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
