Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
KOMATSU D37EXi-23 D37PXi-23 D39EXi-23 D39PXi-23 BULLDOZER SHOP MANUAL SEN06486-07 – PDF DOWNLOAD
$32.95
KOMATSU D37EXi-23 D37PXi-23 D39EXi-23 D39PXi-23 BULLDOZER SHOP MANUAL SEN06486-07 – PDF DOWNLOAD
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
KOMATSU D37EXi-23 D37PXi-23 D39EXi-23 D39PXi-23 BULLDOZER SHOP MANUAL SEN06486-07 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU D37EXi-23 D37PXi-23 D39EXi-23 D39PXi-23 BULLDOZER SHOP MANUAL SEN06486-07 – PDF DOWNLOAD
Language : English
Pages : 1774
Downloadable : Yes
File Type : PDF
SERIAL NUMBERS
D37EXi-80179 and up
D37PXi-80179 and up
D39EXi-90404 and up
D39PXi-90404 and up
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU D37EXi-23 D37PXi-23 D39EXi-23 D39PXi-23 BULLDOZER SHOP MANUAL SEN06486-07 – PDF DOWNLOAD
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 .............................................................................................................................. 415 Testing engine speed ............................................................................................................................... 415 Testing exhaust gas color .......................................................................................................................... 417 Testing and adjusting valve clearance .............................................................................................................. 419 Testing compression pressure ....................................................................................................................... 421 Testing blowby pressure ............................................................................................................................ 424 Testing engine oil pressure ........................................................................................................................ 425 Visual check inside of EGR valve.................................................................................................................... 426 Clean inside of EGR valve........................................................................................................................... 427 Testing fuel pressure .............................................................................................................................. 430 Testing fuel return rate and leakage ............................................................................................................... 431 Bleeding air from fuel system ...................................................................................................................... 434 Testing fuel circuit for leakage ................................................................................................................... 435 Handling cylinder cutout mode operation ............................................................................................................ 436 Handling no-injection cranking operation ........................................................................................................... 437 Testing of installed condition of cylinder heads and manifolds ..................................................................................... 438 Testing engine piping for damage and looseness ..................................................................................................... 439 Check alternator and air conditioner compressor belt, replace ...................................................................................... 440 Check auto-tensioner, replace ...................................................................................................................... 442 Writing compensation values at replacement of injector and engine controller ....................................................................... 444 Power train ............................................................................................................................................ 448 Testing and adjusting HST oil pressure ............................................................................................................. 448 Testing outlet pressure of solenoid valve .......................................................................................................... 453 Testing if machine travels straight ................................................................................................................ 457 Simple test procedure for brake performance ........................................................................................................ 458 Adjusting deceleration/brake pedal ................................................................................................................. 459 Adjusting parking brake lever ...................................................................................................................... 462 Move disabled machine urgently ..................................................................................................................... 464 Undercarriage and frame ................................................................................................................................ 467 Adjusting idler clearance .......................................................................................................................... 467 Checking sprocket wear ............................................................................................................................. 468 Testing and adjusting track tension ................................................................................................................ 469 Hydraulic system ....................................................................................................................................... 470 Releasing remaining pressure in work equipment cylinder ............................................................................................ 470 Testing and adjusting work equipment oil pressure .................................................................................................. 471 Testing source pressure of control circuit ......................................................................................................... 473 Testing outlet pressure of work equipment EPC valve and fan EPC valve .............................................................................. 474 Isolating the parts causing hydraulic drift in blade and ripper .................................................................................... 476 Testing internal oil leakage of work equipment cylinder ............................................................................................ 477 Testing fan speed .................................................................................................................................. 479 Testing fan circuit oil pressure ................................................................................................................... 480 Bleeding air from hydraulic circuit ................................................................................................................ 481 Work equipment ......................................................................................................................................... 482 Adjusting work equipment lock lever ................................................................................................................ 482 Adjusting play of blade center ball ................................................................................................................ 484 Testing and adjusting play of blade electric lever.................................................................................................. 485 Electrical system ...................................................................................................................................... 493 Special functions of machine monitor ............................................................................................................... 493 Special functions of control box ................................................................................................................... 570 Testing stroke sensor for lift cylinder ............................................................................................................ 606 Testing stroke sensor for tilt cylinder ............................................................................................................ 608 Testing stroke sensor for angle cylinder ........................................................................................................... 609 Testing and adjusting reset sensor for lift cylinder ............................................................................................... 610 Testing and adjusting reset sensor for angle cylinder .............................................................................................. 611 Adjustment method when HST controller has been replaced ............................................................................................ 612 Adjustment method when ICT sensor controller has been replaced ..................................................................................... 615 Adjustment method when devices have been repaired or replaced ...................................................................................... 618 KOMTRAX terminal start-up procedure ................................................................................................................ 620 Adjusting rearview camera angle .................................................................................................................... 623 Testing windshield wiper operation ................................................................................................................. 624 Replacing windshield wiper blade ................................................................................................................... 625 Handling voltage circuit of engine controller ...................................................................................................... 626 Handling battery disconnect switch ................................................................................................................. 627 Testing diodes ..................................................................................................................................... 628 Pm clinic .............................................................................................................................................. 629 Pm Clinic service (D37EXI-23,D37PXI-23) ............................................................................................................ 629 Pm Clinic service (D39EXI-23,D39PXI-23) ............................................................................................................ 630 40 Troubleshooting ......................................................................................................................................... 643 Table of contents ...................................................................................................................................... 644 Related information on troubleshooting ................................................................................................................. 652 Troubleshooting points ............................................................................................................................. 652 Sequence of events in troubleshooting .............................................................................................................. 654 Checks before troubleshooting ...................................................................................................................... 656 Inspection procedure before troubleshooting ........................................................................................................ 658 Preparation for troubleshooting of electrical system ............................................................................................... 676 Classification and procedures for troubleshooting .................................................................................................. 679 Symptom and troubleshooting numbers ................................................................................................................ 681 Information in troubleshooting table ............................................................................................................... 684 Troubleshooting method for open circuit in wiring harness of pressure sensor system ................................................................ 686 Connector list and layout .......................................................................................................................... 688 Connector contact identification ................................................................................................................... 701 T-branch box and T-branch adapter table ............................................................................................................ 740 Fuse location table ................................................................................................................................ 745 Failure codes table ................................................................................................................................ 750 Troubleshooting by failure code (Display of code) ...................................................................................................... 761 Failure code [6091NX] HST Oil Filter Clogging ...................................................................................................... 761 Failure code [989L00] Engine Controller Lock Caution 1 ............................................................................................. 763 Failure code [989M00] Engine Controller Lock Caution 2 ............................................................................................. 764 Failure code [989N00] Engine Controller Lock Caution 3 ............................................................................................. 765 Failure code [AA10NX] Air Cleaner Clogging ......................................................................................................... 766 Failure code [AB00KE] Charge Voltage Low ........................................................................................................... 768 Failure code [B@BAZG] Eng Oil Press Low ............................................................................................................ 770 Failure code [B@BCNS] Eng Water Overheat ........................................................................................................... 771 Failure code [B@CRNS] HST Oil Overheat ............................................................................................................. 772 Failure code [B@CRZG] HST Charge Press Low ......................................................................................................... 773 Failure code [CA115] Eng Ne and Bkup Speed Sens Error .............................................................................................. 774 Failure code [CA122] Chg Air Press Sensor High Error ............................................................................................... 775 Failure code [CA123] Chg Air Press Sensor Low Error ................................................................................................ 777 Failure code [CA131] Throttle Sensor High Error .................................................................................................... 779 Failure code [CA132] Throttle Sensor Low Error ..................................................................................................... 781 Failure code [CA144] Coolant Temp Sens High Error .................................................................................................. 783 Failure code [CA145] Coolant Temp Sens Low Error ................................................................................................... 785 Failure code [CA153] Chg Air Temp Sensor High Error ................................................................................................ 787 Failure code [CA154] Chg Air Temp Sensor Low Error ................................................................................................. 789 Failure code [CA187] Sensor 2 Supply Volt Low Error ................................................................................................ 791 Failure code [CA221] Ambient Press Sensor High Error ............................................................................................... 793 Failure code [CA222] Ambient Press Sensor Low Error ................................................................................................ 795 Failure code [CA227] Sensor 2 Supply Volt High Error ............................................................................................... 797 Failure code [CA234] Eng Overspeed ................................................................................................................. 798 Failure code [CA238] Ne Speed Sensor Supply Volt Error ............................................................................................. 799 Failure code [CA239] Ne Speed Sens Supply Volt High Error .......................................................................................... 800 Failure code [CA271] IMV/PCV1 Short Error .......................................................................................................... 801 Failure code [CA272] IMV/PCV1 Open Error ........................................................................................................... 802 Failure code [CA322] Inj #1(L#1) Open/Short Error .................................................................................................. 803 Failure code [CA324] Inj #3(L#3) Open/Short Error .................................................................................................. 805 Failure code [CA331] Inj #2(L#2) Open/Short Error .................................................................................................. 807 Failure code [CA332] Inj #4(L#4) Open/Short Error .................................................................................................. 809 Failure code [CA343] ECM Critical Internal Failure ................................................................................................. 811 Failure code [CA351] Injectors Drive Circuit Error ................................................................................................. 812 Failure code [CA352] Sensor 1 Supply Volt Low Error ................................................................................................ 813 Failure code [CA356] Mass Air Flow Sensor High Error ............................................................................................... 815 Failure code [CA357] Mass Air Flow Sensor Low Error ................................................................................................ 817 Failure code [CA386] Sensor 1 Supply Volt High Error ............................................................................................... 819 Failure code [CA435] Eng Oil Press Sw Error ........................................................................................................ 820 Failure code [CA441] Battery Voltage Low Error ..................................................................................................... 821 Failure code [CA442] Battery Voltage High Error .................................................................................................... 823 Failure code [CA449] Rail Press Very High Error .................................................................................................... 824 Failure code [CA451] Rail Press Sensor High Error .................................................................................................. 825 Failure code [CA452] Rail Press Sensor Low Error ................................................................................................... 827 Failure code [CA466] KVGT Motor Driver Position Error .............................................................................................. 829 Failure code [CA515] Rail Press Sens Sup Volt High Error ........................................................................................... 831 Failure code [CA516] Rail Press Sens Sup Volt Low Error ............................................................................................ 833 Failure code [CA553] Rail Press High Error ......................................................................................................... 835 Failure code [CA555] Crankcase Press High Error 1 .................................................................................................. 836 Failure code [CA556] Crankcase Press High Error 2 .................................................................................................. 837 Failure code [CA559] Rail Press Low Error .......................................................................................................... 838 Failure code [CA689] Eng Ne Speed Sensor Error ..................................................................................................... 841 Failure code [CA691] Intake Air Temp Sens High Error ............................................................................................... 843 Failure code [CA692] Intake Air Temp Sens Low Error ................................................................................................ 845 Failure code [CA697] ECM Internal Temp Sensor High Error ........................................................................................... 847 Failure code [CA698] ECM Int Temp Sensor Low Error ................................................................................................. 848 Failure code [CA731] Eng Bkup Speed Sens Phase Error ............................................................................................... 849 Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................................................... 851 Failure code [CA1117] Persistent Data Lost Error ................................................................................................... 855 Failure code [CA1695] Sensor 5 Supply Volt High Error .............................................................................................. 856 Failure code [CA1696] Sensor 5 Supply Volt Low Error ............................................................................................... 857 Failure code [CA1843] Crankcase Press Sens High Error .............................................................................................. 858 Failure code [CA1844] Crankcase Press Sens Low Error ............................................................................................... 860 Failure code [CA1896] EGR Valve Stuck Error ........................................................................................................ 862 Failure code [CA1942] Crankcase Press Sens In Range Error .......................................................................................... 867 Failure code [CA1961] EGR_Motor Driver IC Over Temp Error .......................................................................................... 868 Failure code [CA2185] Throt Sensor Sup Volt High Error ............................................................................................. 869 Failure code [CA2186] Throt Sensor Sup Volt Low Error .............................................................................................. 870 Failure code [CA2249] Rail Press Very Low Error .................................................................................................... 871 Failure code [CA2272] EGR Valve Pos Sens Low Error ................................................................................................. 872 Failure code [CA2311] IMV Solenoid Error ........................................................................................................... 874 Failure code [CA2349] EGR Valve Solenoid Open Error ................................................................................................ 875 Failure code [CA2353] EGR Valve Solenoid Short Error ............................................................................................... 877 Failure code [CA2357] EGR Valve Servo Error ........................................................................................................ 879 Failure code [CA2555] Grid Htr Relay Volt Low Error ................................................................................................ 880 Failure code [CA2556] Grid Htr Relay Volt High Error ............................................................................................... 882 Failure code [CA2765] Inj Trim Data Error .......................................................................................................... 884 Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ..................................................................................... 885 Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ...................................................................................... 887 Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error ........................................................................................ 889 Failure code [CA3918] KVGT Stuck Error ............................................................................................................. 891 Failure code [CA3919] KVGT Motor Driver IC Over Temp Error ......................................................................................... 892 Failure code [CA3921] KVGT Servo Error 2 ........................................................................................................... 893 Failure code [CA3922] KVGT Motor Driver Open Error ................................................................................................. 894 Failure code [CA3923] KVGT Motor Driver Short Error ................................................................................................ 896 Failure code [D130KA] Neutral relay Open ........................................................................................................... 898 Failure code [D130KB] Neutral relay Short circuit .................................................................................................. 900 Failure code [D130KY] Neutral relay: Hot Short ..................................................................................................... 902 Failure code [D19JKZ] Personal Code Relay Abnormality .............................................................................................. 904 Failure code [D811MC] KOMTRAX Error ................................................................................................................ 907 Failure code [D862KA] GPS Antenna Open Circuit ..................................................................................................... 908 Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ........................................................................................ 909 Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ....................................................................................... 911 Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ........................................................................................................ 912 Failure code [DAF0MB] Monitor ROM Abnormality ...................................................................................................... 914 Failure code [DAF0MC] Monitor Error ................................................................................................................ 915 Failure code [DAF8KB] Camera Power Supply Short Circuit ............................................................................................ 916 Failure code [DAF9KQ] Model Selection Abnormality .................................................................................................. 917 Failure code [DAFGMC] GPS Module Error ............................................................................................................. 918 Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) ........................................................................................ 919 Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) ....................................................................................... 921 Failure code [DAFQKR] CAN2 Discon (Monitor) ........................................................................................................ 922 Failure code [DAJ000] HST controller: Abnormality in controller .................................................................................... 923 Failure code [DAJ0KQ] HST controller: Type select signal ........................................................................................... 924 Failure code [DAJ0KT] HST controller: Abnormality in controller .................................................................................... 925 Failure code [DAJ0MC] HST Con Error ................................................................................................................ 926 Failure code [DAJ1KK] HST controller: Source voltage low ........................................................................................... 927 Failure code [DAJ2KK] HST controller: Output voltage low ........................................................................................... 929 Failure code [DAJ5KK] HST: Sensor volt 5V (0) Out of normal range .................................................................................. 931 Failure code [DAJ6KK] HST: Sensor volt 5V (1) Out of normal range .................................................................................. 933 Failure code [DAJLKA] Operating Lamp Open Circuit (HST Con) ........................................................................................ 935 Failure code [DAJLKB] Operating Lamp Short Circuit (HST Con) ....................................................................................... 937 Failure code [DAJPMA] Inconsistency of Option Selection (HST) ...................................................................................... 938 Failure code [DAJQKR] CAN2 Discon ( HST Con) ....................................................................................................... 939 Failure code [DAJRKR] CAN1 Discon ( HST Con) ....................................................................................................... 940 Failure code [DB2QKR] CAN2 Discon (Engine Con) ..................................................................................................... 941 Failure code [DB2RKR] CAN1 Discon (Engine Con) ..................................................................................................... 946 Failure code [DBR0KT] ICT Controller: Abnormality in controller .................................................................................... 951 Failure code [DBR0MC] ICT Con Error ................................................................................................................ 952 Failure code [DBR1KK] ICT controller: Source voltage low ........................................................................................... 953 Failure code [DBR2KK] ICT controller: Output voltage low ........................................................................................... 955 Failure code [DBR5KK] ICT: Sensor volt 5V (0) Out of normal range .................................................................................. 957 Failure code [DBRLKA] Operating Lamp Open Circuit (ICT Con) ........................................................................................ 959 Failure code [DBRLKB] Operating Lamp Short Circuit (ICT Con) ....................................................................................... 961 Failure code [DBRPMA] Inconsistency of Option Selection (ICT) ...................................................................................... 962 Failure code [DBRQKR] CAN2 Discon (ICT Con) ........................................................................................................ 963 Failure code [DBRRKR] CAN1 Discon (ICT Con) ........................................................................................................ 966 Failure code [DBTSKR] LAN Discon (iB Monitor) ...................................................................................................... 967 Failure code [DBUTKA] GNSS Antenna Open Circuit .................................................................................................... 969 Failure code [DD12KA] Shift up SW: Open ............................................................................................................ 970 Failure code [DD12KB] Shift up SW: Short Circuit ................................................................................................... 972 Failure code [DD13KA] Shift down SW: Open .......................................................................................................... 974 Failure code [DD13KB] Shift down SW: Short Circuit ................................................................................................. 976 Failure code [DD14KA] Parking lever SW: Open ....................................................................................................... 978 Failure code [DD14KB] Parking lever SW: Short circuit .............................................................................................. 980 Failure code [DDKAKA] Blade float Sw: Open ......................................................................................................... 982 Failure code [DDKAKB] Blade float Sw: Short circuit ................................................................................................ 984 Failure code [DDKFL4] Left Angle Sw: Signal mismatch ............................................................................................... 986 Failure code [DDKGL4] Right Angle Sw: Signal mismatch .............................................................................................. 988 Failure code [DDKHKA] iB Sw: Open .................................................................................................................. 990 Failure code [DDKHKB] iB Sw: Short circuit ......................................................................................................... 992 Failure code [DDNLKA] Weq lock Sw: Open ............................................................................................................ 994 Failure code [DDNLKB] Weq lock Sw: Short circuit ................................................................................................... 996 Failure code [DDP6KA] Brake Pressure Sensor: Open .................................................................................................. 998 Failure code [DDP6KB] Brake Pressure Sensor: Hot Short .............................................................................................1000 Failure code [DDP6MA] Brake pressure sensor: Malfunction ...........................................................................................1002 Failure code [DDU1FS] Parking lever Switch 2: Signal mismatch ......................................................................................1004 Failure code [DDU1KA] Parking lever Sw2:Open .......................................................................................................1006 Failure code [DDU1KY] Parking lever Sw2:Hot Short ..................................................................................................1008 Failure code [DFA4KX] Blade lift lever: Main and Sub Error .........................................................................................1010 Failure code [DFA4KZ] Blade lift lever: Main and Sub Error .........................................................................................1011 Failure code [DFA4L8] Blade lift lever: Signal mismatch ............................................................................................1012 Failure code [DFA5KA] Blade lift lever1: Open ......................................................................................................1013 Failure code [DFA5KB] Blade lift lever1: Hot Short .................................................................................................1016 Failure code [DFA6KA] Blade lift lever2: Open ......................................................................................................1018 Failure code [DFA6KB] Blade lift lever2: Hot Short .................................................................................................1020 Failure code [DFA7KX] Blade tilt lever: Main and Sub Error .........................................................................................1022 Failure code [DFA7KZ] Blade tilt lever: Main and Sub Error .........................................................................................1023 Failure code [DFA7L8] Blade tilt lever: Signal mismatch ............................................................................................1024 Failure code [DFA8KA] Blade tilt lever1: Open ......................................................................................................1025 Failure code [DFA8KB] Blade tilt lever1: Hot Short .................................................................................................1028 Failure code [DFA9KA] Blade tilt lever2: Open ......................................................................................................1030 Failure code [DFA9KB] Blade tilt lever2: Hot Short .................................................................................................1033 Failure code [DGS1KA] HST oil temp sensor: Open ....................................................................................................1035 Failure code [DGS1KX] HST oil temp sensor:Out of normal range ......................................................................................1037 Failure code [DH21KA] Weq pressure sensor: Open ....................................................................................................1038 Failure code [DH21KB] Weq pressure sensor: Hot Short ...............................................................................................1040 Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit .........................................................................................1042 Failure code [DHH7KA] LF HST Pressure Sensor: Open .................................................................................................1044 Failure code [DHH7KB] LF HST Pressure Sensor: Hot Short ............................................................................................1046 Failure code [DHH8KA] RF HST Pressure Sensor: Open .................................................................................................1048 Failure code [DHH8KB] RF HST Pressure Sensor: Hot Short ............................................................................................1050 Failure code [DHH9KA] LR HST Pressure Sensor: Open .................................................................................................1052 Failure code [DHH9KB] LR HST Pressure Sensor: Hot Short ............................................................................................1054 Failure code [DHHAKA] RR HST Pressure Sensor: Open .................................................................................................1056 Failure code [DHHAKB] RR HST Pressure Sensor: Hot Short ............................................................................................1058 Failure code [DK30KA] ST lever1: Open ..............................................................................................................1060 Failure code [DK30KB] ST lever1: Hot Short .........................................................................................................1062 Failure code [DK30KX] ST lever: Main and Sub Error .................................................................................................1064 Failure code [DK30KZ] ST lever: Main and Sub Error .................................................................................................1065 Failure code [DK30L8] ST lever: Signal mismatch ....................................................................................................1066 Failure code [DK31KA] ST lever2: Open ..............................................................................................................1067 Failure code [DK31KB] ST lever2: Hot Short .........................................................................................................1069 Failure code [DK40KA] Decel/Brake potentiometer: Open ..............................................................................................1071 Failure code [DK40KB] Decel/Brake potentiometer: Hot Short .........................................................................................1074 Failure code [DK55KX] FR lever: Main and Sub Error .................................................................................................1076 Failure code [DK55KZ] FR lever: Main and Sub Error .................................................................................................1077 Failure code [DK55L8] FR lever: Signal mismatch ....................................................................................................1078 Failure code [DK56KA] FR lever1: Open ..............................................................................................................1079 Failure code [DK56KB] FR lever1: Hot Short .........................................................................................................1081 Failure code [DK57KA] FR lever2: Open ..............................................................................................................1083 Failure code [DK57KB] FR lever2: Hot Short .........................................................................................................1085 Failure code [DK80KA] IMU Sensor: Open .............................................................................................................1087 Failure code [DKS0L8] Blade lift Stroke sensor: Signal mismatch ....................................................................................1089 Failure code [DKS1KA] Blade lift Stroke sensor A: Open .............................................................................................1090 Failure code [DKS1KB] Blade lift Stroke sensor A: Hot Short ........................................................................................1092 Failure code [DKS2KA] Blade lift Stroke sensor B: Open .............................................................................................1094 Failure code [DKS2KB] Blade lift Stroke sensor B: Hot Short ........................................................................................1096 Failure code [DKS3KA] Blade lift Reset sensor: Open ................................................................................................1098 Failure code [DKS3KB] Blade lift Reset sensor: Hot Short ...........................................................................................1100 Failure code [DKS3MB] Blade lift Reset sensor: Signal mismatch .....................................................................................1102 Failure code [DKS4L8] Blade tilt Stroke sensor: Signal mismatch ....................................................................................1103 Failure code [DKS5KA] Blade tilt Stroke sensor A: Open .............................................................................................1104 Failure code [DKS5KB] Blade tilt Stroke sensor A: Hot Short ........................................................................................1106 Failure code [DKS6KA] Blade tilt Stroke sensor B: Open .............................................................................................1108 Failure code [DKS6KB] Blade tilt Stroke sensor B: Hot Short ........................................................................................1110 Failure code [DKS7MB] Blade tilt Reset sensor: Signal mismatch .....................................................................................1112 Failure code [DKSCL8] Angle left Stroke sensor: Signal mismatch ....................................................................................1113 Failure code [DKSDKA] Angle left Stroke sensor A: Open .............................................................................................1114 Failure code [DKSDKB] Angle left Stroke sensor A: Hot Short ........................................................................................1116 Failure code [DKSEKA] Angle left Stroke sensor B: Open .............................................................................................1118 Failure code [DKSEKB] Angle left Stroke sensor B: Hot Short ........................................................................................1120 Failure code [DKSFKA] Angle left Reset sensor: Open ................................................................................................1122 Failure code [DKSFKB] Angle left Reset sensor: Hot Short ...........................................................................................1124 Failure code [DKSFMB] Angle left Reset sensor: Signal mismatch .....................................................................................1126 Failure code [DLM0KX] HST Motor Speed Sensor: Left/Right Error .....................................................................................1127 Failure code [DLM0MA] HST motor speed sensor: Malfunction ..........................................................................................1128 Failure code [DLM1KA] Left HST motor speed sensor: Open ............................................................................................1129 Failure code [DLM1KB] Left HST motor speed sensor: Short circuit ...................................................................................1131 Failure code [DLM1MA] Left HST motor speed sensor: Malfunction .....................................................................................1133 Failure code [DLM2KA] Right HST motor speed sensor: Open ...........................................................................................1134 Failure code [DLM2KB] Right HST motor speed sensor: Short circuit ..................................................................................1136 Failure code [DLM2MA] Right HST motor speed sensor: Malfunction ....................................................................................1138 Failure code [DLM3KA] Fan Speed Sensor Open Circuit ................................................................................................1139 Failure code [DLM3KB] Fan Speed Sensor Short Circuit ...............................................................................................1141 Failure code [DLM3MB] Fan control: Mismatch ........................................................................................................1143 Failure code [DN21FS] Decel/Brake pedal SW: Signal mismatch ........................................................................................1144 Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality ......................................................................................1146 Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality ......................................................................................1147 Failure code [DV20KB] Back-up alarm : Short circuit ................................................................................................1148 Failure code [DW4BKA] Parking brake solenoid: Open .................................................................................................1150 Failure code [DW4BKB] Parking brake solenoid: Short circuit ........................................................................................1152 Failure code [DW4BKY] Parking brake solenoid: Hot Short ............................................................................................1154 Failure code [DW7BKA] Fan reverse solenoid: Open ...................................................................................................1156 Failure code [DW7BKB] Fan reverse solenoid: Short circuit ..........................................................................................1158 Failure code [DW7EKA] Slow brake solenoid: Open ....................................................................................................1159 Failure code [DW7EKB] Slow brake solenoid: Short circuit ...........................................................................................1161 Failure code [DW7EKY] Slow brake solenoid: Hot Short ...............................................................................................1163 Failure code [DWN5KA] Fan EPC: Open ................................................................................................................1165 Failure code [DWN5KB] Fan EPC: Short circuit .......................................................................................................1167 Failure code [DWN5KY] Fan EPC: Hot Short ...........................................................................................................1168 Failure code [DXA4KA] LF HST pump EPC: Open ........................................................................................................1170 Failure code [DXA4KB] LF HST pump EPC: Short circuit ...............................................................................................1172 Failure code [DXA4KY] LF HST pump EPC: Hot Short ...................................................................................................1173 Failure code [DXA5KA] LR HST pump EPC:Open .........................................................................................................1175 Failure code [DXA5KB] LR HST pump EPC:Short circuit ................................................................................................1177 Failure code [DXA5KY] LR HST pump EPC: Hot Short ...................................................................................................1179 Failure code [DXA6KA] RF HST pump EPC: Open ........................................................................................................1181 Failure code [DXA6KB] RF HST pump EPC: Short circuit ...............................................................................................1183 Failure code [DXA6KY] RF HST pump EPC: Hot Short ...................................................................................................1184 Failure code [DXA7KA] RR HST pump EPC: Open ........................................................................................................1186 Failure code [DXA7KB] RR HST pump EPC: Short circuit ...............................................................................................1188 Failure code [DXA7KY] RR HST pump EPC: Hot Short ...................................................................................................1189 Failure code [DXHRKA] Blade lift up EPC: Open ......................................................................................................1191 Failure code [DXHRKB] Blade lift up EPC: Short circuit .............................................................................................1193 Failure code [DXHRKY] Blade lift up EPC: Hot short .................................................................................................1194 Failure code [DXHSKA] Blade lift down EPC: Open ....................................................................................................1196 Failure code [DXHSKB] Blade lift down EPC: Short circuit ...........................................................................................1198 Failure code [DXHSKY] Blade lift down EPC: Hot short ...............................................................................................1199 Failure code [DXHTKA] Blade tilt left EPC: Open ....................................................................................................1201 Failure code [DXHTKB] Blade tilt left EPC: Short circuit ...........................................................................................1203 Failure code [DXHTKY] Blade tilt left EPC: Hot short ...............................................................................................1204 Failure code [DXHUKA] Blade tilt right EPC: Open ...................................................................................................1206 Failure code [DXHUKB] Blade tilt right EPC: Short circuit ..........................................................................................1208 Failure code [DXHUKY] Blade tilt right EPC: Hot short ..............................................................................................1209 Failure code [DXJ4KA] Weq lock Sol.: Open ..........................................................................................................1211 Failure code [DXJ4KB] Weq lock Sol.: Short circuit .................................................................................................1213 Failure code [DXJCKA] Blade angle left EPC: Open ...................................................................................................1215 Failure code [DXJCKB] Blade angle left EPC: Short circuit ..........................................................................................1216 Failure code [DXJCKY] Blade angle left EPC: Hot short ..............................................................................................1217 Failure code [DXJDKA] Blade angle right EPC: Open ..................................................................................................1219 Failure code [DXJDKB] Blade angle right EPC: Short circuit .........................................................................................1220 Failure code [DXJDKY] Blade angle right EPC: Hot short .............................................................................................1221 Failure code [DXK1KA] Left HST motor EPC: Open .....................................................................................................1223 Failure code [DXK1KB] Left HST motor EPC: Short circuit ............................................................................................1225 Failure code [DXK1KY] Left HST motor EPC: Hot Short ................................................................................................1226 Failure code [DXK2KA] Right HST motor EPC: Open ....................................................................................................1228 Failure code [DXK2KB] Right HST motor EPC: Short circuit ...........................................................................................1230 Failure code [DXK2KY] Right HST motor EPC: Hot Short ...............................................................................................1231 Troubleshooting of electrical system (E-mode) ..........................................................................................................1233 E-1 Engine does not start (Engine does not crank) ..................................................................................................1233 E-2 Manual preheating system does not work .........................................................................................................1239 E-3 Automatic preheating system does not work ......................................................................................................1242 E-4 While preheating is working, preheating monitor does not light up ..............................................................................1244 E-5 When starting switch is turned to ON position, machine monitor displays nothing ................................................................1246 E-6 When starting switch is turned to ON position (with engine stopped), basic check monitor lights up .............................................1249 E-7 Air cleaner clogging monitor lights up in yellow while engine is running .......................................................................1250 E-8 Charge level monitor lights up in red while engine is running ..................................................................................1251 E-9 Engine coolant temperature monitor lights up in red while engine is running ....................................................................1252 E-10 Engine oil pressure monitor lights up in red while engine is running ..........................................................................1253 E-11 HST charge pressure monitor lights up in red while engine is running ..........................................................................1254 E-12 Hydraulic oil temperature monitor lights up in red while engine is running ....................................................................1255 E-13 HST oil filter clogging monitor lights up in red while engine is running ......................................................................1256 E-14 Fuel level gauge does not indicate correct level ..............................................................................................1257 E-15 Engine coolant temperature gauge does not indicate correct temperature ........................................................................1260 E-16 Hydraulic oil temperature gauge does not indicate correct temperature .........................................................................1261 E-17 Operation mode does not change ................................................................................................................1262 E-18 Service mode cannot be selected ...............................................................................................................1263 E-19 Operating customize switch does not display customize screen ..................................................................................1264 E-20 Modifying setting on customize screen does not change setting of machine ......................................................................1265 E-21 Service meter is not displayed, while starting switch is in OFF position ......................................................................1266 E-22 Work equipment does not operate ...............................................................................................................1267 E-23 Foot heater does not operate ..................................................................................................................1269 E-24 Horn does not sound ...........................................................................................................................1274 E-25 Horn does not stop sounding ...................................................................................................................1276 E-26 Backup alarm does not sound ...................................................................................................................1277 E-27 Backup alarm does not stop sounding ...........................................................................................................1278 E-28 Headlamp does not light up ....................................................................................................................1279 E-29 Rear lamp does not light up ...................................................................................................................1282 E-30 No wiper operates continuously or intermittently ..............................................................................................1285 E-31 Front wiper does not operate ..................................................................................................................1287 E-32 Rear wiper does not operate ...................................................................................................................1289 E-33 Left door wiper does not operate (failed in both continuous and intermittent operations) ......................................................1291 E-34 Right door wiper does not operate (failed in both continuous and intermittent operations) .....................................................1295 E-35 Front washer does not operate .................................................................................................................1299 E-36 Rear washer does not operate ..................................................................................................................1301 E-37 Left door washer does not operate .............................................................................................................1303 E-38 Right door washer does not operate ............................................................................................................1305 E-39 KOMTRAX system does not operate normally ......................................................................................................1307 E-40 Control box shuts down after displaying the messages [GPS receiver not connected!] and [Slope sensor not connected!] ..........................1309 E-41 Control box displays the messages [GPS receiver not connected!] and [Slope sensor not connected!] .............................................1313 E-42 Control box displays the message [Waiting for radio link...] ..................................................................................1316 E-43 Control box displays the message [IMU sensor not connected] ...................................................................................1317 E-44 Control box displays the message [Waiting for satellites...] ..................................................................................1318 E-45 Control box displays the message [Komatsu controller not connected!] ..........................................................................1319 E-46 Control box displays the message [Cylinder Stroke Reading Abnormal] ...........................................................................1321 E-47 Control box displays the message [Komatsu CAN Comms Abnormal] .................................................................................1322 E-48 Control box displays the message [Komatsu Machine Trouble] ....................................................................................1323 E-49 Control box displays the message [Waiting to initialize....] ..................................................................................1324 E-50 Control box displays the message [System Initializing...] .....................................................................................1325 E-51 Control box displays the message [Initializing....] ...........................................................................................1326 E-52 Control box displays the message [Configuring GPS] ............................................................................................1327 E-53 Control box displays the message [No GPS Localization...] .....................................................................................1328 E-54 Control box displays the message [Low precisions...] ..........................................................................................1329 E-55 Control box displays the message [Heading Initializing] .......................................................................................1330 E-56 Control box displays [Out of design area...] ..................................................................................................1331 E-57 Control box can not be turned on ..............................................................................................................1332 E-58 Control box does not display intelligent Machine Control screen ...............................................................................1333 E-59 Control box does not display bulldozer image ..................................................................................................1334 E-60 Control box does not display design surface ...................................................................................................1335 E-61 Control box touch panel does not respond ......................................................................................................1336 E-62 Control box touch panel is inaccurate .........................................................................................................1337 E-63 Cylinder stroke reset indication does not go out ..............................................................................................1338 E-64 AUTO is not displayed when Auto/manual switch is pressed (AUTO indication goes out) ...........................................................1339 E-65 Blade automatic lower control does not start while AUTO is displayed ..........................................................................1340 E-66 Blade automatic raise control does not start while AUTO is displayed ..........................................................................1341 E-67 Blade automatic control function is not activated while AUTO is displayed (Blade automatic control stops) .....................................1342 E-68 When checking and adjusting the blade elevation, the value is different from actual machine ...................................................1343 E-69 Finished surface is inaccurate (The average height of finished surface is lower than designed surface or blade does not touch the surface) ....1344 E-70 Finished surface is inaccurate (The finished surface is not smooth) ...........................................................................1345 E-71 Finished surface is inaccurate (When finishing slope horizontally, steps are made in each direction) ..........................................1346 E-72 Machine can not escape from shoes slip while blade automatic control is activated (Shoes frequently slips) ....................................1348 E-73 Machine speed does not increase while blade automatic control is activated ....................................................................1349 E-74 Blade tilt angle does not coincide with design surface ........................................................................................1350 E-75 Blade tilts back while blade automatic control is activated ...................................................................................1352 E-76 When pressing cut/fill level switch (RAISE), the design surface does not rise .................................................................1354 E-77 When pressing cut/fill level switch (LOWER), the design surface does not lower ................................................................1356 E-78 When starting switch is turned to ON position, reverse leveling mode switch LED does not light up or does not go out ..........................1358 E-79 When reverse leveling mode switch is pressed, buzzer does not sound (does not switch to reverse leveling mode) ................................1360 Troubleshooting of hydraulic and mechanical system (H-mode) ............................................................................................1362 Information described in troubleshooting table (H-mode) ............................................................................................1362 System chart of hydraulic and mechanical systems ...................................................................................................1363 Failure mode and cause table .......................................................................................................................1365 H-1 Neither RH nor LH of tracks does not travel forward nor reverse (None of the travel system operates) ...........................................1369 H-2 Either RH or LH of track does not travel forward nor reverse (Only RH or LH of travel system operates) .........................................1371 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) ................1372 H-4 Travel speed or power is low ...................................................................................................................1374 H-5 Travel speed range does not change .............................................................................................................1376 H-6 Shock is large when machine starts or stops ....................................................................................................1377 H-7 Machine deviates largely .......................................................................................................................1378 H-8 Machine drift on a slope is large ..............................................................................................................1381 H-9 Engine stalls during travel or engine speed drops significantly ................................................................................1382 H-10 Unusual noise is heard from around HST pump or motor ..........................................................................................1384 H-11 All work equipment do not operate .............................................................................................................1385 H-12 All work equipment operates slowly or lacks power .............................................................................................1387 H-13 Blade lift speed or power is low ..............................................................................................................1389 H-14 Blade tilt speed or power is low ..............................................................................................................1390 H-15 Blade angle speed or power is low .............................................................................................................1391 H-16 Time lag of blade lift is large ...............................................................................................................1392 H-17 Hydraulic drift of lifted blade is large ......................................................................................................1393 H-18 Hydraulic drift of tilted blade is large ......................................................................................................1394 H-19 Unusual noise is heard from around work equipment pump or control valve .......................................................................1395 H-20 HST oil temperature (hydraulic oil temperature) rises too high ................................................................................1396 H-21 Fan speed is abnormal (too high or low, or fan doe not rotate) ................................................................................1398 H-22 Unusual noise is heard from around fan ........................................................................................................1400 Troubleshooting of engine (S-mode) .....................................................................................................................1401 Information described in troubleshooting table (S mode) ............................................................................................1401 S-1 Engine does not crank when starting switch is turned to START position .........................................................................1402 S-2 Engine cranks but no exhaust smoke comes out ...................................................................................................1403 S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) .................................................1404 S-4 Engine startability is poor ....................................................................................................................1405 S-5 Engine does not pick up smoothly ...............................................................................................................1407 S-6 Engine stops during operation ..................................................................................................................1409 S-7 Engine runs rough or is unstable ...............................................................................................................1411 S-8 Engine lacks power .............................................................................................................................1412 S-9 Exhaust smoke is black .........................................................................................................................1414 S-10 Engine oil consumption is excessive ...........................................................................................................1416 S-11 Oil becomes contaminated quickly ..............................................................................................................1417 S-12 Fuel consumption is excessive .................................................................................................................1418 S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ..............................................................................1419 S-14 Oil pressure drops ............................................................................................................................1420 S-15 Fuel mixes into engine oil ....................................................................................................................1421 S-16 Water mixes into engine oil (milky) ...........................................................................................................1422 S-17 Coolant temperature rises too high (overheating) ..............................................................................................1423 S-18 Unusual noise is heard ........................................................................................................................1424 S-19 Vibration is excessive ........................................................................................................................1425 S-20 Air cannot be bled from fuel circuit ..........................................................................................................1426 50 Disassembly and assembly ................................................................................................................................1427 Table of contents ......................................................................................................................................1428 Related information on disassembly and assembly ........................................................................................................1430 How to read this manual ............................................................................................................................1430 Coating materials list .............................................................................................................................1432 Special tools list .................................................................................................................................1436 Sketches of special tools ..........................................................................................................................1444 Engine and cooling system ..............................................................................................................................1459 Removal and installation of supply pump assembly ...................................................................................................1459 Removal and installation of fuel injector assembly .................................................................................................1462 Removal and installation of cylinder head assembly .................................................................................................1467 Removal and installation of radiator assembly ......................................................................................................1477 Removal and installation of aftercooler assembly ...................................................................................................1480 Removal and installation of hydraulic oil cooler assembly ..........................................................................................1483 Removal and installation of cooling fan drive assembly .............................................................................................1485 Removal and installation of cooling fan motor assembly .............................................................................................1487 Removal and installation of engine and HST pump assembly ...........................................................................................1489 Disassembly and assembly of damper assembly ........................................................................................................1493 Removal and installation of engine front oil seal ..................................................................................................1494 Removal and installation of engine rear oil seal ...................................................................................................1496 Removal and installation of engine hood assembly ...................................................................................................1498 Removal and installation of fuel tank assembly .....................................................................................................1501 Removal and installation of KCCV assembly ..........................................................................................................1503 Removal and installation of turbocharger assembly ..................................................................................................1504 Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly ........................................................................1505 Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly .........................................................................1507 Removal and installation of starting motor assembly ................................................................................................1508 Removal and installation of belt for alternator and air conditioner compressor .....................................................................1509 Removal and installation of air cleaner assembly ...................................................................................................1511 Power train ............................................................................................................................................1513 Removal and installation of HST motor and final drive assembly .....................................................................................1513 Disassembly and assembly of final drive ............................................................................................................1515 Undercarriage and frame ................................................................................................................................1523 Removal and installation of idler and recoil spring assembly .......................................................................................1523 Disassembly and assembly of idler ..................................................................................................................1524 Disassembly and assembly of recoil spring ..........................................................................................................1527 Disassembly and assembly of track roller assembly ..................................................................................................1531 Disassembly and assembly of carrier roller assembly ................................................................................................1535 Separation and connection of track shoe assembly (Standard type track shoe) ........................................................................1537 Separation and connection of track shoe assembly (PLUS type track shoe) ............................................................................1541 Hydraulic system .......................................................................................................................................1542 Removal and installation of hydraulic tank assembly ................................................................................................1542 Removal and installation of control valve assembly .................................................................................................1544 Removal and installation of HST pump assembly ......................................................................................................1546 Disassembly and assembly of hydraulic cylinder assembly ............................................................................................1548 Work equipment .........................................................................................................................................1556 Removal and installation of work equipment assembly ................................................................................................1556 Removal and installation of blade assembly .........................................................................................................1560 Removal and installation of U-frame assembly .......................................................................................................1563 Cab and its attachments ................................................................................................................................1566 Removal and installation of ROPS cab assembly ......................................................................................................1566 Removal and installation of wiper arm ..............................................................................................................1571 Removal and installation of operator's cab glass (adhesion glass) ..................................................................................1573 Removal and installation of operator's seat ........................................................................................................1579 Removal and installation of seat belt ..............................................................................................................1580 Removal and installation of foot heater assembly ...................................................................................................1581 Disassembly and assembly of foot heater assembly ...................................................................................................1583 Removal and installation of air conditioner unit assembly ..........................................................................................1584 Removal and installation of air conditioner compressor assembly ....................................................................................1589 Electrical system ......................................................................................................................................1591 Removal and installation of machine monitor assembly ...............................................................................................1591 Removal and installation of engine controller assembly .............................................................................................1592 Removal and installation of HST controller assembly ................................................................................................1593 Removal and installation of mass air flow and temperature sensor ...................................................................................1594 Removal and installation of KOMTRAX terminal .......................................................................................................1595 Removal and installation of ICT sensor controller assembly .........................................................................................1596 Removal and installation of control box ............................................................................................................1597 Removal and installation of GNSS receiver ..........................................................................................................1598 Removal and installation of GNSS antenna ...........................................................................................................1599 Removal and installation of IMU sensor .............................................................................................................1602 60 Maintenance standard ....................................................................................................................................1605 Table of contents ......................................................................................................................................1606 Engine and cooling system ..............................................................................................................................1607 Engine mount .......................................................................................................................................1607 Cooling fan motor ..................................................................................................................................1608 Oil cooler bypass and HST charge safety valve ......................................................................................................1610 Power train ............................................................................................................................................1611 Damper .............................................................................................................................................1611 HST pump ...........................................................................................................................................1612 HST motor ..........................................................................................................................................1614 Charge pump ........................................................................................................................................1615 Solenoid valve .....................................................................................................................................1616 Final drive ........................................................................................................................................1617 Sprocket ...........................................................................................................................................1618 Full-scale drawing of sprocket tooth profile .......................................................................................................1622 Undercarriage and frame ................................................................................................................................1624 Track frame and idler cushion ......................................................................................................................1624 Idler ..............................................................................................................................................1627 Track roller .......................................................................................................................................1631 Carrier roller .....................................................................................................................................1635 Track shoe .........................................................................................................................................1637 Hydraulic system .......................................................................................................................................1642 Hydraulic tank .....................................................................................................................................1642 Work equipment and cooling fan pump ................................................................................................................1643 Control valve ......................................................................................................................................1646 Ripper PPC valve ...................................................................................................................................1653 Work equipment .........................................................................................................................................1655 Blade ..............................................................................................................................................1655 Cutting edge and end bit ...........................................................................................................................1658 Ripper .............................................................................................................................................1659 Lift cylinder ......................................................................................................................................1661 Lift cylinder with stroke and reset sensor .........................................................................................................1662 Tilt cylinder with stroke sensor ...................................................................................................................1663 Angle cylinder .....................................................................................................................................1664 Angle cylinder with stroke and reset sensor ........................................................................................................1665 Ripper cylinder ....................................................................................................................................1666 Cab and its attachments ................................................................................................................................1667 Cab mount ..........................................................................................................................................1667 Electrical system ......................................................................................................................................1668 System component parts .............................................................................................................................1668 Sensor .............................................................................................................................................1669 80 Appendix ................................................................................................................................................1673 Table of contents ......................................................................................................................................1674 Air conditioner components .............................................................................................................................1675 Precautions for refrigerant ........................................................................................................................1675 Air conditioner component ..........................................................................................................................1676 Configuration and function of refrigeration cycle ..................................................................................................1679 Outline of refrigeration cycle .....................................................................................................................1680 Air conditioner unit ...............................................................................................................................1682 Dual pressure switch ...............................................................................................................................1686 Pressure switch ....................................................................................................................................1687 Compressor .........................................................................................................................................1688 Condenser ..........................................................................................................................................1689 Receiver drier .....................................................................................................................................1691 Procedure for testing and troubleshooting ..........................................................................................................1692 Electrical circuit diagram .........................................................................................................................1695 System diagram .....................................................................................................................................1696 Parts and connectors layout ........................................................................................................................1698 Testing relays .....................................................................................................................................1703 Troubleshooting chart 1 ............................................................................................................................1705 Troubleshooting chart 2 ............................................................................................................................1706 Information described in troubleshooting table .....................................................................................................1708 A-1 Troubleshooting for condenser fan ..............................................................................................................1709 A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ......................................................................1712 A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) .............................................................1716 A-4 Troubleshooting for temperature control ........................................................................................................1718 Troubleshooting with gauge pressure ................................................................................................................1721 Connection of service tool .........................................................................................................................1724 Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit ............................................................1726 Handling of compressor oil .........................................................................................................................1728 90 Diagrams and drawings ...................................................................................................................................1731 Table of contents ......................................................................................................................................1732 Hydraulic circuit diagram ..............................................................................................................................1733 Symbols in hydraulic circuit diagram ...............................................................................................................1733 Hydraulic circuit diagram ..........................................................................................................................1737 Electric circuit diagram ...............................................................................................................................1739 Symbols in electric circuit diagram ................................................................................................................1739 Electrical circuit diagram .........................................................................................................................1743 INDEX.......................................................................................................................................................1763
DESCRIPTION:
KOMATSU D37EXi-23 D37PXi-23 D39EXi-23 D39PXi-23 BULLDOZER SHOP MANUAL SEN06486-07 – PDF DOWNLOAD
General precautions
• Before performing any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the operation and maintenance manual.
• Locate a place in the repair workshop to keep the tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
• When performing any work, always wear the safety shoes and helmet. Do not wear loose work cloths, or clothes with buttons missing.
1. Always wear the protective eyeglasses when hitting parts with a hammer.
2. Always wear the protective eyeglasses when grinding parts with a grinder, etc.
• When performing any work with 2 or more workers, always agree on the working procedure before starting. While working, always keep conversations of the work between your fellow workers and your self on any step of the work. During the work, hang the warning tag of “UNDER WORKING” in the operator’s compartment.
• Only qualified workers must perform the work and operation which require license or qualification.
• Keep the tools in good condition. And learn the correct way to use the tools, and use the proper ones among them. Before starting the work, thoroughly check the tools, lift truck, service vehicle, etc.
• If welding repairs is required, always have a trained and experienced welder with good knowledge of welding perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap, etc.
• Before starting work, warm up your body thoroughly to start work under good condition.
• Avoid continuing work for long hours and take rests with proper intervals to keep your body in good condition. Take a rest in a specified safe place
S.S 28/12/24
