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Komatsu D37EX-23, D37PX-23, D39EX-23, D39PX-23 Bulldozer Shop Manual 80001, 90001 and up – PDF DOWNLOAD
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Komatsu D37EX-23, D37PX-23, D39EX-23, D39PX-23 Bulldozer Shop Manual
Komatsu D37EX-23, D37PX-23, D39EX-23, D39PX-23 Bulldozer Shop Manual
Book Code: SEN06061-03SERIAL NUMBERS:
D37EX-80001 and up
D37PX-80001 and up
D39EX-90001 and up
D39PX-90001 and up
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Description
Komatsu D37EX-23, D37PX-23, D39EX-23, D39PX-23 Bulldozer Shop Manual
FILE DETAILS:
Komatsu D37EX-23, D37PX-23, D39EX-23, D39PX-23 Bulldozer Shop Manual
Brands: Komatsu
Equipment Type: Crawler Bulldozer
Manuals Type: Shop Manual
Machine Model: D37EX-23, D37PX-23, D39EX-23, D39PX-23
Serial Number: 80001 and up, 90001 and up
Book Code: SEN06061-03
Language: English
Pages: 1555
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu D37EX-23, D37PX-23, D39EX-23, D39PX-23 Bulldozer Shop Manual
How to read the shop manual:
Composition of shop manual:
• This shop manual describes the technical information required for the services performed in a workshop. The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword:
• This section includes the index, foreword, safety and basic information.
01. Specification:
• This section explains the specifications of the machine.
10. Structure and function:
• This section explains the structure and function of the machine. The section of “Structure and function” serves not only to give an understanding for the structure of each component, but also serves as reference material for troubleshooting.
20. Standard value table:
• The standard values for a new machine and trouble shooting are described. This standard value table is used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting:
• This section describes the measuring tools and how to measure, and how to adjust various parts. As for the standard value and failure criterion, see the standard value table.
40. Troubleshooting:
• This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for
the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly:
• This section explains the procedures for removing, installing, disassembling, and assembling each part or component and the special tools for the works as well as precautions for doing them safely. In addition, tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the works are also explained.
60. Maintenance standard:
• This section describes the maintenance standard values for each component. This section gives the criterion values for each component and required remedy at disassembly or maintenance.
80. Appendix:
• The structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings:
• This section gives hydraulic circuit diagrams and electrical circuit diagrams.
TABLE OF CONTENTS:
Komatsu D37EX-23, D37PX-23, D39EX-23, D39PX-23 Bulldozer Shop Manual
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 VFT .................................................................................................................................... 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 .................................................................................................................. 364 Testing engine speed ................................................................................................................... 364 Testing exhaust gas color .............................................................................................................. 366 Testing and adjusting valve clearance .................................................................................................. 368 Testing compression pressure ........................................................................................................... 370 Testing blowby pressure ................................................................................................................ 373 Testing engine oil pressure ............................................................................................................ 374 Testing fuel pressure .................................................................................................................. 375 Testing fuel return rate and leakage ................................................................................................... 376 Bleeding air from fuel system .......................................................................................................... 379 Testing fuel circuit for leakage ....................................................................................................... 380 Handling cylinder cutout mode operation ................................................................................................ 381 Handling no-injection cranking operation ............................................................................................... 382 Testing of installed condition of cylinder heads and manifolds ......................................................................... 383 Testing engine piping for damage and looseness ......................................................................................... 384 Replacing belt for alternator and air conditioner compressor ........................................................................... 385 Writing compensation values at replacement of injector and engine controller ........................................................... 386 Power train ................................................................................................................................ 390 Testing and adjusting HST oil pressure ................................................................................................. 390 Testing outlet pressure of solenoid valve .............................................................................................. 395 Testing if machine travels straight .................................................................................................... 399 Simple test procedure for brake performance ............................................................................................ 400 Adjusting deceleration/brake pedal ..................................................................................................... 401 Adjusting parking brake lever .......................................................................................................... 404 Move disabled machine urgently ......................................................................................................... 406 Undercarriage and frame .................................................................................................................... 409 Adjusting idler clearance .............................................................................................................. 409 Checking sprocket wear ................................................................................................................. 410 Testing and adjusting track tension .................................................................................................... 411 Hydraulic system ........................................................................................................................... 412 Releasing remaining pressure in work equipment cylinder ................................................................................ 412 Testing and adjusting work equipment oil pressure ...................................................................................... 413 Testing source pressure of control circuit ............................................................................................. 415 Testing outlet pressure of work equipment EPC valve and fan EPC valve .................................................................. 416 Isolating the parts causing hydraulic drift in blade and ripper ........................................................................ 418 Testing internal oil leakage of work equipment cylinder ................................................................................ 419 Testing fan speed ...................................................................................................................... 421 Testing fan circuit oil pressure ....................................................................................................... 422 Bleeding air from hydraulic circuit .................................................................................................... 423 Work equipment ............................................................................................................................. 424 Adjusting work equipment lock lever .................................................................................................... 424 Adjusting play of blade center ball .................................................................................................... 426 Electrical system .......................................................................................................................... 427 Special functions of machine monitor ................................................................................................... 427 Adjustment method when HST controller has been replaced ................................................................................ 499 Adjustment method when electric or hydraulic device has been replaced .................................................................. 502 Adjusting rearview camera angle ........................................................................................................ 503 Testing windshield wiper operation ..................................................................................................... 504 Replacing windshield wiper blade ....................................................................................................... 505 Handling voltage circuit of engine controller .......................................................................................... 506 Handling battery disconnect switch ..................................................................................................... 507 Testing diodes ......................................................................................................................... 508 Pm clinic .................................................................................................................................. 509 Pm Clinic service ...................................................................................................................... 509 Pm Clinic service (D39EX-23,D39PX-23) .................................................................................................. 511 Pm Clinic check sheet .................................................................................................................. 513 Pm Clinic check sheet (D39EX-23,D39PX-23) .............................................................................................. 522 40 Troubleshooting ............................................................................................................................. 531 Table of contents .......................................................................................................................... 532 Related information on troubleshooting ..................................................................................................... 539 Troubleshooting points ................................................................................................................. 539 Sequence of events in troubleshooting .................................................................................................. 541 Checks before troubleshooting .......................................................................................................... 543 Inspection procedure before troubleshooting ............................................................................................ 545 Preparation for troubleshooting of electrical system ................................................................................... 563 Classification and procedures for troubleshooting ...................................................................................... 566 Symptom and troubleshooting numbers .................................................................................................... 568 Information in troubleshooting table ................................................................................................... 570 Troubleshooting method for open circuit in wiring harness of pressure sensor system .................................................... 572 Connector list and layout .............................................................................................................. 574 Connector contact identification ....................................................................................................... 585 T-branch box and T-branch adapter table ................................................................................................ 623 Fuse location table .................................................................................................................... 628 Failure codes table .................................................................................................................... 633 Troubleshooting by failure code (Display of code) .......................................................................................... 642 Failure code [6091NX] HST Oil Filter Clogging .......................................................................................... 642 Failure code [989L00] Engine Controller Lock Caution 1 ................................................................................. 644 Failure code [989M00] Engine Controller Lock Caution 2 ................................................................................. 645 Failure code [989N00] Engine Controller Lock Caution 3 ................................................................................. 646 Failure code [AA10NX] Air Cleaner Clogging ............................................................................................. 647 Failure code [AB00KE] Charge Voltage Low ............................................................................................... 649 Failure code [B@BAZG] Eng Oil Press Low ................................................................................................ 651 Failure code [B@BCNS] Eng Water Overheat ............................................................................................... 652 Failure code [B@CRNS] HST Oil Overheat ................................................................................................. 653 Failure code [B@CRZG] HST Charge Press Low ............................................................................................. 654 Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................................................. 655 Failure code [CA122] Chg Air Press Sensor High Error ................................................................................... 656 Failure code [CA123] Chg Air Press Sensor Low Error .................................................................................... 658 Failure code [CA131] Throttle Sensor High Error ........................................................................................ 660 Failure code [CA132] Throttle Sensor Low Error ......................................................................................... 662 Failure code [CA144] Coolant Temp Sens High Error ...................................................................................... 664 Failure code [CA145] Coolant Temp Sens Low Error ....................................................................................... 666 Failure code [CA153] Chg Air Temp Sensor High Error .................................................................................... 668 Failure code [CA154] Chg Air Temp Sensor Low Error ..................................................................................... 670 Failure code [CA187] Sensor 2 Supply Volt Low Error .................................................................................... 672 Failure code [CA221] Ambient Press Sensor High Error ................................................................................... 674 Failure code [CA222] Ambient Press Sensor Low Error .................................................................................... 676 Failure code [CA227] Sensor 2 Supply Volt High Error ................................................................................... 678 Failure code [CA234] Eng Overspeed ..................................................................................................... 679 Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................................................. 680 Failure code [CA239] Ne Speed Sens Supply Volt High Error .............................................................................. 681 Failure code [CA271] IMV/PCV1 Short Error .............................................................................................. 682 Failure code [CA272] IMV/PCV1 Open Error ............................................................................................... 683 Failure code [CA322] Inj #1(L#1) Open/Short Error ...................................................................................... 684 Failure code [CA324] Inj #3(L#3) Open/Short Error ...................................................................................... 686 Failure code [CA331] Inj #2(L#2) Open/Short Error ...................................................................................... 688 Failure code [CA332] Inj #4(L#4) Open/Short Error ...................................................................................... 690 Failure code [CA343] ECM Critical Internal Failure ..................................................................................... 692 Failure code [CA351] Injectors Drive Circuit Error ..................................................................................... 693 Failure code [CA352] Sensor 1 Supply Volt Low Error .................................................................................... 694 Failure code [CA356] Mass Air Flow Sensor High Error ................................................................................... 696 Failure code [CA357] Mass Air Flow Sensor Low Error .................................................................................... 698 Failure code [CA386] Sensor 1 Supply Volt High Error ................................................................................... 700 Failure code [CA435] Eng Oil Press Sw Error ............................................................................................ 701 Failure code [CA441] Battery Voltage Low Error ......................................................................................... 702 Failure code [CA442] Battery Voltage High Error ........................................................................................ 704 Failure code [CA449] Rail Press Very High Error ........................................................................................ 705 Failure code [CA451] Rail Press Sensor High Error ...................................................................................... 706 Failure code [CA452] Rail Press Sensor Low Error ....................................................................................... 708 Failure code [CA466] KVGT Motor Driver Position Error .................................................................................. 710 Failure code [CA515] Rail Press Sens Sup Volt High Error ............................................................................... 712 Failure code [CA516] Rail Press Sens Sup Volt Low Error ................................................................................ 714 Failure code [CA553] Rail Press High Error ............................................................................................. 716 Failure code [CA555] Crankcase Press High Error 1 ...................................................................................... 717 Failure code [CA556] Crankcase Press High Error 2 ...................................................................................... 718 Failure code [CA559] Rail Press Low Error .............................................................................................. 719 Failure code [CA689] Eng Ne Speed Sensor Error ......................................................................................... 722 Failure code [CA691] Intake Air Temp Sens High Error ................................................................................... 724 Failure code [CA692] Intake Air Temp Sens Low Error .................................................................................... 726 Failure code [CA697] ECM Internal Temp Sensor High Error ............................................................................... 728 Failure code [CA698] ECM Int Temp Sensor Low Error ..................................................................................... 729 Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................................................... 730 Failure code [CA778] Eng Bkup Speed Sensor Error ....................................................................................... 733 Failure code [CA1117] Persistent Data Lost Error ....................................................................................... 737 Failure code [CA1695] Sensor 5 Supply Volt High Error .................................................................................. 738 Failure code [CA1696] Sensor 5 Supply Volt Low Error ................................................................................... 739 Failure code [CA1843] Crankcase Press Sens High Error .................................................................................. 740 Failure code [CA1844] Crankcase Press Sens Low Error ................................................................................... 742 Failure code [CA1896] EGR Valve Stuck Error ............................................................................................ 744 Failure code [CA1942] Crankcase Press Sens In Range Error .............................................................................. 745 Failure code [CA1961] EGR_Motor Driver IC Over Temp Error .............................................................................. 746 Failure code [CA2185] Throt Sensor Sup Volt High Error ................................................................................. 747 Failure code [CA2186] Throt Sensor Sup Volt Low Error .................................................................................. 748 Failure code [CA2249] Rail Press Very Low Error ........................................................................................ 749 Failure code [CA2272] EGR Valve Pos Sens Low Error ..................................................................................... 750 Failure code [CA2311] IMV Solenoid Error ............................................................................................... 752 Failure code [CA2349] EGR Valve Solenoid Open Error .................................................................................... 753 Failure code [CA2353] EGR Valve Solenoid Short Error ................................................................................... 755 Failure code [CA2357] EGR Valve Servo Error ............................................................................................ 757 Failure code [CA2555] Grid Htr Relay Volt Low Error .................................................................................... 758 Failure code [CA2556] Grid Htr Relay Volt High Error ................................................................................... 760 Failure code [CA2765] Inj Trim Data Error .............................................................................................. 762 Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ......................................................................... 763 Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error .......................................................................... 765 Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error ............................................................................ 767 Failure code [CA3918] KVGT Stuck Error ................................................................................................. 769 Failure code [CA3919] KVGT Motor Driver IC Over Temp Error ............................................................................. 770 Failure code [CA3921] KVGT Servo Error 2 ............................................................................................... 771 Failure code [CA3922] KVGT Motor Driver Open Error ..................................................................................... 772 Failure code [CA3923] KVGT Motor Driver Short Error .................................................................................... 774 Failure code [D130KA] Neutral relay Open ............................................................................................... 776 Failure code [D130KB] Neutral relay Short circuit ...................................................................................... 778 Failure code [D130KY] Neutral relay: Hot Short ......................................................................................... 780 Failure code [D19JKZ] Personal Code Relay Abnormality .................................................................................. 782 Failure code [D811MC] KOMTRAX Error .................................................................................................... 785 Failure code [D862KA] GPS Antenna Open Circuit ......................................................................................... 786 Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ............................................................................ 787 Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ........................................................................... 789 Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ............................................................................................ 790 Failure code [DAF0MB] Monitor ROM Abnormality .......................................................................................... 792 Failure code [DAF0MC] Monitor Error .................................................................................................... 793 Failure code [DAF8KB] Camera Power Supply Short Circuit ................................................................................ 794 Failure code [DAF9KQ] Model Selection Abnormality ...................................................................................... 795 Failure code [DAFGMC] GPS Module Error ................................................................................................. 796 Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) ............................................................................ 797 Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) ........................................................................... 799 Failure code [DAFQKR] CAN2 Discon (Monitor) ............................................................................................ 800 Failure code [DAJ000] HST controller: Abnormality in controller ........................................................................ 801 Failure code [DAJ0KQ] HST controller: Type select signal ............................................................................... 802 Failure code [DAJ0KT] HST controller: Abnormality in controller ........................................................................ 803 Failure code [DAJ0MC] HST Con Error .................................................................................................... 804 Failure code [DAJ1KK] HST controller: Source voltage low ............................................................................... 805 Failure code [DAJ2KK] HST controller: Output voltage low ............................................................................... 807 Failure code [DAJ5KK] HST: Sensor volt 5V (0) Out of normal range ...................................................................... 809 Failure code [DAJ6KK] HST: Sensor volt 5V (1) Out of normal range ...................................................................... 811 Failure code [DAJLKA] Operating Lamp Open Circuit (HST Con) ............................................................................ 813 Failure code [DAJLKB] Operating Lamp Short Circuit (HST Con) ........................................................................... 815 Failure code [DAJPMA] Inconsistency of Option Selection (HST) .......................................................................... 816 Failure code [DAJQKR] CAN2 Discon (HST Con) ............................................................................................ 817 Failure code [DAJRKR] CAN1 Discon (HST Con) ............................................................................................ 818 Failure code [DB2QKR] CAN2 Discon (Engine Con) ......................................................................................... 819 Failure code [DB2RKR] CAN1 Discon (Engine Con) ......................................................................................... 823 Failure code [DD12KA] Shift up SW: Open ................................................................................................ 827 Failure code [DD12KB] Shift up SW: Short Circuit ....................................................................................... 829 Failure code [DD13KA] Shift down SW: Open .............................................................................................. 831 Failure code [DD13KB] Shift down SW: Short Circuit ..................................................................................... 833 Failure code [DD14KA] Parking lever SW: Open ........................................................................................... 835 Failure code [DD14KB] Parking lever SW: Short circuit .................................................................................. 837 Failure code [DDKAKA] Blade float Sw: Open ............................................................................................. 839 Failure code [DDKAKB] Blade float Sw: Short circuit .................................................................................... 841 Failure code [DDKFL4] Left Angle Sw: Signal mismatch ................................................................................... 843 Failure code [DDKGL4] Right Angle Sw: Signal mismatch .................................................................................. 845 Failure code [DDKHKA] iB Sw: Open ...................................................................................................... 847 Failure code [DDKHKB] iB Sw: Short circuit ............................................................................................. 849 Failure code [DDNLKA] Weq lock Sw: Open ................................................................................................ 851 Failure code [DDNLKB] Weq lock Sw: Short circuit ....................................................................................... 853 Failure code [DDP6KA] Brake Pressure Sensor: Open ...................................................................................... 855 Failure code [DDP6KB] Brake Pressure Sensor: Hot Short ................................................................................. 857 Failure code [DDP6MA] Brake pressure sensor: Malfunction ............................................................................... 859 Failure code [DDU1FS] Parking lever Switch 2: Signal mismatch .......................................................................... 861 Failure code [DDU1KA] Parking lever Sw2:Open ........................................................................................... 863 Failure code [DDU1KY] Parking lever Sw2:Hot Short ...................................................................................... 865 Failure code [DFA4KX] Blade lift lever: Main and Sub Error ............................................................................. 867 Failure code [DFA4KZ] Blade lift lever: Main and Sub Error ............................................................................. 868 Failure code [DFA4L8] Blade lift lever: Signal mismatch ................................................................................ 869 Failure code [DFA5KA] Blade lift lever1: Open .......................................................................................... 870 Failure code [DFA5KB] Blade lift lever1: Hot Short ..................................................................................... 873 Failure code [DFA6KA] Blade lift lever2: Open .......................................................................................... 875 Failure code [DFA6KB] Blade lift lever2: Hot Short ..................................................................................... 877 Failure code [DFA7KX] Blade tilt lever: Main and Sub Error ............................................................................. 879 Failure code [DFA7KZ] Blade tilt lever: Main and Sub Error ............................................................................. 880 Failure code [DFA7L8] Blade tilt lever: Signal mismatch ................................................................................ 881 Failure code [DFA8KA] Blade tilt lever1: Open .......................................................................................... 882 Failure code [DFA8KB] Blade tilt lever1: Hot Short ..................................................................................... 885 Failure code [DFA9KA] Blade tilt lever2: Open .......................................................................................... 887 Failure code [DFA9KB] Blade tilt lever2: Hot Short ..................................................................................... 890 Failure code [DGS1KA] HST oil temp sensor: Open ........................................................................................ 892 Failure code [DGS1KX] HST oil temp sensor:Out of normal range .......................................................................... 894 Failure code [DH21KA] Weq pressure sensor: Open ........................................................................................ 895 Failure code [DH21KB] Weq pressure sensor: Hot Short ................................................................................... 897 Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit ............................................................................. 899 Failure code [DHH7KA] LF HST Pressure Sensor: Open ..................................................................................... 901 Failure code [DHH7KB] LF HST Pressure Sensor: Hot Short ................................................................................ 903 Failure code [DHH8KA] RF HST Pressure Sensor: Open ..................................................................................... 905 Failure code [DHH8KB] RF HST Pressure Sensor: Hot Short ................................................................................ 907 Failure code [DHH9KA] LR HST Pressure Sensor: Open ..................................................................................... 909 Failure code [DHH9KB] LR HST Pressure Sensor: Hot Short ................................................................................ 911 Failure code [DHHAKA] RR HST Pressure Sensor: Open ..................................................................................... 913 Failure code [DHHAKB] RR HST Pressure Sensor: Hot Short ................................................................................ 915 Failure code [DK30KA] ST lever1: Open .................................................................................................. 917 Failure code [DK30KB] ST lever1: Hot Short ............................................................................................. 919 Failure code [DK30KX] ST lever: Main and Sub Error ..................................................................................... 921 Failure code [DK30KZ] ST lever: Main and Sub Error ..................................................................................... 922 Failure code [DK30L8] ST lever: Signal mismatch ........................................................................................ 923 Failure code [DK31KA] ST lever2: Open .................................................................................................. 924 Failure code [DK31KB] ST lever2: Hot Short ............................................................................................. 926 Failure code [DK40KA] Decel/Brake potentiometer: Open .................................................................................. 928 Failure code [DK40KB] Decel/Brake potentiometer: Hot Short ............................................................................. 931 Failure code [DK55KX] FR lever: Main and Sub Error ..................................................................................... 933 Failure code [DK55KZ] FR lever: Main and Sub Error ..................................................................................... 934 Failure code [DK55L8] FR lever: Signal mismatch ........................................................................................ 935 Failure code [DK56KA] FR lever1: Open .................................................................................................. 936 Failure code [DK56KB] FR lever1: Hot Short ............................................................................................. 938 Failure code [DK57KA] FR lever2: Open .................................................................................................. 940 Failure code [DK57KB] FR lever2: Hot Short ............................................................................................. 942 Failure code [DLM0KX] HST Motor Speed Sensor: Left/Right Error ......................................................................... 944 Failure code [DLM1KA] Left HST motor speed sensor: Open ................................................................................ 945 Failure code [DLM1KB] Left HST motor speed sensor: Short circuit ....................................................................... 947 Failure code [DLM1MA] Left HST motor speed sensor: Malfunction ......................................................................... 949 Failure code [DLM2KA] Right HST motor speed sensor: Open ............................................................................... 950 Failure code [DLM2KB] Right HST motor speed sensor: Short circuit ...................................................................... 952 Failure code [DLM2MA] Right HST motor speed sensor: Malfunction ........................................................................ 954 Failure code [DLM3KA] Fan Speed Sensor Open Circuit .................................................................................... 955 Failure code [DLM3KB] Fan Speed Sensor Short Circuit ................................................................................... 957 Failure code [DLM3MB] Fan control: Mismatch ............................................................................................ 959 Failure code [DN21FS] Decel/Brake pedal SW: Signal mismatch ............................................................................ 960 Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality .......................................................................... 962 Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality .......................................................................... 963 Failure code [DV20KB] Back-up alarm : Short circuit .................................................................................... 964 Failure code [DW4BKA] Parking brake solenoid: Open ..................................................................................... 966 Failure code [DW4BKB] Parking brake solenoid: Short circuit ............................................................................ 968 Failure code [DW4BKY] Parking brake solenoid: Hot Short ................................................................................ 970 Failure code [DW7BKA] Fan reverse solenoid: Open ....................................................................................... 972 Failure code [DW7BKB] Fan reverse solenoid: Short circuit .............................................................................. 974 Failure code [DW7EKA] Slow brake solenoid: Open ........................................................................................ 975 Failure code [DW7EKB] Slow brake solenoid: Short circuit ............................................................................... 977 Failure code [DW7EKY] Slow brake solenoid: Hot Short ................................................................................... 979 Failure code [DWN5KA] Fan EPC: Open .................................................................................................... 981 Failure code [DWN5KB] Fan EPC: Short circuit ........................................................................................... 983 Failure code [DWN5KY] Fan EPC: Hot Short ............................................................................................... 984 Failure code [DXA4KA] LF HST pump EPC: Open ............................................................................................ 986 Failure code [DXA4KB] LF HST pump EPC: Short circuit ................................................................................... 988 Failure code [DXA4KY] LF HST pump EPC: Hot Short ....................................................................................... 989 Failure code [DXA5KA] LR HST pump EPC:Open ............................................................................................. 991 Failure code [DXA5KB] LR HST pump EPC:Short circuit .................................................................................... 993 Failure code [DXA5KY] LR HST pump EPC: Hot Short ....................................................................................... 995 Failure code [DXA6KA] RF HST pump EPC: Open ............................................................................................ 997 Failure code [DXA6KB] RF HST pump EPC: Short circuit ................................................................................... 999 Failure code [DXA6KY] RF HST pump EPC: Hot Short .......................................................................................1000 Failure code [DXA7KA] RR HST pump EPC: Open ............................................................................................1002 Failure code [DXA7KB] RR HST pump EPC: Short circuit ...................................................................................1004 Failure code [DXA7KY] RR HST pump EPC: Hot Short .......................................................................................1005 Failure code [DXHRKA] Blade lift up EPC: Open ..........................................................................................1007 Failure code [DXHRKB] Blade lift up EPC: Short circuit .................................................................................1009 Failure code [DXHRKY] Blade lift up EPC: Hot short .....................................................................................1010 Failure code [DXHSKA] Blade lift down EPC: Open ........................................................................................1012 Failure code [DXHSKB] Blade lift down EPC: Short circuit ...............................................................................1014 Failure code [DXHSKY] Blade lift down EPC: Hot short ...................................................................................1015 Failure code [DXHTKA] Blade tilt left EPC: Open ........................................................................................1017 Failure code [DXHTKB] Blade tilt left EPC: Short circuit ...............................................................................1019 Failure code [DXHTKY] Blade tilt left EPC: Hot short ...................................................................................1020 Failure code [DXHUKA] Blade tilt right EPC: Open .......................................................................................1022 Failure code [DXHUKB] Blade tilt right EPC: Short circuit ..............................................................................1024 Failure code [DXHUKY] Blade tilt right EPC: Hot short ..................................................................................1025 Failure code [DXJ4KA] Weq lock Sol.: Open ..............................................................................................1027 Failure code [DXJ4KB] Weq lock Sol.: Short circuit .....................................................................................1029 Failure code [DXJCKA] Blade angle left EPC: Open .......................................................................................1031 Failure code [DXJCKB] Blade angle left EPC: Short circuit ..............................................................................1032 Failure code [DXJCKY] Blade angle left EPC: Hot short ..................................................................................1033 Failure code [DXJDKA] Blade angle right EPC: Open ......................................................................................1035 Failure code [DXJDKB] Blade angle right EPC: Short circuit .............................................................................1036 Failure code [DXJDKY] Blade angle right EPC: Hot short .................................................................................1037 Failure code [DXK1KA] Left HST motor EPC: Open .........................................................................................1039 Failure code [DXK1KB] Left HST motor EPC: Short circuit ................................................................................1041 Failure code [DXK1KY] Left HST motor EPC: Hot Short ....................................................................................1042 Failure code [DXK2KA] Right HST motor EPC: Open ........................................................................................1044 Failure code [DXK2KB] Right HST motor EPC: Short circuit ...............................................................................1046 Failure code [DXK2KY] Right HST motor EPC: Hot Short ...................................................................................1047 Troubleshooting of electrical system (E-mode) ..............................................................................................1049 E-1 Engine does not start (Engine does not crank) ......................................................................................1049 E-2 Manual preheating system does not work .............................................................................................1055 E-3 Automatic preheating system does not work ..........................................................................................1058 E-4 While preheating is working, preheating monitor does not light up ..................................................................1060 E-5 When starting switch is turned to ON position, machine monitor displays nothing ....................................................1062 E-6 When starting switch is turned to ON position (with engine stopped), basic check monitor lights up .................................1065 E-7 Air cleaner clogging monitor lights up in yellow while engine is running ...........................................................1066 E-8 Charge level monitor lights up in red while engine is running ......................................................................1067 E-9 Engine coolant temperature monitor lights up in red while engine is running ........................................................1068 E-10 Engine oil pressure monitor lights up in red while engine is running ..............................................................1069 E-11 HST charge pressure monitor lights up in red while engine is running ..............................................................1070 E-12 Hydraulic oil temperature monitor lights up in red while engine is running ........................................................1071 E-13 HST oil filter clogging monitor lights up in red while engine is running ..........................................................1072 E-14 Fuel level gauge does not indicate correct level ..................................................................................1073 E-15 Engine coolant temperature gauge does not indicate correct temperature ............................................................1076 E-16 Hydraulic oil temperature gauge does not indicate correct temperature .............................................................1077 E-17 Operation mode does not change ....................................................................................................1078 E-18 Service mode cannot be selected ...................................................................................................1079 E-19 Operating customize switch does not display customize screen ......................................................................1080 E-20 Modifying setting on customize screen does not change setting of machine ..........................................................1081 E-21 Service meter is not displayed, while starting switch is in OFF position ..........................................................1082 E-22 Work equipment does not operate ...................................................................................................1083 E-23 Foot heater does not operate ......................................................................................................1085 E-24 Horn does not sound ...............................................................................................................1090 E-25 Horn does not stop sounding .......................................................................................................1092 E-26 Backup alarm does not sound .......................................................................................................1093 E-27 Backup alarm does not stop sounding ...............................................................................................1094 E-28 Headlamp does not light up ........................................................................................................1095 E-29 Rear lamp does not light up .......................................................................................................1098 E-30 No wiper operates continuously or intermittently ..................................................................................1101 E-31 Front wiper does not operate ......................................................................................................1103 E-32 Rear wiper does not operate .......................................................................................................1105 E-33 Left door wiper does not operate (failed in both continuous and intermittent operations) ..........................................1107 E-34 Right door wiper does not operate (failed in both continuous and intermittent operations) .........................................1111 E-35 Front washer does not operate .....................................................................................................1115 E-36 Rear washer does not operate ......................................................................................................1117 E-37 Left door washer does not operate .................................................................................................1119 E-38 Right door washer does not operate ................................................................................................1121 E-39 KOMTRAX system does not operate normally ..........................................................................................1123 Troubleshooting of hydraulic and mechanical system (H-mode) ................................................................................1125 Information described in troubleshooting table (H-mode) ................................................................................1125 System chart of hydraulic and mechanical systems .......................................................................................1126 Failure mode and cause table ...........................................................................................................1128 H-1 Neither RH nor LH of tracks does not travel forward nor reverse (None of the travel system operates) ...............................1132 H-2 Either RH or LH of track does not travel forward nor reverse (Only RH or LH of travel system operates) .............................1134 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) ....1135 H-4 Travel speed or power is low .......................................................................................................1137 H-5 Travel speed range does not change .................................................................................................1138 H-6 Shock is large when machine starts or stops ........................................................................................1139 H-7 Machine deviates largely ...........................................................................................................1140 H-8 Machine drift on a slope is large ..................................................................................................1142 H-9 Engine stalls during travel or engine speed drops significantly ....................................................................1143 H-10 Unusual noise is heard from around HST pump or motor ..............................................................................1144 H-11 All work equipment do not operate .................................................................................................1145 H-12 All work equipment operates slowly or lacks power .................................................................................1147 H-13 Blade lift speed or power is low ..................................................................................................1149 H-14 Blade tilt speed or power is low ..................................................................................................1150 H-15 Blade angle speed or power is low .................................................................................................1151 H-16 Time lag of blade lift is large ...................................................................................................1152 H-17 Hydraulic drift of lifted blade is large ..........................................................................................1153 H-18 Hydraulic drift of tilted blade is large ..........................................................................................1154 H-19 Unusual noise is heard from around work equipment pump or control valve ...........................................................1155 H-20 HST oil temperature (hydraulic oil temperature) rises too high ....................................................................1156 H-21 Fan speed is abnormal (too high or low, or fan doe not rotate) ....................................................................1158 H-22 Unusual noise is heard from around fan ............................................................................................1160 Troubleshooting of engine (S-mode) .........................................................................................................1161 Information described in troubleshooting table (S mode) ................................................................................1161 S-1 Engine does not crank when starting switch is turned to START position .............................................................1162 S-2 Engine cranks but no exhaust smoke comes out .......................................................................................1163 S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) .....................................1164 S-4 Engine startability is poor ........................................................................................................1165 S-5 Engine does not pick up smoothly ...................................................................................................1167 S-6 Engine stops during operation ......................................................................................................1169 S-7 Engine runs rough or is unstable ...................................................................................................1171 S-8 Engine lacks power .................................................................................................................1172 S-9 Exhaust smoke is black .............................................................................................................1174 S-10 Engine oil consumption is excessive ...............................................................................................1176 S-11 Oil becomes contaminated quickly ..................................................................................................1177 S-12 Fuel consumption is excessive .....................................................................................................1178 S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ..................................................................1179 S-14 Oil pressure drops ................................................................................................................1180 S-15 Fuel mixes into engine oil ........................................................................................................1181 S-16 Water mixes into engine oil (milky) ...............................................................................................1182 S-17 Coolant temperature rises too high (overheating) ..................................................................................1183 S-18 Unusual noise is heard ............................................................................................................1184 S-19 Vibration is excessive ............................................................................................................1185 S-20 Air cannot be bled from fuel circuit ..............................................................................................1186 50 Disassembly and assembly ....................................................................................................................1187 Table of contents ..........................................................................................................................1188 Related information on disassembly and assembly ............................................................................................1190 How to read this manual ................................................................................................................1190 Coating materials list .................................................................................................................1192 Special tools list .....................................................................................................................1196 Sketches of special tools ..............................................................................................................1204 Engine and cooling system ..................................................................................................................1218 Removal and installation of supply pump assembly .......................................................................................1218 Removal and installation of fuel injector assembly .....................................................................................1221 Removal and installation of cylinder head assembly .....................................................................................1226 Removal and installation of radiator assembly ..........................................................................................1236 Removal and installation of aftercooler assembly .......................................................................................1239 Removal and installation of hydraulic oil cooler assembly ..............................................................................1242 Removal and installation of cooling fan drive assembly .................................................................................1244 Removal and installation of cooling fan motor assembly .................................................................................1246 Removal and installation of engine and HST pump assembly ...............................................................................1248 Disassembly and assembly of damper assembly ............................................................................................1252 Removal and installation of engine front oil seal ......................................................................................1253 Removal and installation of engine rear oil seal .......................................................................................1255 Removal and installation of engine hood assembly .......................................................................................1257 Removal and installation of fuel tank assembly .........................................................................................1260 Removal and installation of KCCV assembly ..............................................................................................1262 Removal and installation of VFT assembly ...............................................................................................1263 Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly ............................................................1264 Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly .............................................................1266 Removal and installation of starting motor assembly ....................................................................................1267 Removal and installation of belt for alternator and air conditioner compressor .........................................................1268 Removal and installation of air cleaner assembly .......................................................................................1270 Power train ................................................................................................................................1272 Removal and installation of HST motor and final drive assembly .........................................................................1272 Disassembly and assembly of final drive ................................................................................................1274 Undercarriage and frame ....................................................................................................................1282 Removal and installation of idler and recoil spring assembly ...........................................................................1282 Disassembly and assembly of idler ......................................................................................................1283 Disassembly and assembly of recoil spring ..............................................................................................1286 Disassembly and assembly of track roller assembly ......................................................................................1290 Disassembly and assembly of carrier roller assembly ....................................................................................1294 Separation and connection of track shoe assembly (Standard type track shoe) ............................................................1296 Separation and connection of track shoe assembly (PLUS type track shoe) ................................................................1298 Overall disassembly and assembly of track shoe assembly (Standard type track shoe) .....................................................1299 Overall disassembly and assembly of track shoe assembly (PLUS type track shoe) .........................................................1312 Disassembly and assembly of one track link assembly in field (Standard type track shoe) ................................................1325 Disassembly and assembly of one track link assembly in field (PLUS type track shoe) ....................................................1332 Hydraulic system ...........................................................................................................................1337 Removal and installation of hydraulic tank assembly ....................................................................................1337 Removal and installation of control valve assembly .....................................................................................1339 Removal and installation of HST pump assembly ..........................................................................................1341 Disassembly and assembly of hydraulic cylinder assembly ................................................................................1343 Work equipment .............................................................................................................................1347 Removal and installation of work equipment assembly ....................................................................................1347 Removal and installation of blade assembly .............................................................................................1349 Removal and installation of U-frame assembly ...........................................................................................1351 Cab and its attachments ....................................................................................................................1353 Removal and installation of ROPS cab assembly ..........................................................................................1353 Removal and installation of wiper arm ..................................................................................................1357 Removal and installation of operator's cab glass (adhesion glass) ......................................................................1359 Removal and installation of operator's seat ............................................................................................1365 Removal and installation of seat belt ..................................................................................................1366 Removal and installation of foot heater assembly .......................................................................................1367 Disassembly and assembly of foot heater assembly .......................................................................................1369 Removal and installation of air conditioner unit assembly ..............................................................................1370 Removal and installation of air conditioner compressor assembly ........................................................................1375 Electrical system ..........................................................................................................................1377 Removal and installation of machine monitor assembly ...................................................................................1377 Removal and installation of engine controller assembly .................................................................................1378 Removal and installation of HST controller assembly ....................................................................................1379 Removal and installation of mass air flow and temperature sensor .......................................................................1380 Removal and installation of KOMTRAX terminal ...........................................................................................1381 60 Maintenance standard ........................................................................................................................1383 Table of contents ..........................................................................................................................1384 Engine and cooling system ..................................................................................................................1385 Engine mount ...........................................................................................................................1385 Cooling fan motor ......................................................................................................................1386 Oil cooler bypass and HST charge safety valve ..........................................................................................1388 Power train ................................................................................................................................1389 Damper .................................................................................................................................1389 HST pump ...............................................................................................................................1390 HST motor ..............................................................................................................................1392 Charge pump ............................................................................................................................1393 Solenoid valve .........................................................................................................................1394 Final drive ............................................................................................................................1395 Sprocket ...............................................................................................................................1396 Full-scale drawing of sprocket tooth profile ...........................................................................................1402 Undercarriage and frame ....................................................................................................................1407 Track frame and idler cushion ..........................................................................................................1407 Idler ..................................................................................................................................1410 Track roller ...........................................................................................................................1418 Carrier roller .........................................................................................................................1426 Track shoe .............................................................................................................................1430 Hydraulic system ...........................................................................................................................1442 Hydraulic tank .........................................................................................................................1442 Work equipment and cooling fan pump ....................................................................................................1443 Control valve ..........................................................................................................................1446 Ripper PPC valve .......................................................................................................................1453 Work equipment .............................................................................................................................1455 Blade ..................................................................................................................................1455 Cutting edge and end bit ...............................................................................................................1458 Ripper .................................................................................................................................1459 Lift cylinder ..........................................................................................................................1461 Tilt cylinder ..........................................................................................................................1462 Angle cylinder .........................................................................................................................1463 Ripper cylinder ........................................................................................................................1464 Cab and its attachments ....................................................................................................................1465 Cab mount ..............................................................................................................................1465 Electrical system ..........................................................................................................................1466 System component parts .................................................................................................................1466 80 Appendix ....................................................................................................................................1467 Table of contents ..........................................................................................................................1468 Air conditioner components .................................................................................................................1469 Precautions for refrigerant ............................................................................................................1469 Air conditioner component ..............................................................................................................1470 Configuration and function of refrigeration cycle ......................................................................................1473 Outline of refrigeration cycle .........................................................................................................1474 Air conditioner unit ...................................................................................................................1476 Dual pressure switch ...................................................................................................................1480 Pressure switch ........................................................................................................................1481 Compressor .............................................................................................................................1482 Condenser ..............................................................................................................................1483 Receiver drier .........................................................................................................................1485 Procedure for testing and troubleshooting ..............................................................................................1486 Electrical circuit diagram .............................................................................................................1489 System diagram .........................................................................................................................1490 Parts and connectors layout ............................................................................................................1492 Testing relays .........................................................................................................................1497 Troubleshooting chart 1 ................................................................................................................1499 Troubleshooting chart 2 ................................................................................................................1500 Information described in troubleshooting table .........................................................................................1502 A-1 Troubleshooting for condenser fan ..................................................................................................1503 A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ..........................................................1506 A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) .................................................1510 A-4 Troubleshooting for temperature control ............................................................................................1512 Troubleshooting with gauge pressure ....................................................................................................1515 Connection of service tool .............................................................................................................1518 Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit ................................................1520 Handling of compressor oil .............................................................................................................1522 90 Diagrams and drawings .......................................................................................................................1525 Table of contents ..........................................................................................................................1526 Hydraulic circuit diagram ..................................................................................................................1527 Symbols in hydraulic circuit diagram ...................................................................................................1527 Hydraulic circuit diagram...............................................................................................................1531 Electric circuit diagram ...................................................................................................................1532 Symbols in electric circuit diagram ....................................................................................................1532 Electrical circuit diagram..............................................................................................................1536 INDEX...........................................................................................................................................1546
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