Komatsu D37EXi-23 D37PXi-23 D39EXi-23 D39PXi-23 Bulldozer Shop Manual SEN06486-03 PDF

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Komatsu D37EXi-23 D37PXi-23 D39EXi-23 D39PXi-23 Bulldozer Shop Manual SEN06486-03 – PDF DOWNLOAD

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Komatsu D37EXi-23 D37PXi-23 D39EXi-23 D39PXi-23 Bulldozer Shop Manual SEN06486-03 – PDF DOWNLOAD 

Language : English
Pages : 1743
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu D37EXi-23 D37PXi-23 D39EXi-23 D39PXi-23 Bulldozer Shop Manual SEN06486-03 – PDF DOWNLOAD 

SERIAL NUMBERS
D37EXi-80179 and up
D37PXi-80179 and up
D39EXi-90404 and up
D39PXi-90404 and up

Cover 1
00 Index and foreword 3
Index 4
Foreword, safety and general information 17
Important safety notice 17
How to read the shop manual 24
Explanation of terms for maintenance standard 26
Handling equipment of fuel system devices 28
Handling of intake system parts 29
Handling of hydraulic equipment 30
Method of disconnecting and connecting of push-pull type coupler 32
Handling of electrical equipment 35
How to read electric wire code 43
Precautions when performing operation 46
Practical use of KOMTRAX 51
Standard tightening torque table 52
List of abbreviation 58
Conversion table 63
01 Specification 69
Table of contents 70
Specifications 71
Specification drawing 71
Specifications 75
Weight table 95
Table of fuel, coolant, and lubricants 103
10 Structure and function 105
Table of contents 106
Engine and cooling system 107
Engine related parts 107
Variable flow turbocharger 109
EGR system piping drawing 113
EGR system circuit diagram 115
EGR valve 116
EGR cooler 118
KCCV layout drawing 120
KCCV ventilator 122
KDOC muffler 126
Cooling system 128
Cooling fan motor 130
Oil cooler bypass and HST charge safety valve 138
Power train 145
Power train system 145
Damper 148
Hydraulic component layout of HST 149
Steering and brake control 150
HST pump 152
HST motor 166
Charge pump 182
Solenoid valve 183
Final drive 193
Undercarriage and frame 197
Main frame 197
Track frame and idler cushion 198
Hydraulic system 200
Hydraulic component layout of work equipment 200
Work equipment control system 202
Hydraulic tank 204
CLSS 206
Work equipment and cooling fan pump 209
Control valve 220
Ripper PPC valve 237
Angle control EPC valve 242
Accumulator 247
Work equipment 249
Blade 249
Ripper 250
Piston valve 251
Cab and its attachments 252
ROPS cab 252
Cab mount 254
Electrical system 255
Electrical control system 255
Machine monitor system 297
KOMTRAX system 319
System component parts 323
Sensor 349
20 Standard value tables 373
Table of contents 374
Standard service value table 375
Standard value table for engine 375
Standard value table for machine 376
Standard value table for electrical system 393
30 Testing and adjusting 403
Table of contents 404
Related information on testing and adjusting 406
Tools for testing and adjusting 406
Sketch of tools for testing and adjusting 409
Engine and cooling system 413
Testing engine speed 413
Testing exhaust gas color 415
Testing and adjusting valve clearance 417
Testing compression pressure 419
Testing blowby pressure 422
Testing engine oil pressure 423
Testing fuel pressure 424
Testing fuel return rate and leakage 425
Bleeding air from fuel system 428
Testing fuel circuit for leakage 429
Handling cylinder cutout mode operation 430
Handling no-injection cranking operation 431
Testing of installed condition of cylinder heads and manifolds 432
Testing engine piping for damage and looseness 433
Check alternator and air conditioner compressor belt, replace 434
Check auto-tensioner, replace 436
Writing compensation values at replacement of injector and engine controller 438
Power train 442
Testing and adjusting HST oil pressure 442
Testing outlet pressure of solenoid valve 447
Testing if machine travels straight 451
Simple test procedure for brake performance 452
Adjusting deceleration/brake pedal 453
Adjusting parking brake lever 456
Move disabled machine urgently 458
Undercarriage and frame 461
Adjusting idler clearance 461
Checking sprocket wear 462
Testing and adjusting track tension 463
Hydraulic system 464
Releasing remaining pressure in work equipment cylinder 464
Testing and adjusting work equipment oil pressure 465
Testing source pressure of control circuit 467
Testing outlet pressure of work equipment EPC valve and fan EPC valve 468
Isolating the parts causing hydraulic drift in blade and ripper 470
Testing internal oil leakage of work equipment cylinder 471
Testing fan speed 473
Testing fan circuit oil pressure 474
Bleeding air from hydraulic circuit 475
Work equipment 476
Adjusting work equipment lock lever 476
Adjusting play of blade center ball 478
Electrical system 479
Special functions of machine monitor 479
Special functions of control box 556
Testing stroke sensor for lift cylinder 592
Testing stroke sensor for tilt cylinder 594
Testing stroke sensor for angle cylinder 595
Testing and adjusting reset sensor for lift cylinder 596
Testing and adjusting reset sensor for angle cylinder 597
Adjustment method when HST controller has been replaced 598
Adjustment method when ICT sensor controller has been replaced 601
Adjustment method when devices have been repaired or replaced 604
KOMTRAX terminal start-up procedure 606
Adjusting rearview camera angle 609
Testing windshield wiper operation 610
Replacing windshield wiper blade 611
Handling voltage circuit of engine controller 612
Handling battery disconnect switch 613
Testing diodes 614
Pm clinic 615
Pm Clinic service (D37EXI-23,D37PXI-23) 615
Pm Clinic service (D39EXI-23,D39PXI-23) 616
40 Troubleshooting 629
Table of contents 630
Related information on troubleshooting 638
Troubleshooting points 638
Sequence of events in troubleshooting 640
Checks before troubleshooting 642
Inspection procedure before troubleshooting 644
Preparation for troubleshooting of electrical system 662
Classification and procedures for troubleshooting 665
Symptom and troubleshooting numbers 667
Information in troubleshooting table 670
Troubleshooting method for open circuit in wiring harness of pressure sensor system 672
Connector list and layout 674
Connector contact identification 687
T-branch box and T-branch adapter table 726
Fuse location table 731
Failure codes table 736
Troubleshooting by failure code (Display of code) 747
Failure code [6091NX] HST Oil Filter Clogging 747
Failure code [989L00] Engine Controller Lock Caution 1 749
Failure code [989M00] Engine Controller Lock Caution 2 750
Failure code [989N00] Engine Controller Lock Caution 3 751
Failure code [AA10NX] Air Cleaner Clogging 752
Failure code [AB00KE] Charge Voltage Low 754
Failure code [B@BAZG] Eng Oil Press Low 756
Failure code [B@BCNS] Eng Water Overheat 757
Failure code [B@CRNS] HST Oil Overheat 758
Failure code [B@CRZG] HST Charge Press Low 759
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 760
Failure code [CA122] Chg Air Press Sensor High Error 761
Failure code [CA123] Chg Air Press Sensor Low Error 763
Failure code [CA131] Throttle Sensor High Error 765
Failure code [CA132] Throttle Sensor Low Error 767
Failure code [CA144] Coolant Temp Sens High Error 769
Failure code [CA145] Coolant Temp Sens Low Error 771
Failure code [CA153] Chg Air Temp Sensor High Error 773
Failure code [CA154] Chg Air Temp Sensor Low Error 775
Failure code [CA187] Sensor 2 Supply Volt Low Error 777
Failure code [CA221] Ambient Press Sensor High Error 779
Failure code [CA222] Ambient Press Sensor Low Error 781
Failure code [CA227] Sensor 2 Supply Volt High Error 783
Failure code [CA234] Eng Overspeed 784
Failure code [CA238] Ne Speed Sensor Supply Volt Error 785
Failure code [CA239] Ne Speed Sens Supply Volt High Error 786
Failure code [CA271] IMV/PCV1 Short Error 787
Failure code [CA272] IMV/PCV1 Open Error 788
Failure code [CA322] Inj #1(L#1) Open/Short Error 789
Failure code [CA324] Inj #3(L#3) Open/Short Error 791
Failure code [CA331] Inj #2(L#2) Open/Short Error 793
Failure code [CA332] Inj #4(L#4) Open/Short Error 795
Failure code [CA343] ECM Critical Internal Failure 797
Failure code [CA351] Injectors Drive Circuit Error 798
Failure code [CA352] Sensor 1 Supply Volt Low Error 799
Failure code [CA356] Mass Air Flow Sensor High Error 801
Failure code [CA357] Mass Air Flow Sensor Low Error 803
Failure code [CA386] Sensor 1 Supply Volt High Error 805
Failure code [CA435] Eng Oil Press Sw Error 806
Failure code [CA441] Battery Voltage Low Error 807
Failure code [CA442] Battery Voltage High Error 809
Failure code [CA449] Rail Press Very High Error 810
Failure code [CA451] Rail Press Sensor High Error 811
Failure code [CA452] Rail Press Sensor Low Error 813
Failure code [CA466] KVGT Motor Driver Position Error 815
Failure code [CA515] Rail Press Sens Sup Volt High Error 817
Failure code [CA516] Rail Press Sens Sup Volt Low Error 819
Failure code [CA553] Rail Press High Error 821
Failure code [CA555] Crankcase Press High Error 1 822
Failure code [CA556] Crankcase Press High Error 2 823
Failure code [CA559] Rail Press Low Error 824
Failure code [CA689] Eng Ne Speed Sensor Error 827
Failure code [CA691] Intake Air Temp Sens High Error 829
Failure code [CA692] Intake Air Temp Sens Low Error 831
Failure code [CA697] ECM Internal Temp Sensor High Error 833
Failure code [CA698] ECM Int Temp Sensor Low Error 834
Failure code [CA731] Eng Bkup Speed Sens Phase Error 835
Failure code [CA778] Eng Bkup Speed Sensor Error 837
Failure code [CA1117] Persistent Data Lost Error 841
Failure code [CA1695] Sensor 5 Supply Volt High Error 842
Failure code [CA1696] Sensor 5 Supply Volt Low Error 843
Failure code [CA1843] Crankcase Press Sens High Error 844
Failure code [CA1844] Crankcase Press Sens Low Error 846
Failure code [CA1896] EGR Valve Stuck Error 848
Failure code [CA1942] Crankcase Press Sens In Range Error 849
Failure code [CA1961] EGR_Motor Driver IC Over Temp Error 850
Failure code [CA2185] Throt Sensor Sup Volt High Error 851
Failure code [CA2186] Throt Sensor Sup Volt Low Error 852
Failure code [CA2249] Rail Press Very Low Error 853
Failure code [CA2272] EGR Valve Pos Sens Low Error 854
Failure code [CA2311] IMV Solenoid Error 856
Failure code [CA2349] EGR Valve Solenoid Open Error 857
Failure code [CA2353] EGR Valve Solenoid Short Error 859
Failure code [CA2357] EGR Valve Servo Error 861
Failure code [CA2555] Grid Htr Relay Volt Low Error 862
Failure code [CA2556] Grid Htr Relay Volt High Error 864
Failure code [CA2765] Inj Trim Data Error 866
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error 867
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error 869
Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error 871
Failure code [CA3918] KVGT Stuck Error 873
Failure code [CA3919] KVGT Motor Driver IC Over Temp Error 874
Failure code [CA3921] KVGT Servo Error 2 875
Failure code [CA3922] KVGT Motor Driver Open Error 876
Failure code [CA3923] KVGT Motor Driver Short Error 878
Failure code [D130KA] Neutral relay Open 880
Failure code [D130KB] Neutral relay Short circuit 882
Failure code [D130KY] Neutral relay: Hot Short 884
Failure code [D19JKZ] Personal Code Relay Abnormality 886
Failure code [D811MC] KOMTRAX Error 889
Failure code [D862KA] GPS Antenna Open Circuit 890
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) 891
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) 893
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) 894
Failure code [DAF0MB] Monitor ROM Abnormality 896
Failure code [DAF0MC] Monitor Error 897
Failure code [DAF8KB] Camera Power Supply Short Circuit 898
Failure code [DAF9KQ] Model Selection Abnormality 899
Failure code [DAFGMC] GPS Module Error 900
Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) 901
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) 903
Failure code [DAFQKR] CAN2 Discon (Monitor) 904
Failure code [DAJ000] HST controller: Abnormality in controller 905
Failure code [DAJ0KQ] HST controller: Type select signal 906
Failure code [DAJ0KT] HST controller: Abnormality in controller 907
Failure code [DAJ0MC] HST Con Error 908
Failure code [DAJ1KK] HST controller: Source voltage low 909
Failure code [DAJ2KK] HST controller: Output voltage low 911
Failure code [DAJ5KK] HST: Sensor volt 5V (0) Out of normal range 913
Failure code [DAJ6KK] HST: Sensor volt 5V (1) Out of normal range 915
Failure code [DAJLKA] Operating Lamp Open Circuit (HST Con) 917
Failure code [DAJLKB] Operating Lamp Short Circuit (HST Con) 919
Failure code [DAJPMA] Inconsistency of Option Selection (HST) 920
Failure code [DAJQKR] CAN2 Discon ( HST Con) 921
Failure code [DAJRKR] CAN1 Discon ( HST Con) 922
Failure code [DB2QKR] CAN2 Discon (Engine Con) 923
Failure code [DB2RKR] CAN1 Discon (Engine Con) 928
Failure code [DBR0KT] ICT Controller: Abnormality in controller 933
Failure code [DBR0MC] ICT Con Error 934
Failure code [DBR1KK] ICT controller: Source voltage low 935
Failure code [DBR2KK] ICT controller: Output voltage low 937
Failure code [DBR5KK] ICT: Sensor volt 5V (0) Out of normal range 939
Failure code [DBRLKA] Operating Lamp Open Circuit (ICT Con) 941
Failure code [DBRLKB] Operating Lamp Short Circuit (ICT Con) 943
Failure code [DBRPMA] Inconsistency of Option Selection (ICT) 944
Failure code [DBRQKR] CAN2 Discon (ICT Con) 945
Failure code [DBRRKR] CAN1 Discon (ICT Con) 948
Failure code [DBTSKR] LAN Discon (iB Monitor) 949
Failure code [DBUTKA] GNSS Antenna Open Circuit 951
Failure code [DD12KA] Shift up SW: Open 952
Failure code [DD12KB] Shift up SW: Short Circuit 954
Failure code [DD13KA] Shift down SW: Open 956
Failure code [DD13KB] Shift down SW: Short Circuit 958
Failure code [DD14KA] Parking lever SW: Open 960
Failure code [DD14KB] Parking lever SW: Short circuit 962
Failure code [DDKAKA] Blade float Sw: Open 964
Failure code [DDKAKB] Blade float Sw: Short circuit 966
Failure code [DDKFL4] Left Angle Sw: Signal mismatch 968
Failure code [DDKGL4] Right Angle Sw: Signal mismatch 970
Failure code [DDKHKA] iB Sw: Open 972
Failure code [DDKHKB] iB Sw: Short circuit 974
Failure code [DDNLKA] Weq lock Sw: Open 976
Failure code [DDNLKB] Weq lock Sw: Short circuit 978
Failure code [DDP6KA] Brake Pressure Sensor: Open 980
Failure code [DDP6KB] Brake Pressure Sensor: Hot Short 982
Failure code [DDP6MA] Brake pressure sensor: Malfunction 984
Failure code [DDU1FS] Parking lever Switch 2: Signal mismatch 986
Failure code [DDU1KA] Parking lever Sw2:Open 988
Failure code [DDU1KY] Parking lever Sw2:Hot Short 990
Failure code [DFA4KX] Blade lift lever: Main and Sub Error 992
Failure code [DFA4KZ] Blade lift lever: Main and Sub Error 993
Failure code [DFA4L8] Blade lift lever: Signal mismatch 994
Failure code [DFA5KA] Blade lift lever1: Open 995
Failure code [DFA5KB] Blade lift lever1: Hot Short 998
Failure code [DFA6KA] Blade lift lever2: Open 1000
Failure code [DFA6KB] Blade lift lever2: Hot Short 1002
Failure code [DFA7KX] Blade tilt lever: Main and Sub Error 1004
Failure code [DFA7KZ] Blade tilt lever: Main and Sub Error 1005
Failure code [DFA7L8] Blade tilt lever: Signal mismatch 1006
Failure code [DFA8KA] Blade tilt lever1: Open 1007
Failure code [DFA8KB] Blade tilt lever1: Hot Short 1010
Failure code [DFA9KA] Blade tilt lever2: Open 1012
Failure code [DFA9KB] Blade tilt lever2: Hot Short 1015
Failure code [DGS1KA] HST oil temp sensor: Open 1017
Failure code [DGS1KX] HST oil temp sensor:Out of normal range 1019
Failure code [DH21KA] Weq pressure sensor: Open 1020
Failure code [DH21KB] Weq pressure sensor: Hot Short 1022
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit 1024
Failure code [DHH7KA] LF HST Pressure Sensor: Open 1026
Failure code [DHH7KB] LF HST Pressure Sensor: Hot Short 1028
Failure code [DHH8KA] RF HST Pressure Sensor: Open 1030
Failure code [DHH8KB] RF HST Pressure Sensor: Hot Short 1032
Failure code [DHH9KA] LR HST Pressure Sensor: Open 1034
Failure code [DHH9KB] LR HST Pressure Sensor: Hot Short 1036
Failure code [DHHAKA] RR HST Pressure Sensor: Open 1038
Failure code [DHHAKB] RR HST Pressure Sensor: Hot Short 1040
Failure code [DK30KA] ST lever1: Open 1042
Failure code [DK30KB] ST lever1: Hot Short 1044
Failure code [DK30KX] ST lever: Main and Sub Error 1046
Failure code [DK30KZ] ST lever: Main and Sub Error 1047
Failure code [DK30L8] ST lever: Signal mismatch 1048
Failure code [DK31KA] ST lever2: Open 1049
Failure code [DK31KB] ST lever2: Hot Short 1051
Failure code [DK40KA] Decel/Brake potentiometer: Open 1053
Failure code [DK40KB] Decel/Brake potentiometer: Hot Short 1056
Failure code [DK55KX] FR lever: Main and Sub Error 1058
Failure code [DK55KZ] FR lever: Main and Sub Error 1059
Failure code [DK55L8] FR lever: Signal mismatch 1060
Failure code [DK56KA] FR lever1: Open 1061
Failure code [DK56KB] FR lever1: Hot Short 1063
Failure code [DK57KA] FR lever2: Open 1065
Failure code [DK57KB] FR lever2: Hot Short 1067
Failure code [DK80KA] IMU Sensor: Open 1069
Failure code [DKS0L8] Blade lift Stroke sensor: Signal mismatch 1071
Failure code [DKS1KA] Blade lift Stroke sensor A: Open 1072
Failure code [DKS1KB] Blade lift Stroke sensor A: Hot Short 1074
Failure code [DKS2KA] Blade lift Stroke sensor B: Open 1076
Failure code [DKS2KB] Blade lift Stroke sensor B: Hot Short 1078
Failure code [DKS3KA] Blade lift Reset sensor: Open 1080
Failure code [DKS3KB] Blade lift Reset sensor: Hot Short 1082
Failure code [DKS3MB] Blade lift Reset sensor: Signal mismatch 1084
Failure code [DKS4L8] Blade tilt Stroke sensor: Signal mismatch 1085
Failure code [DKS5KA] Blade tilt Stroke sensor A: Open 1086
Failure code [DKS5KB] Blade tilt Stroke sensor A: Hot Short 1088
Failure code [DKS6KA] Blade tilt Stroke sensor B: Open 1090
Failure code [DKS6KB] Blade tilt Stroke sensor B: Hot Short 1092
Failure code [DKS7MB] Blade tilt Reset sensor: Signal mismatch 1094
Failure code [DKSCL8] Angle left Stroke sensor: Signal mismatch 1095
Failure code [DKSDKA] Angle left Stroke sensor A: Open 1096
Failure code [DKSDKB] Angle left Stroke sensor A: Hot Short 1098
Failure code [DKSEKA] Angle left Stroke sensor B: Open 1100
Failure code [DKSEKB] Angle left Stroke sensor B: Hot Short 1102
Failure code [DKSFKA] Angle left Reset sensor: Open 1104
Failure code [DKSFKB] Angle left Reset sensor: Hot Short 1106
Failure code [DKSFMB] Angle left Reset sensor: Signal mismatch 1108
Failure code [DLM0KX] HST Motor Speed Sensor: Left/Right Error 1109
Failure code [DLM0MA] HST motor speed sensor: Malfunction 1110
Failure code [DLM1KA] Left HST motor speed sensor: Open 1111
Failure code [DLM1KB] Left HST motor speed sensor: Short circuit 1113
Failure code [DLM1MA] Left HST motor speed sensor: Malfunction 1115
Failure code [DLM2KA] Right HST motor speed sensor: Open 1116
Failure code [DLM2KB] Right HST motor speed sensor: Short circuit 1118
Failure code [DLM2MA] Right HST motor speed sensor: Malfunction 1120
Failure code [DLM3KA] Fan Speed Sensor Open Circuit 1121
Failure code [DLM3KB] Fan Speed Sensor Short Circuit 1123
Failure code [DLM3MB] Fan control: Mismatch 1125
Failure code [DN21FS] Decel/Brake pedal SW: Signal mismatch 1126
Failure code [DR21KX] Camera 2 Picture Rev Drive Abnormality 1128
Failure code [DR31KX] Camera 3 Picture Rev Drive Abnormality 1129
Failure code [DV20KB] Back-up alarm : Short circuit 1130
Failure code [DW4BKA] Parking brake solenoid: Open 1132
Failure code [DW4BKB] Parking brake solenoid: Short circuit 1134
Failure code [DW4BKY] Parking brake solenoid: Hot Short 1136
Failure code [DW7BKA] Fan reverse solenoid: Open 1138
Failure code [DW7BKB] Fan reverse solenoid: Short circuit 1140
Failure code [DW7EKA] Slow brake solenoid: Open 1141
Failure code [DW7EKB] Slow brake solenoid: Short circuit 1143
Failure code [DW7EKY] Slow brake solenoid: Hot Short 1145
Failure code [DWN5KA] Fan EPC: Open 1147
Failure code [DWN5KB] Fan EPC: Short circuit 1149
Failure code [DWN5KY] Fan EPC: Hot Short 1150
Failure code [DXA4KA] LF HST pump EPC: Open 1152
Failure code [DXA4KB] LF HST pump EPC: Short circuit 1154
Failure code [DXA4KY] LF HST pump EPC: Hot Short 1155
Failure code [DXA5KA] LR HST pump EPC:Open 1157
Failure code [DXA5KB] LR HST pump EPC:Short circuit 1159
Failure code [DXA5KY] LR HST pump EPC: Hot Short 1161
Failure code [DXA6KA] RF HST pump EPC: Open 1163
Failure code [DXA6KB] RF HST pump EPC: Short circuit 1165
Failure code [DXA6KY] RF HST pump EPC: Hot Short 1166
Failure code [DXA7KA] RR HST pump EPC: Open 1168
Failure code [DXA7KB] RR HST pump EPC: Short circuit 1170
Failure code [DXA7KY] RR HST pump EPC: Hot Short 1171
Failure code [DXHRKA] Blade lift up EPC: Open 1173
Failure code [DXHRKB] Blade lift up EPC: Short circuit 1175
Failure code [DXHRKY] Blade lift up EPC: Hot short 1176
Failure code [DXHSKA] Blade lift down EPC: Open 1178
Failure code [DXHSKB] Blade lift down EPC: Short circuit 1180
Failure code [DXHSKY] Blade lift down EPC: Hot short 1181
Failure code [DXHTKA] Blade tilt left EPC: Open 1183
Failure code [DXHTKB] Blade tilt left EPC: Short circuit 1185
Failure code [DXHTKY] Blade tilt left EPC: Hot short 1186
Failure code [DXHUKA] Blade tilt right EPC: Open 1188
Failure code [DXHUKB] Blade tilt right EPC: Short circuit 1190
Failure code [DXHUKY] Blade tilt right EPC: Hot short 1191
Failure code [DXJ4KA] Weq lock Sol : Open 1193
Failure code [DXJ4KB] Weq lock Sol : Short circuit 1195
Failure code [DXJCKA] Blade angle left EPC: Open 1197
Failure code [DXJCKB] Blade angle left EPC: Short circuit 1198
Failure code [DXJCKY] Blade angle left EPC: Hot short 1199
Failure code [DXJDKA] Blade angle right EPC: Open 1201
Failure code [DXJDKB] Blade angle right EPC: Short circuit 1202
Failure code [DXJDKY] Blade angle right EPC: Hot short 1203
Failure code [DXK1KA] Left HST motor EPC: Open 1205
Failure code [DXK1KB] Left HST motor EPC: Short circuit 1207
Failure code [DXK1KY] Left HST motor EPC: Hot Short 1208
Failure code [DXK2KA] Right HST motor EPC: Open 1210
Failure code [DXK2KB] Right HST motor EPC: Short circuit 1212
Failure code [DXK2KY] Right HST motor EPC: Hot Short 1213
Troubleshooting of electrical system (E-mode) 1215
E-1 Engine does not start (Engine does not crank) 1215
E-2 Manual preheating system does not work 1221
E-3 Automatic preheating system does not work 1224
E-4 While preheating is working, preheating monitor does not light up 1226
E-5 When starting switch is turned to ON position, machine monitor displays nothing 1228
E-6 When starting switch is turned to ON position (with engine stopped), basic check monitor lights up 1231
E-7 Air cleaner clogging monitor lights up in yellow while engine is running 1232
E-8 Charge level monitor lights up in red while engine is running 1233
E-9 Engine coolant temperature monitor lights up in red while engine is running 1234
E-10 Engine oil pressure monitor lights up in red while engine is running 1235
E-11 HST charge pressure monitor lights up in red while engine is running 1236
E-12 Hydraulic oil temperature monitor lights up in red while engine is running 1237
E-13 HST oil filter clogging monitor lights up in red while engine is running 1238
E-14 Fuel level gauge does not indicate correct level 1239
E-15 Engine coolant temperature gauge does not indicate correct temperature 1242
E-16 Hydraulic oil temperature gauge does not indicate correct temperature 1243
E-17 Operation mode does not change 1244
E-18 Service mode cannot be selected 1245
E-19 Operating customize switch does not display customize screen 1246
E-20 Modifying setting on customize screen does not change setting of machine 1247
E-21 Service meter is not displayed, while starting switch is in OFF position 1248
E-22 Work equipment does not operate 1249
E-23 Foot heater does not operate 1251
E-24 Horn does not sound 1256
E-25 Horn does not stop sounding 1258
E-26 Backup alarm does not sound 1259
E-27 Backup alarm does not stop sounding 1260
E-28 Headlamp does not light up 1261
E-29 Rear lamp does not light up 1264
E-30 No wiper operates continuously or intermittently 1267
E-31 Front wiper does not operate 1269
E-32 Rear wiper does not operate 1271
E-33 Left door wiper does not operate (failed in both continuous and intermittent operations) 1273
E-34 Right door wiper does not operate (failed in both continuous and intermittent operations) 1277
E-35 Front washer does not operate 1281
E-36 Rear washer does not operate 1283
E-37 Left door washer does not operate 1285
E-38 Right door washer does not operate 1287
E-39 KOMTRAX system does not operate normally 1289
E-40 Control box shuts down after displaying the messages [GPS receiver not connected!] and [Slope sensor not connected!] 1291
E-41 Control box displays the messages [GPS receiver not connected!] and [Slope sensor not connected!] 1295
E-42 Control box displays the message [Waiting for radio link ] 1298
E-43 Control box displays the message [IMU sensor not connected] 1299
E-44 Control box displays the message [Waiting for satellites ] 1300
E-45 Control box displays the message [Komatsu controller not connected!] 1301
E-46 Control box displays the message [Cylinder Stroke Reading Abnormal] 1303
E-47 Control box displays the message [Komatsu CAN Comms Abnormal] 1304
E-48 Control box displays the message [Komatsu Machine Trouble] 1305
E-49 Control box displays the message [Waiting to initialize ] 1306
E-50 Control box displays the message [System Initializing ] 1307
E-51 Control box displays the message [Initializing ] 1308
E-52 Control box displays the message [Configuring GPS] 1309
E-53 Control box displays the message [No GPS Localization ] 1310
E-54 Control box displays the message [Low precisions ] 1311
E-55 Control box displays the message [Heading Initializing] 1312
E-56 Control box displays [Out of design area ] 1313
E-57 Control box can not be turned on 1314
E-58 Control box does not display intelligent Machine Control screen 1315
E-59 Control box does not display bulldozer image 1316
E-60 Control box does not display design surface 1317
E-61 Control box touch panel does not respond 1318
E-62 Control box touch panel is inaccurate 1319
E-63 Cylinder stroke reset indication does not go out 1320
E-64 AUTO is not displayed when Auto/manual switch is pressed (AUTO indication goes out) 1321
E-65 Blade automatic lower control does not start while AUTO is displayed 1322
E-66 Blade automatic raise control does not start while AUTO is displayed 1323
E-67 Blade automatic control function is not activated while AUTO is displayed (Blade automatic control stops) 1324
E-68 When checking and adjusting the blade elevation, the value is different from actual machine 1325
E-69 Finished surface is inaccurate (The average height of finished surface is lower than designed surface or blade does not touch the surface) 1326
E-70 Finished surface is inaccurate (The finished surface is not smooth) 1327
E-71 Finished surface is inaccurate (When finishing slope horizontally, steps are made in each direction) 1328
E-72 Machine can not escape from shoes slip while blade automatic control is activated (Shoes frequently slips) 1330
E-73 Machine speed does not increase while blade automatic control is activated 1331
E-74 Blade tilt angle does not coincide with design surface 1332
E-75 Blade tilts back while blade automatic control is activated 1334
E-76 When pressing cut/fill level switch (RAISE), the design surface does not rise 1336
E-77 When pressing cut/fill level switch (LOWER), the design surface does not lower 1338
E-78 When starting switch is turned to ON position, reverse leveling mode switch LED does not light up or does not go out 1340
E-79 When reverse leveling mode switch is pressed, buzzer does not sound (does not switch to reverse leveling mode) 1342
Troubleshooting of hydraulic and mechanical system (H-mode) 1344
Information described in troubleshooting table (H-mode) 1344
System chart of hydraulic and mechanical systems 1345
Failure mode and cause table 1347
H-1 Neither RH nor LH of tracks does not travel forward nor reverse (None of the travel system operates) 1351
H-2 Either RH or LH of track does not travel forward nor reverse (Only RH or LH of travel system operates) 1353
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) 1354
H-4 Travel speed or power is low 1356
H-5 Travel speed range does not change 1358
H-6 Shock is large when machine starts or stops 1359
H-7 Machine deviates largely 1360
H-8 Machine drift on a slope is large 1363
H-9 Engine stalls during travel or engine speed drops significantly 1364
H-10 Unusual noise is heard from around HST pump or motor 1366
H-11 All work equipment do not operate 1367
H-12 All work equipment operates slowly or lacks power 1369
H-13 Blade lift speed or power is low 1371
H-14 Blade tilt speed or power is low 1372
H-15 Blade angle speed or power is low 1373
H-16 Time lag of blade lift is large 1374
H-17 Hydraulic drift of lifted blade is large 1375
H-18 Hydraulic drift of tilted blade is large 1376
H-19 Unusual noise is heard from around work equipment pump or control valve 1377
H-20 HST oil temperature (hydraulic oil temperature) rises too high 1378
H-21 Fan speed is abnormal (too high or low, or fan doe not rotate) 1380
H-22 Unusual noise is heard from around fan 1382
Troubleshooting of engine (S-mode) 1383
Information described in troubleshooting table (S mode) 1383
S-1 Engine does not crank when starting switch is turned to START position 1384
S-2 Engine cranks but no exhaust smoke comes out 1385
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) 1386
S-4 Engine startability is poor 1387
S-5 Engine does not pick up smoothly 1389
S-6 Engine stops during operation 1391
S-7 Engine runs rough or is unstable 1393
S-8 Engine lacks power 1394
S-9 Exhaust smoke is black 1396
S-10 Engine oil consumption is excessive 1398
S-11 Oil becomes contaminated quickly 1399
S-12 Fuel consumption is excessive 1400
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) 1401
S-14 Oil pressure drops 1402
S-15 Fuel mixes into engine oil 1403
S-16 Water mixes into engine oil (milky) 1404
S-17 Coolant temperature rises too high (overheating) 1405
S-18 Unusual noise is heard 1406
S-19 Vibration is excessive 1407
S-20 Air cannot be bled from fuel circuit 1408
50 Disassembly and assembly 1409
Table of contents 1410
Related information on disassembly and assembly 1412
How to read this manual 1412
Coating materials list 1414
Special tools list 1418
Sketches of special tools 1426
Engine and cooling system 1441
Removal and installation of supply pump assembly 1441
Removal and installation of fuel injector assembly 1444
Removal and installation of cylinder head assembly 1449
Removal and installation of radiator assembly 1459
Removal and installation of aftercooler assembly 1462
Removal and installation of hydraulic oil cooler assembly 1465
Removal and installation of cooling fan drive assembly 1467
Removal and installation of cooling fan motor assembly 1469
Removal and installation of engine and HST pump assembly 1471
Disassembly and assembly of damper assembly 1475
Removal and installation of engine front oil seal 1476
Removal and installation of engine rear oil seal 1478
Removal and installation of engine hood assembly 1480
Removal and installation of fuel tank assembly 1483
Removal and installation of KCCV assembly 1485
Removal and installation of turbocharger assembly 1486
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly 1487
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly 1489
Removal and installation of starting motor assembly 1490
Removal and installation of belt for alternator and air conditioner compressor 1491
Removal and installation of air cleaner assembly 1493
Power train 1495
Removal and installation of HST motor and final drive assembly 1495
Disassembly and assembly of final drive 1497
Undercarriage and frame 1505
Removal and installation of idler and recoil spring assembly 1505
Disassembly and assembly of idler 1506
Disassembly and assembly of recoil spring 1509
Disassembly and assembly of track roller assembly 1513
Disassembly and assembly of carrier roller assembly 1517
Separation and connection of track shoe assembly (Standard type track shoe) 1519
Separation and connection of track shoe assembly (PLUS type track shoe) 1521
Hydraulic system 1522
Removal and installation of hydraulic tank assembly 1522
Removal and installation of control valve assembly 1524
Removal and installation of HST pump assembly 1526
Disassembly and assembly of hydraulic cylinder assembly 1528
Work equipment 1536
Removal and installation of work equipment assembly 1536
Removal and installation of blade assembly 1540
Removal and installation of U-frame assembly 1543
Cab and its attachments 1546
Removal and installation of ROPS cab assembly 1546
Removal and installation of wiper arm 1551
Removal and installation of operator’s cab glass (adhesion glass) 1553
Removal and installation of operator’s seat 1559
Removal and installation of seat belt 1560
Removal and installation of foot heater assembly 1561
Disassembly and assembly of foot heater assembly 1563
Removal and installation of air conditioner unit assembly 1564
Removal and installation of air conditioner compressor assembly 1569
Electrical system 1571
Removal and installation of machine monitor assembly 1571
Removal and installation of engine controller assembly 1572
Removal and installation of HST controller assembly 1573
Removal and installation of mass air flow and temperature sensor 1574
Removal and installation of KOMTRAX terminal 1575
Removal and installation of ICT sensor controller assembly 1576
Removal and installation of control box 1577
Removal and installation of GNSS receiver 1578
Removal and installation of GNSS antenna 1579
Removal and installation of IMU sensor 1582
60 Maintenance standard 1585
Table of contents 1586
Engine and cooling system 1587
Engine mount 1587
Cooling fan motor 1588
Oil cooler bypass and HST charge safety valve 1590
Power train 1591
Damper 1591
HST pump 1592
HST motor 1594
Charge pump 1595
Solenoid valve 1596
Final drive 1597
Sprocket 1598
Full-scale drawing of sprocket tooth profile 1602
Undercarriage and frame 1604
Track frame and idler cushion 1604
Idler 1607
Track roller 1611
Carrier roller 1615
Track shoe 1617
Hydraulic system 1622
Hydraulic tank 1622
Work equipment and cooling fan pump 1623
Control valve 1626
Ripper PPC valve 1633
Work equipment 1635
Blade 1635
Cutting edge and end bit 1638
Ripper 1639
Lift cylinder 1641
Lift cylinder with stroke and reset sensor 1642
Tilt cylinder with stroke sensor 1643
Angle cylinder 1644
Angle cylinder with stroke and reset sensor 1645
Ripper cylinder 1646
Cab and its attachments 1647
Cab mount 1647
Electrical system 1648
System component parts 1648
Sensor 1649
80 Appendix 1653
Table of contents 1654
Air conditioner components 1655
Precautions for refrigerant 1655
Air conditioner component 1656
Configuration and function of refrigeration cycle 1659
Outline of refrigeration cycle 1660
Air conditioner unit 1662
Dual pressure switch 1666
Pressure switch 1667
Compressor 1668
Condenser 1669
Receiver drier 1671
Procedure for testing and troubleshooting 1672
Electrical circuit diagram 1675
System diagram 1676
Parts and connectors layout 1678
Testing relays 1683
Troubleshooting chart 1 1685
Troubleshooting chart 2 1686
Information described in troubleshooting table 1688
A-1 Troubleshooting for condenser fan 1689
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) 1692
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) 1696
A-4 Troubleshooting for temperature control 1698
Troubleshooting with gauge pressure 1701
Connection of service tool 1704
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 1706
Handling of compressor oil 1708
90 Diagrams and drawings 1711
Table of contents 1712
Hydraulic circuit diagram 1713
Symbols in hydraulic circuit diagram 1713
Hydraulic circuit diagram 1717
Electric circuit diagram 1718
Symbols in electric circuit diagram 1718
Electrical circuit diagram 1722
INDEX 1732

DESCRIPTION:

Komatsu D37EXi-23 D37PXi-23 D39EXi-23 D39PXi-23 Bulldozer Shop Manual SEN06486-03 – PDF DOWNLOAD 

How to read the shop manual (ALL-0320-010-A-01-A)
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 indicated. 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.

S.V 26/12/24