Komatsu Bulldozer D37EX-23 D37PX-23 D39EX-23 D39PX-23 Shop Manual SEN06061-11 PDF

Description

Komatsu Bulldozer D37EX-23 D37PX-23 D39EX-23 D39PX-23 Shop Manual SEN06061-11 – PDF DOWNLOAD

FILE DETAILS:

Komatsu Bulldozer D37EX-23 D37PX-23 D39EX-23 D39PX-23 Shop Manual SEN06061-11 – PDF DOWNLOAD

Language : English
Pages :1594
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu Bulldozer D37EX-23 D37PX-23 D39EX-23 D39PX-23 Shop Manual SEN06061-11 – PDF DOWNLOAD

SERIAL NUMBERS
D37EX-80001
D37PX-80001
D39EX-90001
D39PX-90001
and up

General precautions

Inappropriate handling causes an extreme danger. Read and understand what is described in the operation and maintenance manual before operating the machine. Read and understand what is described in this manual before starting the work. •

• Before performing any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the operation and maintenance manual.
• Locate a place in the repair workshop to keep the tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
• When performing any work, always wear the safety shoes and helmet. Do not wear loose work cloths, or clothes with buttons missing. 1. Always wear the protective eyeglasses when hitting parts with a hammer. 2. Always wear the protective eyeglasses when grinding parts with a grinder, etc.
• When performing any work with 2 or more workers, always agree on the working procedure before starting. While working, always keep conversations of the work between your fellow workers and your self on any step of the work. During the work, hang the warning tag of “UNDER WORKING” in the operator’s compartment.
• Only qualified workers must perform the work and operation which require license or qualification.
• Keep the tools in good condition. And learn the correct way to use the tools, and use the proper ones among them. Before starting the work, thoroughly check the tools, lift truck, service vehicle, etc.
• If welding repairs is required, always have a trained and experienced welder with good knowledge of welding perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap, etc
• Before starting work, warm up your body thoroughly to start work under good condition.
• Avoid continuing work for long hours and take rests with proper intervals to keep your body in good condition. Take a rest in a specified safe place.

TABLE OF CONTENTS:

Komatsu Bulldozer D37EX-23 D37PX-23 D39EX-23 D39PX-23 Shop Manual SEN06061-11 – PDF DOWNLOAD

SERIAL NUMBERS
D37EX-80001
D37PX-80001
D39EX-90001
D39PX-90001
and up

Cover 1
00 Index and foreword 3
Index 4
Foreword, safety and general information 16
Important safety notice 16
How to read the shop manual 23
Explanation of terms for maintenance standard 25
Handling equipment of fuel system devices 27
Handling of intake system parts 28
Handling of hydraulic equipment 29
Method of disconnecting and connecting of push-pull type coupler 31
Handling of electrical equipment 34
How to read electric wire code 42
Precautions when performing operation 45
Practical use of KOMTRAX 50
Standard tightening torque table 51
List of abbreviation 57
Conversion table 62
01 Specification 67
Table of contents 68
Specifications 69
Specification drawing 69
Specifications 73
Weight table 93
Table of fuel, coolant, and lubricants 101
10 Structure and function 103
Table of contents 104
Engine and cooling system 105
Engine related parts 105
Variable flow turbocharger 107
EGR system piping drawing 111
EGR system circuit diagram 113
EGR valve 114
EGR cooler 116
KCCV layout drawing 118
KCCV ventilator 120
KDOC muffler 124
Cooling system 126
Cooling fan motor 128
Oil cooler bypass and HST charge safety valve 136
Power train 143
Power train system 143
Damper 146
Hydraulic component layout of HST 147
Steering and brake control 148
HST pump 150
HST motor 164
Charge pump 180
Solenoid valve 181
Final drive 191
Undercarriage and frame 195
Main frame 195
Track frame and idler cushion 196
Hydraulic system 198
Hydraulic component layout 198
Work equipment control system 200
Hydraulic tank 202
CLSS 204
Work equipment and cooling fan pump 207
Control valve 218
Ripper PPC valve 235
Angle control EPC valve 240
Accumulator 245
Work equipment 247
Blade 247
Ripper 248
Piston valve 249
Cab and its attachments 250
ROPS cab 250
Cab mount 252
Electrical system 253
Electrical control system 253
Machine monitor system 275
KOMTRAX system 297
System component parts 300
Sensor 317
20 Standard value tables 333
Table of contents 334
Standard service value table 335
Standard value table for engine 335
Standard value table for machine 336
Standard value table for electrical system 349
30 Testing and adjusting 357
Table of contents 358
Related information on testing and adjusting 360
Tools for testing and adjusting 360
Sketch of tools for testing and adjusting 363
Engine and cooling system 366
Testing engine speed 366
Testing exhaust gas color 368
Testing and adjusting valve clearance 370
Testing compression pressure 372
Testing blowby pressure 375
Testing engine oil pressure 376
Visual check inside of EGR valve 377
Clean inside of EGR valve 378
Testing fuel pressure 381
Testing fuel return rate and leakage 382
Bleeding air from fuel system 385
Testing fuel circuit for leakage 386
Handling cylinder cutout mode operation 387
Handling no-injection cranking operation 388
Testing of installed condition of cylinder heads and manifolds 389
Testing engine piping for damage and looseness 390
Check alternator and air conditioner compressor belt, replace 391
Check auto-tensioner, replace 393
Writing compensation values at replacement of injector and engine controller 395
Power train 399
Testing and adjusting HST oil pressure 399
Testing outlet pressure of solenoid valve 404
Testing if machine travels straight 408
Simple test procedure for brake performance 409
Adjusting deceleration/brake pedal 410
Adjusting parking brake lever 413
Move disabled machine urgently 415
Undercarriage and frame 418
Adjusting idler clearance 418
Checking sprocket wear 419
Testing and adjusting track tension 420
Hydraulic system 421
Releasing remaining pressure in work equipment cylinder 421
Testing and adjusting work equipment oil pressure 422
Testing source pressure of control circuit 424
Testing outlet pressure of work equipment EPC valve and fan EPC valve 425
Isolating the parts causing hydraulic drift in blade and ripper 427
Testing internal oil leakage of work equipment cylinder 428
Testing fan speed 430
Testing fan circuit oil pressure 431
Bleeding air from hydraulic circuit 432
Work equipment 433
Adjusting work equipment lock lever 433
Adjusting play of blade center ball 435
Testing and adjusting play of blade electric lever 436
Electrical system 444
Special functions of machine monitor 444
Adjustment method when HST controller has been replaced 516
Adjustment method when electric or hydraulic device has been replaced 519
Adjusting rearview camera angle 520
Testing windshield wiper operation 521
Replacing windshield wiper blade 522
Handling voltage circuit of engine controller 523
Handling battery disconnect switch 524
Testing diodes 525
Pm clinic 526
Pm Clinic service 526
Pm Clinic service (D39EX-23,D39PX-23) 528
Pm Clinic check sheet 530
Pm Clinic check sheet (D39EX-23,D39PX-23) 539
40 Troubleshooting 549
Table of contents 550
Related information on troubleshooting 557
Troubleshooting points 557
Sequence of events in troubleshooting 559
Checks before troubleshooting 561
Inspection procedure before troubleshooting 563
Preparation for troubleshooting of electrical system 581
Classification and procedures for troubleshooting 584
Symptom and troubleshooting numbers 586
Information in troubleshooting table 588
Troubleshooting method for open circuit in wiring harness of pressure sensor system 590
Connector list and layout 592
Connector contact identification 603
T-branch box and T-branch adapter table 642
Fuse location table 647
Failure codes table 652
Troubleshooting by failure code (Display of code) 661
Failure code [6091NX] HST Oil Filter Clogging 661
Failure code [989L00] Engine Controller Lock Caution 1 663
Failure code [989M00] Engine Controller Lock Caution 2 664
Failure code [989N00] Engine Controller Lock Caution 3 665
Failure code [AA10NX] Air Cleaner Clogging 666
Failure code [AB00KE] Charge Voltage Low 668
Failure code [B@BAZG] Eng Oil Press Low 670
Failure code [B@BCNS] Eng Water Overheat 671
Failure code [B@CRNS] HST Oil Overheat 672
Failure code [B@CRZG] HST Charge Press Low 673
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 674
Failure code [CA122] Chg Air Press Sensor High Error 675
Failure code [CA123] Chg Air Press Sensor Low Error 677
Failure code [CA131] Throttle Sensor High Error 679
Failure code [CA132] Throttle Sensor Low Error 681
Failure code [CA144] Coolant Temp Sens High Error 683
Failure code [CA145] Coolant Temp Sens Low Error 685
Failure code [CA153] Chg Air Temp Sensor High Error 687
Failure code [CA154] Chg Air Temp Sensor Low Error 689
Failure code [CA187] Sensor 2 Supply Volt Low Error 691
Failure code [CA221] Ambient Press Sensor High Error 693
Failure code [CA222] Ambient Press Sensor Low Error 695
Failure code [CA227] Sensor 2 Supply Volt High Error 697
Failure code [CA234] Eng Overspeed 698
Failure code [CA238] Ne Speed Sensor Supply Volt Error 699
Failure code [CA239] Ne Speed Sens Supply Volt High Error 700
Failure code [CA271] IMV/PCV1 Short Error 701
Failure code [CA272] IMV/PCV1 Open Error 702
Failure code [CA322] Inj #1(L#1) Open/Short Error 703
Failure code [CA324] Inj #3(L#3) Open/Short Error 705
Failure code [CA331] Inj #2(L#2) Open/Short Error 707
Failure code [CA332] Inj #4(L#4) Open/Short Error 709
Failure code [CA343] ECM Critical Internal Failure 711
Failure code [CA351] Injectors Drive Circuit Error 712
Failure code [CA352] Sensor 1 Supply Volt Low Error 713
Failure code [CA356] Mass Air Flow Sensor High Error 715
Failure code [CA357] Mass Air Flow Sensor Low Error 717
Failure code [CA386] Sensor 1 Supply Volt High Error 719
Failure code [CA435] Eng Oil Press Sw Error 720
Failure code [CA441] Battery Voltage Low Error 721
Failure code [CA442] Battery Voltage High Error 723
Failure code [CA449] Rail Press Very High Error 724
Failure code [CA451] Rail Press Sensor High Error 725
Failure code [CA452] Rail Press Sensor Low Error 727
Failure code [CA466] KVGT Motor Driver Position Error 729
Failure code [CA515] Rail Press Sens Sup Volt High Error 731
Failure code [CA516] Rail Press Sens Sup Volt Low Error 733
Failure code [CA553] Rail Press High Error 735
Failure code [CA555] Crankcase Press High Error 1 736
Failure code [CA556] Crankcase Press High Error 2 737
Failure code [CA559] Rail Press Low Error 738
Failure code [CA689] Eng Ne Speed Sensor Error 741
Failure code [CA691] Intake Air Temp Sens High Error 743
Failure code [CA692] Intake Air Temp Sens Low Error 745
Failure code [CA697] ECM Internal Temp Sensor High Error 747
Failure code [CA698] ECM Int Temp Sensor Low Error 748
Failure code [CA731] Eng Bkup Speed Sens Phase Error 749
Failure code [CA778] Eng Bkup Speed Sensor Error 751
Failure code [CA1117] Persistent Data Lost Error 755
Failure code [CA1695] Sensor 5 Supply Volt High Error 756
Failure code [CA1696] Sensor 5 Supply Volt Low Error 757
Failure code [CA1843] Crankcase Press Sens High Error 758
Failure code [CA1844] Crankcase Press Sens Low Error 760
Failure code [CA1896] EGR Valve Stuck Error 762
Failure code [CA1942] Crankcase Press Sens In Range Error 767
Failure code [CA1961] EGR_Motor Driver IC Over Temp Error 768
Failure code [CA2185] Throt Sensor Sup Volt High Error 769
Failure code [CA2186] Throt Sensor Sup Volt Low Error 770
Failure code [CA2249] Rail Press Very Low Error 771
Failure code [CA2272] EGR Valve Pos Sens Low Error 772
Failure code [CA2311] IMV Solenoid Error 774
Failure code [CA2349] EGR Valve Solenoid Open Error 775
Failure code [CA2353] EGR Valve Solenoid Short Error 777
Failure code [CA2357] EGR Valve Servo Error 779
Failure code [CA2555] Grid Htr Relay Volt Low Error 780
Failure code [CA2556] Grid Htr Relay Volt High Error 782
Failure code [CA2765] Inj Trim Data Error 784
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error 785
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error 787
Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error 789
Failure code [CA3918] KVGT Stuck Error 791
Failure code [CA3919] KVGT Motor Driver IC Over Temp Error 792
Failure code [CA3921] KVGT Servo Error 2 793
Failure code [CA3922] KVGT Motor Driver Open Error 794
Failure code [CA3923] KVGT Motor Driver Short Error 796
Failure code [D130KA] Neutral relay Open 798
Failure code [D130KB] Neutral relay Short circuit 800
Failure code [D130KY] Neutral relay: Hot Short 802
Failure code [D19JKZ] Personal Code Relay Abnormality 804
Failure code [D811MC] KOMTRAX Error 807
Failure code [D862KA] GPS Antenna Open Circuit 808
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) 809
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) 811
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) 812
Failure code [DAF0MB] Monitor ROM Abnormality 814
Failure code [DAF0MC] Monitor Error 815
Failure code [DAF8KB] Camera Power Supply Short Circuit 816
Failure code [DAF9KQ] Model Selection Abnormality 817
Failure code [DAFGMC] GPS Module Error 818
Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) 819
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) 821
Failure code [DAFQKR] CAN2 Discon (Monitor) 822
Failure code [DAJ000] HST controller: Abnormality in controller 823
Failure code [DAJ0KQ] HST controller: Type select signal 824
Failure code [DAJ0KT] HST controller: Abnormality in controller 825
Failure code [DAJ0MC] HST Con Error 826
Failure code [DAJ1KK] HST controller: Source voltage low 827
Failure code [DAJ2KK] HST controller: Output voltage low 829
Failure code [DAJ5KK] HST: Sensor volt 5V (0) Out of normal range 831
Failure code [DAJ6KK] HST: Sensor volt 5V (1) Out of normal range 833
Failure code [DAJLKA] Operating Lamp Open Circuit (HST Con) 835
Failure code [DAJLKB] Operating Lamp Short Circuit (HST Con) 837
Failure code [DAJPMA] Inconsistency of Option Selection (HST) 838
Failure code [DAJQKR] CAN2 Discon (HST Con) 839
Failure code [DAJRKR] CAN1 Discon (HST Con) 840
Failure code [DB2QKR] CAN2 Discon (Engine Con) 841
Failure code [DB2RKR] CAN1 Discon (Engine Con) 845
Failure code [DD12KA] Shift up SW: Open 849
Failure code [DD12KB] Shift up SW: Short Circuit 851
Failure code [DD13KA] Shift down SW: Open 853
Failure code [DD13KB] Shift down SW: Short Circuit 855
Failure code [DD14KA] Parking lever SW: Open 857
Failure code [DD14KB] Parking lever SW: Short circuit 859
Failure code [DDKAKA] Blade float Sw: Open 861
Failure code [DDKAKB] Blade float Sw: Short circuit 863
Failure code [DDKFL4] Left Angle Sw: Signal mismatch 865
Failure code [DDKGL4] Right Angle Sw: Signal mismatch 867
Failure code [DDKHKA] iB Sw: Open 869
Failure code [DDKHKB] iB Sw: Short circuit 871
Failure code [DDNLKA] Weq lock Sw: Open 873
Failure code [DDNLKB] Weq lock Sw: Short circuit 875
Failure code [DDP6KA] Brake Pressure Sensor: Open 877
Failure code [DDP6KB] Brake Pressure Sensor: Hot Short 879
Failure code [DDP6MA] Brake pressure sensor: Malfunction 881
Failure code [DDU1FS] Parking lever Switch 2: Signal mismatch 883
Failure code [DDU1KA] Parking lever Sw2:Open 885
Failure code [DDU1KY] Parking lever Sw2:Hot Short 887
Failure code [DFA4KX] Blade lift lever: Main and Sub Error 889
Failure code [DFA4KZ] Blade lift lever: Main and Sub Error 890
Failure code [DFA4L8] Blade lift lever: Signal mismatch 891
Failure code [DFA5KA] Blade lift lever1: Open 892
Failure code [DFA5KB] Blade lift lever1: Hot Short 895
Failure code [DFA6KA] Blade lift lever2: Open 897
Failure code [DFA6KB] Blade lift lever2: Hot Short 899
Failure code [DFA7KX] Blade tilt lever: Main and Sub Error 901
Failure code [DFA7KZ] Blade tilt lever: Main and Sub Error 902
Failure code [DFA7L8] Blade tilt lever: Signal mismatch 903
Failure code [DFA8KA] Blade tilt lever1: Open 904
Failure code [DFA8KB] Blade tilt lever1: Hot Short 907
Failure code [DFA9KA] Blade tilt lever2: Open 909
Failure code [DFA9KB] Blade tilt lever2: Hot Short 912
Failure code [DGS1KA] HST oil temp sensor: Open 914
Failure code [DGS1KX] HST oil temp sensor:Out of normal range 916
Failure code [DH21KA] Weq pressure sensor: Open 917
Failure code [DH21KB] Weq pressure sensor: Hot Short 919
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit 921
Failure code [DHH7KA] LF HST Pressure Sensor: Open 923
Failure code [DHH7KB] LF HST Pressure Sensor: Hot Short 925
Failure code [DHH8KA] RF HST Pressure Sensor: Open 927
Failure code [DHH8KB] RF HST Pressure Sensor: Hot Short 929
Failure code [DHH9KA] LR HST Pressure Sensor: Open 931
Failure code [DHH9KB] LR HST Pressure Sensor: Hot Short 933
Failure code [DHHAKA] RR HST Pressure Sensor: Open 935
Failure code [DHHAKB] RR HST Pressure Sensor: Hot Short 937
Failure code [DK30KA] ST lever1: Open 939
Failure code [DK30KB] ST lever1: Hot Short 941
Failure code [DK30KX] ST lever: Main and Sub Error 943
Failure code [DK30KZ] ST lever: Main and Sub Error 944
Failure code [DK30L8] ST lever: Signal mismatch 945
Failure code [DK31KA] ST lever2: Open 946
Failure code [DK31KB] ST lever2: Hot Short 948
Failure code [DK40KA] Decel/Brake potentiometer: Open 950
Failure code [DK40KB] Decel/Brake potentiometer: Hot Short 953
Failure code [DK55KX] FR lever: Main and Sub Error 955
Failure code [DK55KZ] FR lever: Main and Sub Error 956
Failure code [DK55L8] FR lever: Signal mismatch 957
Failure code [DK56KA] FR lever1: Open 958
Failure code [DK56KB] FR lever1: Hot Short 960
Failure code [DK57KA] FR lever2: Open 962
Failure code [DK57KB] FR lever2: Hot Short 964
Failure code [DLM0KX] HST Motor Speed Sensor: Left/Right Error 966
Failure code [DLM1KA] Left HST motor speed sensor: Open 967
Failure code [DLM1KB] Left HST motor speed sensor: Short circuit 969
Failure code [DLM1MA] Left HST motor speed sensor: Malfunction 971
Failure code [DLM2KA] Right HST motor speed sensor: Open 972
Failure code [DLM2KB] Right HST motor speed sensor: Short circuit 974
Failure code [DLM2MA] Right HST motor speed sensor: Malfunction 976
Failure code [DLM3KA] Fan Speed Sensor Open Circuit 977
Failure code [DLM3KB] Fan Speed Sensor Short Circuit 979
Failure code [DLM3MB] Fan control: Mismatch 981
Failure code [DN21FS] Decel/Brake pedal SW: Signal mismatch 982
Failure code [DR21KX] Camera 2 Picture Rev Drive Abnormality 984
Failure code [DR31KX] Camera 3 Picture Rev Drive Abnormality 985
Failure code [DV20KB] Back-up alarm : Short circuit 986
Failure code [DW4BKA] Parking brake solenoid: Open 988
Failure code [DW4BKB] Parking brake solenoid: Short circuit 990
Failure code [DW4BKY] Parking brake solenoid: Hot Short 992
Failure code [DW7BKA] Fan reverse solenoid: Open 994
Failure code [DW7BKB] Fan reverse solenoid: Short circuit 996
Failure code [DW7EKA] Slow brake solenoid: Open 997
Failure code [DW7EKB] Slow brake solenoid: Short circuit 999
Failure code [DW7EKY] Slow brake solenoid: Hot Short 1001
Failure code [DWN5KA] Fan EPC: Open 1003
Failure code [DWN5KB] Fan EPC: Short circuit 1005
Failure code [DWN5KY] Fan EPC: Hot Short 1006
Failure code [DXA4KA] LF HST pump EPC: Open 1008
Failure code [DXA4KB] LF HST pump EPC: Short circuit 1010
Failure code [DXA4KY] LF HST pump EPC: Hot Short 1011
Failure code [DXA5KA] LR HST pump EPC:Open 1013
Failure code [DXA5KB] LR HST pump EPC:Short circuit 1015
Failure code [DXA5KY] LR HST pump EPC: Hot Short 1017
Failure code [DXA6KA] RF HST pump EPC: Open 1019
Failure code [DXA6KB] RF HST pump EPC: Short circuit 1021
Failure code [DXA6KY] RF HST pump EPC: Hot Short 1022
Failure code [DXA7KA] RR HST pump EPC: Open 1024
Failure code [DXA7KB] RR HST pump EPC: Short circuit 1026
Failure code [DXA7KY] RR HST pump EPC: Hot Short 1027
Failure code [DXHRKA] Blade lift up EPC: Open 1029
Failure code [DXHRKB] Blade lift up EPC: Short circuit 1031
Failure code [DXHRKY] Blade lift up EPC: Hot short 1032
Failure code [DXHSKA] Blade lift down EPC: Open 1034
Failure code [DXHSKB] Blade lift down EPC: Short circuit 1036
Failure code [DXHSKY] Blade lift down EPC: Hot short 1037
Failure code [DXHTKA] Blade tilt left EPC: Open 1039
Failure code [DXHTKB] Blade tilt left EPC: Short circuit 1041
Failure code [DXHTKY] Blade tilt left EPC: Hot short 1042
Failure code [DXHUKA] Blade tilt right EPC: Open 1044
Failure code [DXHUKB] Blade tilt right EPC: Short circuit 1046
Failure code [DXHUKY] Blade tilt right EPC: Hot short 1047
Failure code [DXJ4KA] Weq lock Sol: Open 1049
Failure code [DXJ4KB] Weq lock Sol: Short circuit 1051
Failure code [DXJCKA] Blade angle left EPC: Open 1053
Failure code [DXJCKB] Blade angle left EPC: Short circuit 1054
Failure code [DXJCKY] Blade angle left EPC: Hot short 1055
Failure code [DXJDKA] Blade angle right EPC: Open 1057
Failure code [DXJDKB] Blade angle right EPC: Short circuit 1058
Failure code [DXJDKY] Blade angle right EPC: Hot short 1059
Failure code [DXK1KA] Left HST motor EPC: Open 1061
Failure code [DXK1KB] Left HST motor EPC: Short circuit 1063
Failure code [DXK1KY] Left HST motor EPC: Hot Short 1064
Failure code [DXK2KA] Right HST motor EPC: Open 1066
Failure code [DXK2KB] Right HST motor EPC: Short circuit 1068
Failure code [DXK2KY] Right HST motor EPC: Hot Short 1069
Troubleshooting of electrical system (E-mode) 1071
E-1 Engine does not start (Engine does not crank) 1071
E-2 Manual preheating system does not work 1077
E-3 Automatic preheating system does not work 1080
E-4 While preheating is working, preheating monitor does not light up 1082
E-5 When starting switch is turned to ON position, machine monitor displays nothing 1084
E-6 When starting switch is turned to ON position (with engine stopped), basic check monitor lights up 1087
E-7 Air cleaner clogging monitor lights up in yellow while engine is running 1088
E-8 Charge level monitor lights up in red while engine is running 1089
E-9 Engine coolant temperature monitor lights up in red while engine is running 1090
E-10 Engine oil pressure monitor lights up in red while engine is running 1091
E-11 HST charge pressure monitor lights up in red while engine is running 1092
E-12 Hydraulic oil temperature monitor lights up in red while engine is running 1093
E-13 HST oil filter clogging monitor lights up in red while engine is running 1094
E-14 Fuel level gauge does not indicate correct level 1095
E-15 Engine coolant temperature gauge does not indicate correct temperature 1098
E-16 Hydraulic oil temperature gauge does not indicate correct temperature 1099
E-17 Operation mode does not change 1100
E-18 Service mode cannot be selected 1101
E-19 Operating customize switch does not display customize screen 1102
E-20 Modifying setting on customize screen does not change setting of machine 1103
E-21 Service meter is not displayed, while starting switch is in OFF position 1104
E-22 Work equipment does not operate 1105
E-23 Foot heater does not operate 1107
E-24 Horn does not sound 1112
E-25 Horn does not stop sounding 1114
E-26 Backup alarm does not sound 1115
E-27 Backup alarm does not stop sounding 1116
E-28 Headlamp does not light up 1117
E-29 Rear lamp does not light up 1120
E-30 No wiper operates continuously or intermittently 1123
E-31 Front wiper does not operate 1125
E-32 Rear wiper does not operate 1127
E-33 Left door wiper does not operate (failed in both continuous and intermittent operations) 1129
E-34 Right door wiper does not operate (failed in both continuous and intermittent operations) 1133
E-35 Front washer does not operate 1137
E-36 Rear washer does not operate 1139
E-37 Left door washer does not operate 1141
E-38 Right door washer does not operate 1143
E-39 KOMTRAX system does not operate normally 1145
Troubleshooting of hydraulic and mechanical system (H-mode) 1147
Information described in troubleshooting table (H-mode) 1147
System chart of hydraulic and mechanical systems 1148
Failure mode and cause table 1150
H-1 Neither RH nor LH of tracks does not travel forward nor reverse (None of the travel system operates) 1154
H-2 Either RH or LH of track does not travel forward nor reverse (Only RH or LH of travel system operates) 1156
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) 1157
H-4 Travel speed or power is low 1159
H-5 Travel speed range does not change 1161
H-6 Shock is large when machine starts or stops 1162
H-7 Machine deviates largely 1163
H-8 Machine drift on a slope is large 1166
H-9 Engine stalls during travel or engine speed drops significantly 1167
H-10 Unusual noise is heard from around HST pump or motor 1169
H-11 All work equipment do not operate 1170
H-12 All work equipment operates slowly or lacks power 1172
H-13 Blade lift speed or power is low 1174
H-14 Blade tilt speed or power is low 1175
H-15 Blade angle speed or power is low 1176
H-16 Time lag of blade lift is large 1177
H-17 Hydraulic drift of lifted blade is large 1178
H-18 Hydraulic drift of tilted blade is large 1179
H-19 Unusual noise is heard from around work equipment pump or control valve 1180
H-20 HST oil temperature (hydraulic oil temperature) rises too high 1181
H-21 Fan speed is abnormal (too high or low, or fan doe not rotate) 1183
H-22 Unusual noise is heard from around fan 1185
Troubleshooting of engine (S-mode) 1186
Information described in troubleshooting table (S mode) 1186
S-1 Engine does not crank when starting switch is turned to START position 1187
S-2 Engine cranks but no exhaust smoke comes out 1188
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) 1189
S-4 Engine startability is poor 1190
S-5 Engine does not pick up smoothly 1192
S-6 Engine stops during operation 1194
S-7 Engine runs rough or is unstable 1196
S-8 Engine lacks power 1197
S-9 Exhaust smoke is black 1199
S-10 Engine oil consumption is excessive 1201
S-11 Oil becomes contaminated quickly 1202
S-12 Fuel consumption is excessive 1203
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) 1204
S-14 Oil pressure drops 1205
S-15 Fuel mixes into engine oil 1206
S-16 Water mixes into engine oil (milky) 1207
S-17 Coolant temperature rises too high (overheating) 1208
S-18 Unusual noise is heard 1209
S-19 Vibration is excessive 1210
S-20 Air cannot be bled from fuel circuit 1211
50 Disassembly and assembly 1213
Table of contents 1214
Related information on disassembly and assembly 1216
How to read this manual 1216
Coating materials list 1218
Special tools list 1222
Sketches of special tools 1230
Engine and cooling system 1244
Removal and installation of supply pump assembly 1244
Removal and installation of fuel injector assembly 1247
Removal and installation of cylinder head assembly 1252
Removal and installation of radiator assembly 1262
Removal and installation of aftercooler assembly 1265
Removal and installation of hydraulic oil cooler assembly 1268
Removal and installation of cooling fan drive assembly 1270
Removal and installation of cooling fan motor assembly 1272
Removal and installation of engine and HST pump assembly 1274
Disassembly and assembly of damper assembly 1278
Removal and installation of engine front oil seal 1279
Removal and installation of engine rear oil seal 1281
Removal and installation of engine hood assembly 1283
Removal and installation of fuel tank assembly 1286
Removal and installation of KCCV assembly 1288
Removal and installation of turbocharger assembly 1289
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly 1290
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly 1292
Removal and installation of starting motor assembly 1293
Removal and installation of belt for alternator and air conditioner compressor 1294
Removal and installation of air cleaner assembly 1296
Power train 1298
Removal and installation of HST motor and final drive assembly 1298
Disassembly and assembly of final drive 1300
Undercarriage and frame 1308
Removal and installation of idler and recoil spring assembly 1308
Disassembly and assembly of idler 1309
Disassembly and assembly of recoil spring 1312
Disassembly and assembly of track roller assembly 1316
Disassembly and assembly of carrier roller assembly 1320
Separation and connection of track shoe assembly (Standard type track shoe) 1322
Separation and connection of track shoe assembly (PLUS type track shoe) 1326
Overall disassembly and assembly of track shoe assembly (Standard type track shoe) 1327
Overall disassembly and assembly of track shoe assembly (PLUS type track shoe) 1340
Disassembly and assembly of one track link assembly in field (Standard type track shoe) 1353
Disassembly and assembly of one track link assembly in field (PLUS type track shoe) 1360
Hydraulic system 1365
Removal and installation of hydraulic tank assembly 1365
Removal and installation of control valve assembly 1367
Removal and installation of HST pump assembly 1369
Disassembly and assembly of hydraulic cylinder assembly 1371
Work equipment 1375
Removal and installation of work equipment assembly 1375
Removal and installation of blade assembly 1377
Removal and installation of U-frame assembly 1379
Cab and its attachments 1381
Removal and installation of ROPS cab assembly 1381
Removal and installation of wiper arm 1385
Removal and installation of operator’s cab glass (adhesion glass) 1387
Removal and installation of operator’s seat 1393
Removal and installation of seat belt 1394
Removal and installation of foot heater assembly 1395
Disassembly and assembly of foot heater assembly 1397
Removal and installation of air conditioner unit assembly 1398
Removal and installation of air conditioner compressor assembly 1403
Electrical system 1405
Removal and installation of machine monitor assembly 1405
Removal and installation of engine controller assembly 1406
Removal and installation of HST controller assembly 1407
Removal and installation of mass air flow and temperature sensor 1408
Removal and installation of KOMTRAX terminal 1409
60 Maintenance standard 1411
Table of contents 1412
Engine and cooling system 1413
Engine mount 1413
Cooling fan motor 1414
Oil cooler bypass and HST charge safety valve 1416
Power train 1417
Damper 1417
HST pump 1418
HST motor 1420
Charge pump 1421
Solenoid valve 1422
Final drive 1423
Sprocket 1424
Full-scale drawing of sprocket tooth profile 1430
Undercarriage and frame 1435
Track frame and idler cushion 1435
Idler 1438
Track roller 1446
Carrier roller 1454
Track shoe 1458
Hydraulic system 1470
Hydraulic tank 1470
Work equipment and cooling fan pump 1471
Control valve 1474
Ripper PPC valve 1481
Work equipment 1483
Blade 1483
Cutting edge and end bit 1486
Ripper 1487
Lift cylinder 1489
Tilt cylinder 1490
Angle cylinder 1491
Ripper cylinder 1492
Cab and its attachments 1493
Cab mount 1493
Electrical system 1494
System component parts 1494
80 Appendix 1495
Table of contents 1496
Air conditioner components 1497
Precautions for refrigerant 1497
Air conditioner component 1498
Configuration and function of refrigeration cycle 1501
Outline of refrigeration cycle 1502
Air conditioner unit 1504
Dual pressure switch 1508
Pressure switch 1509
Compressor 1510
Condenser 1511
Receiver drier 1513
Procedure for testing and troubleshooting 1514
Electrical circuit diagram 1517
System diagram 1518
Parts and connectors layout 1520
Testing relays 1525
Troubleshooting chart 1 1527
Troubleshooting chart 2 1528
Information described in troubleshooting table 1530
A-1 Troubleshooting for condenser fan 1531
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) 1534
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) 1538
A-4 Troubleshooting for temperature control 1540
Troubleshooting with gauge pressure 1543
Connection of service tool 1546
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 1548
Handling of compressor oil 1550
90 Diagrams and drawings 1553
Table of contents 1554
Hydraulic circuit diagram 1555
Symbols in hydraulic circuit diagram 1555
Hydraulic circuit diagram 1559
Electric circuit diagram 1561
Symbols in electric circuit diagram 1561
Electrical circuit diagram 1565
INDEX1585

IMAGES PREVIEW OF THE MANUAL:

S.M 26/12/24