING STORAGE…884
AFTER STORAGE…884
STARTING MACHINE AFTER LONG-TERM STORAGE…884
TROUBLESHOOTING…885
AFTER RUNNING OUT OF FUEL…885
PHENOMENA THAT ARE NOT FAILURES…885
METHOD OF TOWING MACHINE…886
IF BATTERY IS DISCHARGED…887
OTHER TROUBLE…891
MAINTENANCE…900
GUIDE TO MAINTENANCE…901
OUTLINE OF SERVICE…903
HANDLING AND PERFORMANCE OF OIL CLINIC FOR OIL, FUEL, COOLANT…903
RELATING TO ELECTRIC SYSTEM…907
OUTLINE OF HYDRAULIC EQUIPMENT…907
AIR-BLEEDING FROM HYDRAULIC CIRCUIT…908
WEAR PARTS…910
WEAR PARTS LIST…910
JAW CRUSHER RELATED PARTS…911
PRIMARY CONVEYOR RELATED PARTS…913
RECOMMENDED FUEL, COOLANT AND LUBRICANTS…914
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…916
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…917
TORQUE LIST…917
TOOLS TO USE CHECK AND MAINTENANCE CRUSHER…918
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…920
SAFETY CRITICAL PARTS…920
MAINTENANCE SCHEDULE CHART…921
MAINTENANCE SCHEDULE CHART…921
SERVICE PROCEDURE…923
INITIAL 250 HOURS SERVICE (FIRST MAINTENANCE FOR NEW MACHINE ONLY)…923
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)…923
WHEN REQUIRED…924
CHECK BEFORE STARTING…986
EVERY 10 HOURS SERVICE…987
EVERY 100 HOURS SERVICE…988
EVERY 250 HOURS SERVICE…989
EVERY 500 HOURS SERVICE…993
EVERY 1000 HOURS SERVICE…1001
EVERY 2000 HOURS SERVICE…1008
EVERY 4000 HOURS SERVICE…1010
EVERY 5000 HOURS SERVICE…1012
EVERY 8000 HOURS SERVICE…1013
SPECIFICATIONS…1014
SPECIFICATIONS…1015
ATTACHMENTS, OPTIONS…1018
GENERAL PRECAUTIONS…1019
PRECAUTIONS RELATED TO SAFETY…1019
ATTACHMENTS, OPTIONS…1020
ATTACHMENTS, OPTIONS CHART…1020
METHOD FOR CONNECTING HYDRAULIC HOSES FOR OPTIONS…1020
RADIO CONTROL UNIT…1021
ON USE OF RADIO CONTROL UNIT…1021
DIRECTIONS FOR USE…1024
RADIO CONTROL OPERATION…1030
MUCK DISCHARGE CONVEYOR…1043
PROCEDURE FOR RAISING (BENDING) MUCK DISCHARGE CONVEYOR…1043
PROCEDURE FOR LOWERING (EXTEND) MUCK DISCHARGE CONVEYOR…1045
GREASING MUCK DISCHARGE CONVEYOR…1048
CHECK AND ADJUSTMENT OF MUCK DISCHARGE CONVEYOR…1049
FAILURES AND CORRECTIVE ACTIONS…1051
WEARING PARTS…1053
SPECIFICATIONS…1054
M-TYPE CHUTE…1055
METHOD OF OPERATION…1055
GRIZZLY BAR OPENING…1056
HANDLING MACHINES EQUIPPED WITH KOMTRAX…1057
BASIC PRECAUTIONS…1057
MACHINES THAT CAN INSTALL ATTACHMENTS…1058
NAMES OF CONTROL PANEL SWITCHES…1058
HYDRAULIC POWER TAKEOFF PORT…1059
ATTACHMENT PORT…1060
PROCEDURE FOR CONNECTING OPTIONS…1062
SPRINKLER…1063
EXPLANATIONS FOR COMPONENT PARTS…1063
HOW TO USE SPRINKLER…1064
INSPECTION AND MAINTENANCE…1067
ADDITIONAL SPRINKLER NOZZLE…1068
INDEX…1072
TEN00358-01 – Mobile Crusher GALEO BR380JG-1E0 Operation & Maintenance Manual (SN2609&up)…1076
COVER…1076
FOREWORD…1077
BEFORE READING THIS MANUAL…1078
SAFETY INFORMATION…1079
INTRODUCTION…1080
INTRODUCTION…1080
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE…1080
NECESSARY INFORMATION…1081
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…1081
EPA REGULATIONS, ENGINE NUMBER PLATE…1081
POSITION OF SERVICE METER…1082
TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR…1082
CONTENTS…1083
SAFETY…1087
SAFETY…1088
SAFETY LABELS…1091
POSITIONS OF SAFETY PICTOGRAMS…1092
SAFETY LABELS…1093
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…1103
PRECAUTIONS BEFORE STARTING OPERATION…1103
PREPARATIONS FOR SAFE OPERATION…1103
FIRE PREVENTION…1105
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…1106
DO NOT GET CAUGHT IN WORK EQUIPMENT…1108
UNAUTHORIZED MODIFICATION…1108
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…1108
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…1108
PRECAUTIONS FOR OPERATION…1109
PRECAUTIONS FOR JOBSITE…1109
STARTING ENGINE…1111
OPERATION…1114
CRUSHING OPERATION…1117
TRANSPORTATION…1120
TOWING…1121
MAGNETIC SEPARATOR…1122
PRECAUTIONS FOR MAINTENANCE…1123
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…1123
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…1127
OPERATION…1133
GENERAL VIEW…1134
GENERAL VIEW OF MACHINE…1134
GENERAL VIEW OF CONTROLS AND GAUGES…1135
EXPLANATION OF COMPONENTS…1139
MACHINE MONITOR…1139
SWITCHES…1166
CONTROL LEVERS…1178
OPTION-RELATED SWITCHES…1179
CAP, COVER WITH LOCK…1180
REVOLVING WARNING LAMP…1182
ELECTRIC POWER TAKEOFF…1183
FUSIBLE LINK…1185
CONTROLLERS…1185
FUSE…1185
TOOL BOX…1186
OPERATION…1187
CHECK BEFORE STARTING ENGINE…1187
STARTING ENGINE…1212
OPERATIONS AND CHECKS AFTER STARTING ENGINE…1214
STOPPING ENGINE…1220
CHECK AFTER STOPPING ENGINE…1220
MACHINE OPERATION…1221
STEERING MACHINE…1226
OPERATION OF WORK EQUIPMENT…1228
CHECK AND CONFIRMATION OF JAW CRUSHER AFTER WORK…1236
CHECK AFTER FINISHING WORK…1236
LOCKING…1237
RUN-IN OPERATION OF JAW CRUSHER…1238
PRECAUTIONS WHEN OPERATING JAW CRUSHER…1240
EFFICIENT USE OF JAW CRUSHER…1244
SCOPE OF WORKS USING MOBILE CRUSHER…1251
PROHIBITIONS FOR OPERATION…1259
PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS…1262
TRANSPORTATION…1263
TRANSPORTATION PROCEDURE…1263
LOADING, UNLOADING WORK…1264
LIFTING MACHINE…1271
COLD WEATHER OPERATION…1272
PRECAUTIONS FOR LOW TEMPERATURE…1272
AFTER COMPLETION OF WORK…1274
AFTER COLD WEATHER…1274
LONG-TERM STORAGE…1275
BEFORE STORAGE…1275
DURING STORAGE…1275
AFTER STORAGE…1275
STARTING MACHINE AFTER LONG-TERM STORAGE…1275
TROUBLESHOOTING…1276
AFTER RUNNING OUT OF FUEL…1276
PHENOMENA THAT ARE NOT FAILURES…1276
METHOD OF TOWING MACHINE…1277
IF BATTERY IS DISCHARGED…1278
OTHER TROUBLE…1282
MAINTENANCE…1291
GUIDE TO MAINTENANCE…1292
OUTLINE OF SERVICE…1294
HANDLING AND PERFORMANCE OF OIL CLINIC FOR OIL, FUEL, COOLANT…1294
RELATING TO ELECTRIC SYSTEM…1298
OUTLINE OF HYDRAULIC EQUIPMENT…1298
AIR-BLEEDING FROM HYDRAULIC CIRCUIT…1299
WEAR PARTS…1301
WEAR PARTS LIST…1301
JAW CRUSHER RELATED PARTS…1302
PRIMARY CONVEYOR RELATED PARTS…1304
RECOMMENDED FUEL, COOLANT AND LUBRICANTS…1305
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…1307
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…1308
TORQUE LIST…1308
TOOLS TO USE CHECK AND MAINTENANCE CRUSHER…1309
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…1311
SAFETY CRITICAL PARTS…1311
MAINTENANCE SCHEDULE CHART…1312
MAINTENANCE SCHEDULE CHART…1312
SERVICE PROCEDURE…1314
INITIAL 250 HOURS SERVICE (FIRST MAINTENANCE FOR NEW MACHINE ONLY)…1314
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)…1314
WHEN REQUIRED…1315
CHECK BEFORE STARTING…1377
EVERY 10 HOURS SERVICE…1378
EVERY 100 HOURS SERVICE…1379
EVERY 250 HOURS SERVICE…1380
EVERY 500 HOURS SERVICE…1384
EVERY 1000 HOURS SERVICE…1392
EVERY 2000 HOURS SERVICE…1398
EVERY 4000 HOURS SERVICE…1400
EVERY 5000 HOURS SERVICE…1402
EVERY 8000 HOURS SERVICE…1403
SPECIFICATIONS…1405
SPECIFICATIONS…1406
ATTACHMENTS, OPTIONS…1409
GENERAL PRECAUTIONS…1410
PRECAUTIONS RELATED TO SAFETY…1410
ATTACHMENTS, OPTIONS…1411
ATTACHMENTS, OPTIONS CHART…1411
METHOD FOR CONNECTING HYDRAULIC HOSES FOR OPTIONS…1411
RADIO CONTROL UNIT…1412
ON USE OF RADIO CONTROL UNIT…1412
DIRECTIONS FOR USE…1415
RADIO CONTROL OPERATION…1421
MUCK DISCHARGE CONVEYOR…1434
PROCEDURE FOR RAISING (BENDING) MUCK DISCHARGE CONVEYOR…1434
PROCEDURE FOR LOWERING (EXTEND) MUCK DISCHARGE CONVEYOR…1436
GREASING MUCK DISCHARGE CONVEYOR…1439
CHECK AND ADJUSTMENT OF MUCK DISCHARGE CONVEYOR…1440
FAILURES AND CORRECTIVE ACTIONS…1442
WEARING PARTS…1444
SPECIFICATIONS…1445
M-TYPE CHUTE…1446
METHOD OF OPERATION…1446
GRIZZLY BAR OPENING…1447
HANDLING MACHINES EQUIPPED WITH KOMTRAX…1448
BASIC PRECAUTIONS…1448
MACHINES THAT CAN INSTALL ATTACHMENTS…1449
NAMES OF CONTROL PANEL SWITCHES…1449
HYDRAULIC POWER TAKEOFF PORT…1450
ATTACHMENT PORT…1451
PROCEDURE FOR CONNECTING OPTIONS…1453
SPRINKLER…1454
EXPLANATIONS FOR COMPONENT PARTS…1454
HOW TO USE SPRINKLER…1455
INSPECTION AND MAINTENANCE…1458
ADDITIONAL SPRINKLER NOZZLE…1459
INDEX…1463
TEN00476-01 – Mobile Crusher GALEO BR380JG-1E0 Operation & Maintenance Manual (SN2621&up)…1467
COVER…1467
FOREWORD…1468
BEFORE READING THIS MANUAL…1469
SAFETY INFORMATION…1470
INTRODUCTION…1471
INTRODUCTION…1471
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE…1471
NECESSARY INFORMATION…1472
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…1472
EPA REGULATIONS, ENGINE NUMBER PLATE…1472
POSITION OF SERVICE METER…1473
TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR…1473
CONTENTS…1474
SAFETY…1478
SAFETY…1479
SAFETY LABELS…1482
POSITIONS OF SAFETY PICTOGRAMS…1483
SAFETY LABELS…1484
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…1494
PRECAUTIONS BEFORE STARTING OPERATION…1494
PREPARATIONS FOR SAFE OPERATION…1494
FIRE PREVENTION…1496
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…1497
DO NOT GET CAUGHT IN WORK EQUIPMENT…1499
UNAUTHORIZED MODIFICATION…1499
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…1499
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…1499
PRECAUTIONS FOR OPERATION…1500
PRECAUTIONS FOR JOBSITE…1500
STARTING ENGINE…1502
OPERATION…1505
CRUSHING OPERATION…1508
TRANSPORTATION…1511
TOWING…1512
MAGNETIC SEPARATOR…1513
PRECAUTIONS FOR MAINTENANCE…1514
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…1514
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…1518
OPERATION…1524
GENERAL VIEW…1525
GENERAL VIEW OF MACHINE…1525
GENERAL VIEW OF CONTROLS AND GAUGES…1526
EXPLANATION OF COMPONENTS…1530
MACHINE MONITOR…1530
SWITCHES…1557
CONTROL LEVERS…1569
OPTION-RELATED SWITCHES…1570
CAP, COVER WITH LOCK…1571
REVOLVING WARNING LAMP…1573
ELECTRIC POWER TAKEOFF…1574
FUSIBLE LINK…1576
CONTROLLERS…1576
FUSE…1576
TOOL BOX…1577
OPERATION…1578
CHECK BEFORE STARTING ENGINE…1578
STARTING ENGINE…1603
OPERATIONS AND CHECKS AFTER STARTING ENGINE…1605
STOPPING ENGINE…1611
CHECK AFTER STOPPING ENGINE…1611
MACHINE OPERATION…1612
STEERING MACHINE…1617
OPERATION OF WORK EQUIPMENT…1619
CHECK AND CONFIRMATION OF JAW CRUSHER AFTER WORK…1627
CHECK AFTER FINISHING WORK…1627
LOCKING…1628
RUN-IN OPERATION OF JAW CRUSHER…1629
PRECAUTIONS WHEN OPERATING JAW CRUSHER…1631
EFFICIENT USE OF JAW CRUSHER…1635
SCOPE OF WORKS USING MOBILE CRUSHER…1642
PROHIBITIONS FOR OPERATION…1650
PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS…1653
TRANSPORTATION…1654
TRANSPORTATION PROCEDURE…1654
LOADING, UNLOADING WORK…1655
LIFTING MACHINE…1662
COLD WEATHER OPERATION…1663
PRECAUTIONS FOR LOW TEMPERATURE…1663
AFTER COMPLETION OF WORK…1665
AFTER COLD WEATHER…1665
LONG-TERM STORAGE…1666
BEFORE STORAGE…1666
DURING STORAGE…1666
AFTER STORAGE…1666
STARTING MACHINE AFTER LONG-TERM STORAGE…1666
TROUBLESHOOTING…1667
AFTER RUNNING OUT OF FUEL…1667
PHENOMENA THAT ARE NOT FAILURES…1667
METHOD OF TOWING MACHINE…1668
IF BATTERY IS DISCHARGED…1669
OTHER TROUBLE…1673
MAINTENANCE…1682
GUIDE TO MAINTENANCE…1683
OUTLINE OF SERVICE…1685
HANDLING AND PERFORMANCE OF OIL CLINIC FOR OIL, FUEL, COOLANT…1685
RELATING TO ELECTRIC SYSTEM…1689
OUTLINE OF HYDRAULIC EQUIPMENT…1689
AIR-BLEEDING FROM HYDRAULIC CIRCUIT…1690
WEAR PARTS…1692
WEAR PARTS LIST…1692
JAW CRUSHER RELATED PARTS…1693
PRIMARY CONVEYOR RELATED PARTS…1695
RECOMMENDED FUEL, COOLANT AND LUBRICANTS…1696
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…1698
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…1699
TORQUE LIST…1699
TOOLS TO USE CHECK AND MAINTENANCE CRUSHER…1700
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…1702
SAFETY CRITICAL PARTS…1702
MAINTENANCE SCHEDULE CHART…1703
MAINTENANCE SCHEDULE CHART…1703
SERVICE PROCEDURE…1705
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…1705
INITIAL 500 HOURS SERVICE (ONLY AFTER THE FIRST 500 HOURS)…1705
WHEN REQUIRED…1706
CHECK BEFORE STARTING…1768
EVERY 10 HOURS SERVICE…1769
EVERY 100 HOURS SERVICE…1770
EVERY 250 HOURS SERVICE…1771
EVERY 500 HOURS SERVICE…1775
EVERY 1000 HOURS SERVICE…1783
EVERY 2000 HOURS SERVICE…1789
EVERY 4000 HOURS SERVICE…1791
EVERY 5000 HOURS SERVICE…1793
EVERY 8000 HOURS SERVICE…1794
SPECIFICCATIONS…1796
SPECIFICATIONS…1797
ATTACHMENTS, OPTIONS…1800
GENERAL PRECAUTIONS…1801
PRECAUTIONS RELATED TO SAFETY…1801
ATTACHMENTS, OPTIONS…1802
ATTACHMENTS, OPTIONS CHART…1802
METHOD FOR CONNECTING HYDRAULIC HOSES FOR OPTIONS…1802
RADIO CONTROL UNIT…1803
ON USE OF RADIO CONTROL UNIT…1803
DIRECTIONS FOR USE…1806
RADIO CONTROL OPERATION…1812
MUCK DISCHARGE CONVEYOR…1825
PROCEDURE FOR RAISING (BENDING) MUCK DISCHARGE CONVEYOR…1825
PROCEDURE FOR LOWERING (EXTEND) MUCK DISCHARGE CONVEYOR…1827
GREASING MUCK DISCHARGE CONVEYOR…1830
CHECK AND ADJUSTMENT OF MUCK DISCHARGE CONVEYOR…1831
FAILURES AND CORRECTIVE ACTIONS…1833
WEARING PARTS…1835
SPECIFICATIONS…1836
M-TYPE CHUTE…1837
METHOD OF OPERATION…1837
GRIZZLY BAR OPENING…1838
HANDLING MACHINES EQUIPPED WITH KOMTRAX…1839
BASIC PRECAUTIONS…1839
MACHINES THAT CAN INSTALL ATTACHMENTS…1840
NAMES OF CONTROL PANEL SWITCHES…1840
HYDRAULIC POWER TAKEOFF PORT…1841
ATTACHMENT PORT…1842
PROCEDURE FOR CONNECTING OPTIONS…1844
SPRINKLER…1845
EXPLANATIONS FOR COMPONENT PARTS…1845
HOW TO USE SPRINKLER…1846
INSPECTION AND MAINTENANCE…1849
ADDITIONAL SPRINKLER NOZZLE…1850
INDEX…1854

Komatsu Mobile Crusher GALEO BR380JG Operation & Maintenance Manuals

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