Komatsu D39EX-21 D39PX-21 Bulldozer Shop Manual SEBM023810 PDF

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Komatsu D39EX-21 D39PX-21 Bulldozer Shop Manual SEBM023810 – PDF DOWNLOAD

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Komatsu D39EX-21 D39PX-21 Bulldozer Shop Manual SEBM023810 – PDF DOWNLOAD 

Language : English
Pages : 464
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu D39EX-21 D39PX-21 Bulldozer Shop Manual SEBM023810 – PDF DOWNLOAD 

MACHINE MODEL   SERIAL No.
D39EX-21                  1001 and up
D39PX-21                  1001 and up

HOW TO READ THE SHOP MANUAL
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop. For
ease of understanding, the manual is divided into the following sections.
00. FOREWORD
This section explains the safety and basic information.
01. GENERAL
This section explains the specifications of the machine.
10. STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly
and service.
20. TESTING AND ADJUSTING
Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting,
and troubleshooting. This standard value table is used to check the standard values in testing and
adjusting and to judge parts in troubleshooting.
Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided
by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in
the Chassis volume and Engine volume. In this case, see the Chassis volume.
30. DISASSEMBLY AND ASSEMBLY
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and quantity
and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. OTHERS (chassis volume)/Repair and replacement of parts (engine volume)
• Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
• Engine volume
This section explains the method of reproducing, repairing, and replacing parts.

TABLE OF CONTENTS:

Komatsu D39EX-21 D39PX-21 Bulldozer Shop Manual SEBM023810 – PDF DOWNLOAD 

MACHINE MODEL   SERIAL No.
D39EX-21                  1001 and up
D39PX-21                  1001 and up

COVER 1
CONTENTS 2
01 GENERAL 35
SPECIFICATION DRAWING 36
SPECIFICATIONS 37
WEIGHT TABLE 41
TABLE OF FUEL, COOLANT AND LUBRICANTS 43
10 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD 44
COOLING SYSTEM 45
ENGINE CONTROL 46
POWER TRAIN 47
POWER TRAIN SYSTEM 48
HST HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAM 49
STEERING, BRAKE CONTROL 51
DAMPER 57
SOLENOID VALVE 58
FINAL DRIVE 60
HST PUMP 63
SAFETY-SUCTION VALVE 68
CUT-OFF VALVE 71
CHARGE SAFETY VALVE 72
CHARGE PUMP 74
HST BRAKE QUICK RETURN CIRCUIT 75
TOWING VALVE 76
PARKING BRAKE VALVE 77
AS VALVE 79
HST MOTOR 81
STEERING, DIRECTIONAL PPC VALVE 92
INCHING VALVE 101
AUTOMATIC GEARSHIFTING VALVE 103
FRAME ASSEMBLY 108
TRACK FRAME, RECOIL SPRING 109
IDLER 111
TRACK ROLLER 113
CARRIER ROLLER 114
SPROCKET 115
TRACK SHOE 117
ARRANGEMENT OF HYDRAULIC EQUIPMENT FOR WORK EQUIPMENT 121
WORK EQUIPMENT CONTROL 122
HYDRAULIC TANK, FILTER 124
HYDRAULIC PUMP 125
WORK EQUIPMENT CYLINDER 126
SUCTION VALVE 128
CONTROL VALVE 130
CLSS 138
WORK EQUIPMENT PPC VALVE 148
WORK EQUIPMENT 155
CUTTING EDGE, END BIT 158
CAB RELATED 159
SAFETY MECHANISM WHEN STARTING ENGINE 160
GEARSHIFT CONTROL SYSTEM 161
PARKING BRAKE CONTROL SYSTEM 162
COMPONENT EQUIPMENT OF SYSTEM 163
MONITOR SYSTEM 165
SENSORS 169
20 TESTING AND ADJUSTING 172
STANDARD VALUE TABLE FOR ENGINE 173
STANDARD VALUE TABLE FOR CHASSIS 174
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM 179
TESTING AND ADJUSTING 181
TOOLS LIST FOR TESTING AND ADJUSTING 182
MEASURING ENGINE SPEED 185
MEASURING EXHAUST COLOR 186
MEASURING BLOW-BY PRESSURE 187
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) 188
ADJUSTING VALVE CLEARANCE 189
TESTING ADJUSTING FUEL INJECTION TIMING 191
MEASURING COMPRESSION PRESSURE 192
ADJUSTING ENGINE STOP SOLENOIDE LINKAGE 193
MEASURING ENGINE OIL PRESSURE 194
BLEEDING AIR FROM FUEL CIRCUIT 195
REPLACEMENT OF FAN BELT 196
TESTING AND ADJUSTING TENSION OF AIR CONDITIONER COMPRESSOR BELT 198
MEASURING AND ADJUSTING HST OIL PRESSURE 199
MEASURING SOLENOID VALVE OUTPUT PRESSURE 204
MEASURING AND ADJUSTING WORK EQUIPMENT MAIN RELIEF PRESSURE 205
MEASURING PPC VALVE OUTPUT PRESSURE 207
MEASURING LEAKAGE INSIED CYLINDER 208
BLEEDING AIR FROM HYDRAULIC CYLINDERS 208
TESTING AND ADJUSTING TRACK SHOE TENSION 209
TESTING AND ADJUSTING TRAVEL DEVIATION 210
ADJUSTING FUEL CONTROL LINKAGE 213
ADJUSTING DECELERATOR PEDAL LINKAGE 215
ADJUSTING BRAKE PEDAL LINKAGE 216
ADJUSTING STEERING/DIRECTIONAL/GEAR SHIFT LEVER AND LOCK LEVER 218
ADJUSTING BLADE CONTROL LEVER AND LOCK LEVER 221
ADJUSTING WORK EQUIPMENT PPC VALVE 222
PROCEDURE FOR RELEASING PARKING BRAKE 223
PROCEDURE FOR INSPECTING DIODE 225
TROUBLESHOOTING 226
POINTS TO REMEMBER WHEN TROUBLESHOOTING 227
SEQUENCE OF EVENTS IN TROUBLESHOOTING 228
HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT 229
CHECKS BEFORE TROUBLESHOOTING 239
METHOD OF USING TROUBLESHOOTING CHARTS 240
TYPES AND LOCATIONS OF CONNECTORS 241
CONNECTOR ARRANGEMENT DIAGRAM 243
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 245
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 281
TROUBLESHOOTING FOR ELECTRICAL SYSTEM (E-MODE) 284
TABLE OF FAILURE MODES AND CAUSES (ELECTRICAL SYSTEM) 285
ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM 287
E-1 WHEN STARTING SWITCH IS TURNED ON, STARTING MOTOR DOES NOT ROTATE 289
E-2 ENGINE DOES NOT START (ENGINE STOP SOLENOID DOES NOT OPERATE NORMALLY) 291
E-3 HEADLAMP DOES NOT LIGHT UP 292
E-4 WHEN STARTING SWITCH IS TURNED TO HEAT POSITION, ENGINE IS NOT HEATED 294
E-5 WINDSHIELD WIPER DOES NOT OPERATE 295
E-6 WASHING WATER DOES NOT SPOUT 297
E-7 AIR CONDITIONER DOES NOT WORK 299
(a) AIR DOES NOT BLOW OUT 299
(b) AIR IS NOT COOLED 302
E-8 PARKING BRAKE CANNOT BE RELEASED (PARKING BRAKE SOLENOID DOES NOT OPERATE) 306
E-9 TRAVEL SPEED CONTROL IS ABNORMAL 307
(a) WHEN GEAR SHIFT SWITCH IS PRESSED, GEAR SPEED DOES NOT CHANGE OR GEAR SPEED CHANGES BY ITSELF (GEAR SHIFT SWITCH OR CONTROLLER IS ABNORMAL) 307
(b) GEAR SPEED CANNOT BE SELECTED NORMALLY (TRAVEL SPEED CHANGEOVER SOLENOID IS ABNORMAL) 308
E-10 BACKUP ALARM DOES NOT SOUND DURING REVERSE TRAVEL 310
E-11 HORN DOES NOT SOUND 312
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) 313
TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC AND MECHANICAL SYSTEMS) 314
H-1 MACHINE DOES NOT TRAVEL IN EITHER DIRECTION OR IT STOPS SUDDENLY 316
H-2 MACHINE DOES NOT TRAVEL IN ONE DIRECTION 317
H-3 MACHINE TRAVELS WHILE TRAVEL LEVER IS IN NEUTRAL 317
H-5 MACHINE DEVIATES WHILE TRAVEL LEVER IS IN PARTIAL POSITION 317
H-7 MACHINE SWINGS MOMENTARILY WHEN IT STARTS ON FLAT GROUND 317
H-11 TURNING TIME LAG IS LARGE 317
H-12 WHEN OPERATOR INTENDS TO TURN GRADUALLY, MACHINE TURNS SHARPLY 317
H-13 MACHINE DOES NOT RETURN QUICKLY TO STRAIGHT TRAVEL POSITION 317
H-14 MACHINE IS NOT DECELERATED SMOOTHLY OR TRAVEL SPEED CANNOT BE CONTROLLED ON DOWNHILL GROUND 317
H-15 MACHINE DEVIATES WHEN IT IS DECELERATED 317
H-4 MACHINE DEVIATES WHEN TRAVEL LEVER IS MOVED TO STROKE END 318
H-6 MACHINE MOVES BACK WHEN OPERATOR STARTS ON UPHILL GROUND 318
H-8 MACHINE STARTS SHARPLY 318
H-9 MACHINE SWINGS MOMENTARILY WHEN IT STARTS 319
H-10 STARTING TIME LAG IS LARGE 320
H-16 MAXIMUM TRAVEL SPEED IS LOW OR OUTPUT POWER IS INSUFFICIENT OR ACCELERATION IS LOW 321
H-17 ENGINE STALLS 322
H-18 HST NOISE IS LARGE 323
H-19 HST OIL TEMPERATURE RISES TOO HIGH 324
H-20 GEAR SPEED DOES NOT CHANGE 324
H-21 ABNORMAL SOUND IS HEARD FROM AROUND WORK EQUIPMENT PUMP OR HST PUMP 325
H-22 ANY WORK EQUIPMENT DOES NOT MOVE 325
H-23 SPEED OR POWER OF EACH WORK EQUIPMENT IS LOW 326
H-24 SPEED OR POWER OF BLADE LIFT OF BLADE TILT CYLINDER IS LOW 326
H-25 SPEED OR POWER OF BLADE ANGLE CYLINDER IS LOW 327
H-26 HYDRAULIC DRIFT OF BLADE LIFT CYLINDER IS LARGE 328
H-27 HYDRAULIC DRIFT OF BLADE TILT CYLINDER IS LARGE 328
H-28 HYDRAULIC DRIFT OF BLADE ANGLE CYLINDER IS LARGE 329
TROUBLESHOOTING FOR MACHINE MONITOR SYSTEM (M-MODE) 330
TABLE OF FAILURE MODES AND CAUSES (MACHINE MONITOR SYSTEM) 331
ELECTRIC CIRCUIT DIAGRAM FOR EACH SYSTEM 332
M-1 WHEN STARTING SWITCH IS TURNED ON , MONITOR PANEL IS NOT TURNED ON 334
M-2 TROUBLE IN PREHEATING CAUTION LAMP 335
(a) PREHEATING MONITOR DOES NOT LIGHT UP 335
(b) PREHEATING MONITOR KEEPS LIGHTING UP 335
M-3 CAUTION ITEM LIGHTS UP 336
(a) CHARGE CAUTION LAMP LIGHTS UP WHILE ENGINE IS RUNNING 336
(b) OIL PRESSURE CAUTION LAMP LIGHTS UP WHILE ENGINE IS RUNNING 337
(c) HST FILTER CLOGGING CAUTION LAMP LIGHTS UP (WHILE FILTER IS NOT CLOGGED) 337
M-4 TROUBLE IN HST OIL TEMPERATURE GAUGE 338
(a) GAUGE DOES NOT RISE ABOVE C (LOWEST POINT) 338
(b) GAUGE DOES NOT LOWER BELOW H (HIGHEST POINT) 338
(c) HST OIL TEMPERATURE INDICATED BY GAUGE IS DIFFERENT FROM ACTUAL TEMPERATURE 339
M-5 TROUBLE IN ENGINE WATER TEMPERATURE GAUGE 340
(a) GAUGE DOES NOT RISE ABOVE C (LOWEST POINT) 340
(b) GAUGE DOES NOT LOWER BELOW H (HIGHEST POINT) 340
(c) ENGINE WATER TEMPERATURE INDICATED BY GAUGE IS DIFFERENT FROM ACTUAL TEMPERATURE 341
M-6 TROUBLE IN FUEL LEVEL GAUGE 342
(a) GAUGE DOES NOT RISE ABOVE E (LOWEST POINT) 342
(b) GAUGE DOES NOT LOWER BELOW F (HIGHEST POINT) 342
(c) FUEL LEVEL INDICATED BY GAUGE IS DIFFERENT FROM ACTUAL LEVEL 343
M-7 SERVICE METER DOES NOT OPERATE AFTER ENGINE IS STARTED 344
M-8 MONITOR PANEL LAMP DOES NOT LIGHT UP (WHILE HEADLAMP IS NORMAL) 345
M-9 TROUBLE IN DISPLAY OF TRAVEL SPEED (WHILE ACTUAL TRAVEL SPEED IS NORMAL) 346
(a) TRAVEL SPEED IS NOT DISPLAYED 346
(b) DISPLAYED SPEED IS DIFFERENT FROM ACTUAL TRAVEL SPEED 346
TROUBLESHOOTING FOR ENGINE SYSTEM (S-MODE) 348
METHOD OF USING TROUBLESHOOTING CHARTS 349
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 353
S-2 ENGINE DOES NOT START 354
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 357
S-4 ENGINE STOPS DURING OPERATIONS 358
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 359
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER) 360
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) 361
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) 362
S-9 OIL BECOMES CONTAMINATED QUICKLY 363
S-10 FUEL CONSUMPTION IS EXCESSIVE 364
S-11 OIL IS IN COOLANT, OR COOLANT SPURTS BACK, OR COOLANT LEVEL GOES DOWN 365
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) 366
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL) 367
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 368
S-15 ABNORMAL NOISE IS MADE 369
S-16 VIBRATION IS EXCESSIVE 370
30 DISASSEMBLY AND ASSEMBLY 372
HOW TO READ THIS MANUAL 373
COATING MATERIALS LIST 375
SPECIAL TOOL LIST 378
SKETCHES OF SPECIAL TOOLS 380
REMOVAL OF FUEL INJECTION PUMP ASSEMBLY 381
INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY 383
REMOVAL OF CYLINDER HEAD ASSEMBLY 385
INSTALLATION OF CYLINDER HEAD ASSEMBLY 390
REMOVAL OF ENGINE FRONT SEAL 392
INSTALLATION OF ENGINE FRONT SEAL 393
REMOVAL OF ENGINE REAR SEAL 394
INSTALLATION OF ENGINE REAR SEAL 395
REMOVAL OF RADIATOR GUARD ASSEMBLY 396
INSTALLATION OF RADIATOR GUARD ASSEMBLY 398
DISASSEMBLY OF RADIATOR, OIL COOLER, AND CHARGE AIR COOLER ASSEMBLIES 399
ASSEMBLY OF RADIATOR, OIL COOLER, AND CHARGE AIR COOLER ASSEMBLIES 401
REMOVAL OF ENGINE ASSEMBLY 403
INSTALLATION OF ENGINE ASSEMBLY 405
REMOVAL OF DAMPER 406
INSTALLATION OF DAMPER 406
REMOVAL OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 407
INSTALLATION OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 408
DISASSEMBLY OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 409
ASSEMBLY OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 413
REMOVAL OF IDLER AND RECOIL SPRING ASSEMBLY 418
INSTALLATION OF IDLER AND RECOIL SPRING ASSEMBLY 418
DISASSEMBLY OF RECOIL SPRING ASSEMBLY 419
ASSEMBLY OF RECOIL SPRING ASSEMBLY 420
DISASSEMBLY OF IDLER ASSEMBLY 422
ASSEMBLY OF IDLER ASSEMBLY 423
DISASSEMBLY OF TRACK ROLLER ASSEMBLY 425
ASSEMBLY OF TRACK ROLLER ASSEMBLY 426
DISASSEMBLY OF CARRIER ROLLER ASSEMBLY 429
ASSEMBLY OF CARRIER ROLLER ASSEMBLY 430
SPREADING TRACK SHOE ASSEMBLY 431
INSTALLATION OF TRACK SHOE ASSEMBLY 432
REMOVAL OF HST PUMP ASSEMBLY 433
INSTALLATION OF HST PUMP ASSEMBLY 434
REMOVAL OF MAIN CONTROL VALVE ASSEMBLY 435
INSTALLATION OF MAIN CONTROL VALVE ASSEMBLY 436
DISASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY 437
ASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY 441
DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLIES 445
ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLIES 446
REMOVAL OF BALDE ASSEMBLY 448
INSTALLATION OF BLADE ASSEMBLY 449
REMOVAL OF OPERATOR’S CAB FRAME ASSEMBLY 450
INSTALLATION OF OPERATO’S CAB FRAME ASSEMBLY 454
REMOVAL OF FUEL TANK ASSEMBLY 455
INSTALLATION OF FUEL TANK ASSEMBLY 455
REMOVAL OF HYDRAULIC TANK ASSEMBLY 456
INSTALLATION OF HYDRAULIC TANK ASSEMBLY 457
90 OTHERS 458
HYDRAULIC CIRCUIT DIAGRAM (1/2)(D39EX-21 SERIAL NO 1001-1200 D39PX-21 SERIAL NO 1001-1208) 459
HYDRAULIC CIRCUIT DIAGRAM (1/2) (D39EX-21 SERIAL NO 1201 AND UP D39PX-21 SERIAL NO 1209 AND UP) 460
HYDRAULIC CIRCUIT DIAGRAM (2/2) 461
ELECTRICAL CIRCUIT DIAGRAM (1/2) 462
ELECTRICAL CIRCUIT DIAGRAM (2/2) 463
ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER 464

IMAGES PREVIEW OF THE MANUAL:

S.V  17/12/24