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KOMATSU D39EX-22 D39PX-22 BULLDOZER SERVICE REPAIR MANUAL (SEN04041-05)`- PDF DOWNLOAD
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- KOMATSU D39EX-22 D39PX-22 BULLDOZER SERVICE REPAIR MANUAL
- PUBLICATION NUMBER:SEN04041-05
- SERIAL NUMBERS D39EX-3001 and up
D39PX-3001 and up
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Description
KOMATSU D39EX-22 D39PX-22 BULLDOZER SERVICE REPAIR MANUAL (SEN04041-05)
KOMATSU D39EX-22 D39PX-22 BULLDOZER SERVICE REPAIR MANUAL (SEN04041-05)`- PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU D39EX-22 D39PX-22 BULLDOZER SERVICE REPAIR MANUAL (SEN04041-05)
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. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and 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. 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.
30. 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.
40. 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.
50. 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. Diagrams and drawings (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-22 D39PX-22 BULLDOZER SERVICE REPAIR MANUAL (SEN04041-05)
COVER ....................................................................................................................................................... 1 00 Index and foreword........................................................................................................................................ 0 100 Index................................................................................................................................................ 2 Composition of shop manual........................................................................................................................... 3 Table of contents.................................................................................................................................... 5 200 Foreword and general information..................................................................................................................... 14 Safety notice........................................................................................................................................ 15 How to read the shop manual.......................................................................................................................... 20 Explanation of terms for maintenance standard........................................................................................................ 22 Handling of electric equipment and hydraulic component............................................................................................... 24 Handling of connectors newly used for engines........................................................................................................ 33 How to read electric wire code....................................................................................................................... 36 Precautions when carrying out operation.............................................................................................................. 39 Method of disassembling and connecting push-pull type coupler........................................................................................ 42 Standard tightening torque table..................................................................................................................... 45 Conversion table..................................................................................................................................... 49 01 General................................................................................................................................................... 0 100 Specification and technical data..................................................................................................................... 56 Specification dimensional drawing.................................................................................................................... 57 Specifications....................................................................................................................................... 58 Weight table......................................................................................................................................... 62 Table of fuel, coolant and lubricants................................................................................................................ 64 10 Structure, function and maintenance standard.............................................................................................................. 0 100 Engine and cooling system............................................................................................................................ 66 Engine system parts.................................................................................................................................. 67 Cooling system....................................................................................................................................... 68 Cooling fan pump..................................................................................................................................... 69 Cooling fan motor.................................................................................................................................... 70 Oil cooler bypass valve.............................................................................................................................. 75 200 Power train.......................................................................................................................................... 80 Power train.......................................................................................................................................... 81 Power train system................................................................................................................................... 82 Damper............................................................................................................................................... 83 HST hydraulic equipment arrangement diagram.......................................................................................................... 84 Steering and brake control........................................................................................................................... 85 Solenoid valve....................................................................................................................................... 87 Final drive.......................................................................................................................................... 94 HST pump............................................................................................................................................. 97 HST motor............................................................................................................................................ 109 Charge pump.......................................................................................................................................... 119 300 Undercarriage and frame.............................................................................................................................. 122 Main frame........................................................................................................................................... 123 Track frame and idler cushion........................................................................................................................ 125 Idler................................................................................................................................................ 127 Track roller......................................................................................................................................... 129 Carrier roller....................................................................................................................................... 131 Sprocket............................................................................................................................................. 133 Track shoe........................................................................................................................................... 135 410 Hydraulic system, Part 1............................................................................................................................. 142 Arrangement of hydraulic equipment for work equipment................................................................................................ 143 Work equipment control............................................................................................................................... 145 Hydraulic tank and filter............................................................................................................................ 147 Work equipment and fan pump.......................................................................................................................... 149 Control valve........................................................................................................................................ 157 CLSS................................................................................................................................................. 169 Functions and operation of each valve................................................................................................................ 172 420 Hydraulic system, Part 2............................................................................................................................. 182 Blade PPC valve...................................................................................................................................... 183 Accumulator.......................................................................................................................................... 189 500 Work equipment....................................................................................................................................... 192 Work equipment....................................................................................................................................... 193 Cutting edge and end bit............................................................................................................................. 197 Ripper............................................................................................................................................... 198 Work equipment cylinder.............................................................................................................................. 199 Piston valve......................................................................................................................................... 202 600 Cab and its attachments.............................................................................................................................. 204 ROPS cab............................................................................................................................................. 205 Cab mount............................................................................................................................................ 206 Canopy mount......................................................................................................................................... 207 Air conditioner...................................................................................................................................... 208 700 Electrical system.................................................................................................................................... 212 Monitor system....................................................................................................................................... 213 Engine control....................................................................................................................................... 215 Engine control system................................................................................................................................ 216 Cooling control system............................................................................................................................... 217 HST control system................................................................................................................................... 219 Parking brake control system......................................................................................................................... 225 KOMTRAX system....................................................................................................................................... 227 Component equipment of system........................................................................................................................ 229 PCCS lever (for steering)............................................................................................................................ 237 Sensor............................................................................................................................................... 240 20 Standard value table...................................................................................................................................... 0 100 Standard service value table......................................................................................................................... 252 Standard service value table for engine.............................................................................................................. 253 Standard service value table for chassis............................................................................................................. 254 30 Testing and adjusting..................................................................................................................................... 0 110 Testing and adjusting, Part 1........................................................................................................................ 262 Tools for testing, adjusting, and troubleshooting.................................................................................................... 264 Sketches of special tools............................................................................................................................ 267 Measuring engine speed............................................................................................................................... 268 Measuring intake air pressure (boost pressure)....................................................................................................... 269 Measuring exhaust gas color (boost pressure)......................................................................................................... 271 Adjusting valve clearance............................................................................................................................ 272 Measuring compression pressure....................................................................................................................... 274 Measuring blow-by pressure........................................................................................................................... 277 Testing engine oil pressure.......................................................................................................................... 279 Handling fuel system equipment....................................................................................................................... 280 Releasing residual pressure in fuel system........................................................................................................... 280 Bleeding air from fuel circuit....................................................................................................................... 281 Measuring fuel pressure.............................................................................................................................. 282 Measuring fuel discharge, return and leakage......................................................................................................... 284 Testing leakage in fuel system....................................................................................................................... 288 Measurement of fan circuit pressure and fan speed.................................................................................................... 289 Adjustment of fan speed sensor....................................................................................................................... 290 Handling reduced cylinder mode operation............................................................................................................. 291 Handling no-injection cranking operation............................................................................................................. 291 Handling controller voltage circuit.................................................................................................................. 292 Check of muffler and muffler stack for looseness and damage.......................................................................................... 293 Check of muffler function............................................................................................................................ 293 Check of installed condition of cylinder head and manifolds.......................................................................................... 294 Check of engine piping for damage and looseness...................................................................................................... 294 Replacing alternator belt............................................................................................................................ 295 120 Testing and adjusting, Part 2........................................................................................................................ 298 Adjusting decelerator pedal.......................................................................................................................... 299 Testing and adjusting HST oil pressure............................................................................................................... 301 Measuring solenoid valve outlet pressure............................................................................................................. 306 Testing travel deviation............................................................................................................................. 309 Adjusting parking brake lever........................................................................................................................ 310 Simple brake performance test procedure.............................................................................................................. 312 Adjusting brake pedal................................................................................................................................ 313 Method of releasing parking brake (Procedure for emergency escape)................................................................................... 315 Testing and adjusting idler clearance................................................................................................................ 317 Testing and adjusting track shoe tension............................................................................................................. 318 Testing work equipment pressure...................................................................................................................... 319 Testing work equipment PPC valve..................................................................................................................... 321 Adjusting play of work equipment PPC valve........................................................................................................... 323 Adjusting work equipment lock lever.................................................................................................................. 324 Testing internal leakage of work equipment cylinder.................................................................................................. 325 Releasing residual pressure in hydraulic circuit..................................................................................................... 327 Bleeding air from hydraulic circuit.................................................................................................................. 328 Adjusting play of blade center ball.................................................................................................................. 329 Procedure for testing diodes......................................................................................................................... 330 Preparation work for troubleshooting for electrical system........................................................................................... 331 How to start operation of KOMTRAX terminal........................................................................................................... 335 Lamp display of KOMTRAX terminal..................................................................................................................... 338 130 Testing and adjusting, Part 3........................................................................................................................ 342 Special functions of monitor panel (EMMS)............................................................................................................ 343 Items to be adjusted when electric/hydraulic devices are adjusted/replaced........................................................................... 405 Adjustment procedure after replacement of HST controller............................................................................................. 406 Adjustment procedure after replacement of monitor panel.............................................................................................. 408 Pm-clinic............................................................................................................................................ 409 40 Troubleshooting........................................................................................................................................... 0 100 Failure code table and fuse locations................................................................................................................ 420 Failure code table................................................................................................................................... 421 Before carrying out troubleshooting for electrical system (E-mode)................................................................................... 427 200 General information on troubleshooting............................................................................................................... 430 Points to remember when troubleshooting.............................................................................................................. 431 Sequence of events in troubleshooting................................................................................................................ 432 Testing before troubleshooting....................................................................................................................... 433 Classification and procedures of troubleshooting..................................................................................................... 434 Information contained in troubleshooting table....................................................................................................... 437 Connection table for connector pin numbers........................................................................................................... 439 T- branch box and T- branch adapter table............................................................................................................ 475 310 Troubleshooting by failure code (Display of code), Part 1............................................................................................ 480 Failure code [6091NX] HST charge filter element: Clogging............................................................................................ 482 Failure code [AA10NX] Air cleaner: Clogging.......................................................................................................... 483 Failure code [AB00MA] Alternator: Malfunction........................................................................................................ 485 Failure code [B@BAZG] Engine oil: Lowering of oil pressure........................................................................................... 486 Failure code [B@BCNS] Coolant: Overheat.............................................................................................................. 487 Failure code [B@CRNS] HST oil: Overheating........................................................................................................... 488 Failure code [B@CRZG] HST oil: Lowering of oil pressure.............................................................................................. 489 Failure code [CA111] Engine controller: Abnormality in controller.................................................................................... 490 Failure code [CA115] Abnormal engine Ne and Bkup speed sensors: Abnormal speed sensor signal......................................................... 490 Failure code [CA122] Charge pressure sensor tool high: Excessively high voltage detected............................................................. 491 Failure code [CA123] Charge pressure sensor too low: Excessively low voltage detected................................................................ 493 Failure code [CA131] Decelerator pedal sensor tool high: Excessively high voltage detected........................................................... 495 Failure code [CA132] Decelerator pedal sensor too low: Excessively low voltage detected.............................................................. 497 Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected.......................................................... 499 Failure code [CA145] Coolant temperature sensor too low: Excessively low voltage detected............................................................ 501 Failure code [CA153] Charge air temperature sensor too high: Excessively high voltage detected....................................................... 503 Failure code [CA154] Charge temperature sensor too low: Excessively low voltage detected............................................................. 505 Failure code [CA187] Sensor power source 2 too low: Excessively low voltage detected................................................................. 507 Failure code [CA221] Atmospheric pressure sensor too high: Excessively high voltage detected......................................................... 509 Failure code [CA222] Atmospheric pressure sensor too low: Excessively low voltage detected........................................................... 511 Failure code [CA227] Sensor power source 2 too high: Excessively high voltage detected............................................................... 513 Failure code [CA234] Engine over speed: Excessively high speed....................................................................................... 515 Failure code [CA238] Abnormal power source for Ne speed sensor: Excessively low voltage detected..................................................... 516 Failure code [CA271] IMV/PCV1 short circuit: Short circuit........................................................................................... 517 Failure code [CA272] IMV/PCV1 disconnection: Disconnection........................................................................................... 519 320 Troubleshooting by failure code (Display of code), Part 2............................................................................................ 522 Failure code [CA322] Injector No. 1 system disconnection or short circuit: disconnection, short circuit.............................................. 525 Failure code [CA324] Injector No. 3 system disconnection or short circuit: disconnection, short circuit.............................................. 527 Failure code [CA331] Injector No. 2 system disconnection or short circuit: disconnection, short circuit.............................................. 529 Failure code [CA332] Injector No. 4 system disconnection or short circuit: disconnection, short circuit.............................................. 531 Failure code [CA342] Engine controller data matching error: matching error........................................................................... 533 Failure code [CA351] Injector drive circuit abnormality: Abnormal circuit............................................................................ 535 Failure code [CA352] Sensor power source 1 too low: Excessively low voltage detected................................................................. 537 Failure code [CA386] Sensor power source 1 too high: Excessively high voltage detected............................................................... 539 Failure code [CA428] Water in fuel sensor too high: Excessively high voltage detected................................................................ 541 Failure code [CA429] Water in fuel sensor too low: Excessively low voltage detected.................................................................. 543 Failure code [CA435] Abnormal engine oil pressure switch: Abnormal signal circuit.................................................................... 545 Failure code [CA441] Power source voltage too low: Excessively low voltage detected.................................................................. 547 Failure code [CA442] Power source voltage too high: Excessively high voltage has occurred in the controller power source circuit..................... 549 Failure code [CA449] Common rail pressure too high (2): Excessively high pressure trouble occurred................................................... 551 Failure code [CA451] Common rail pressure sensor too high: Excessively high voltage detected......................................................... 553 Failure code [CA452] Common rail pressure sensor too low: Excessively low voltage detected........................................................... 555 Failure code [CA488] Charge temperature too high and torque derated: Exceeded upper control limit of temperature..................................... 557 Failure code [CA553] Common rail pressure too high (1): Excessively high pressure detected........................................................... 558 Failure code [CA559] Loss of pressure feed from supply pump (1): Loss of pressure feed detected...................................................... 559 Failure code [CA689] Abnormal engine Ne speed sensor: Abnormal signal................................................................................ 561 Failure code [CA731] Abnormal engine Bkup speed sensor phase: Abnormal phase......................................................................... 563 Failure code [CA757] Loss of all engine controller data: Loss of all data............................................................................ 565 Failure code [CA778] Abnormal engine Bkup speed sensor: Abnormal Bkup signal......................................................................... 567 Failure code [CA1633] Abnormal KOMNET: Abnormal communication........................................................................................ 569 Failure code [CA2185] Decelerator pedal sensor power source too high: Excessively high voltage detected.............................................. 571 Failure code [CA2186] Decelerator pedal sensor power source too low: Excessively low voltage detected................................................ 573 Failure code [CA2249] Loss of pressure feed from supply pump (2): Loss of pressure feed detected..................................................... 575 Failure code [CA2311] Abnormal IMV solenoid: Abnormal resistance..................................................................................... 577 Failure code [CA2555] Air intake heater relay disconnection: Disconnection........................................................................... 579 Failure code [CA2556] Air intake heater relay short circuit: Short circuit........................................................................... 581 330 Troubleshooting by failure code (Display of code), Part 3............................................................................................ 584 Failure code [D130KA] Neutral safety relay: Disconnection............................................................................................ 587 Failure code [D130KB] Neutral safety relay: Short circuit............................................................................................ 589 Failure code [DAFRKR] CAN communication (Monitor panel - HST controller): Defective communication (Abnormality in objective component system)........ 591 Failure code [DAFRMC] CAN communication (Monitor panel - ENGINE controller): Defective communication (Abnormality in objective component system)..... 594 Failure code [DAJ000] HST controller: Memory error................................................................................................... 597 Failure code [DAJ0KK] HST controller: Lowing of source voltage....................................................................................... 599 Failure code [DAJ0KQ] HST controller: Machine code error............................................................................................. 601 Failure code [DAJ0KT] HST controller: Memory error................................................................................................... 602 Failure code [DAJ5KK] HST controller sensor 5 V power supply No.1: Lowing of source voltage/Input.................................................... 603 Failure code [DAJ6KK] HST controller sensor 5 V power supply No.2: Lowing of source voltage/Input.................................................... 605 Failure code [DAJRKR] CAN communication (HST controller - Monitor panel): Defective communication (Abnormality in objective component system)........ 607 Failure code [DB2RKR] CAN communication (HST controller - Engine controller): Defective communication (Abnormality in objective component system).... 610 Failure code [DD12KA] Shift up switch: Disconnection................................................................................................. 613 Failure code [DD12KB] Shift up switch: Short circuit................................................................................................. 615 Failure code [DD13KA] Shift down switch: Disconnection............................................................................................... 617 Failure code [DD13KB] Shift down switch: Short circuit............................................................................................... 619 Failure code [DD14KB] Travel lock limit switch 1: Short circuit...................................................................................... 621 Failure code [DD1NL4] Fan rotation selector switch: Disagreement of ON, OFF Signals.................................................................. 623 Failure code [DDDCKB] Reverse travel speed switch: Short circuit..................................................................................... 625 Failure code [DDP6KA] Brake oil pressure sensor: Disconnection....................................................................................... 627 Failure code [DDP6KB] Brake oil pressure sensor: Short circuit....................................................................................... 629 Failure code [DDP6MA] Brake oil pressure sensor: Malfunction......................................................................................... 631 Failure code [DDQ2KA] Travel lock limit switch 1: Disconnection...................................................................................... 633 Failure code [DDT0L4] Shift mode switch: Disagreement of ON/ OFF Signals............................................................................. 635 Failure code [DDU1FS] Travel lock limit switches 1 and 2: Fixing..................................................................................... 637 Failure code [DDU1KA] Travel lock limit switch 2: Disconnection...................................................................................... 639 Failure code [DDU1KY] Travel lock limit switch 2: Short circuit with power supply line............................................................... 641 Failure code [DGS1KA] HST oil temperature sensor: Disconnection...................................................................................... 643 Failure code [DGS1KX] HST oil temperature sensor: Out of Input signal range.......................................................................... 645 340 Troubleshooting by failure code (Display of code), Part 4............................................................................................ 648 Failure code [DHH5KA] Left HST pump pressure sensor: Disconnection................................................................................... 651 Failure code [DHH5KB] Left HST pump pressure sensor: Short circuit................................................................................... 653 Failure code [DHH6KA] Right HST pump pressure sensor: Disconnection.................................................................................. 655 Failure code [DHH6KB] Right HST pump pressure sensor: Short circuit.................................................................................. 657 Failure code [DK10KA] Fuel dial sensor: Disconnection................................................................................................ 659 Failure code [DK10KB] Fuel dial sensor: Short circuit................................................................................................ 661 Failure code [DK30KA] Steering angle sensor 1: Disconnection......................................................................................... 663 Failure code [DK30KB] Steering angle sensor 1: Short circuit......................................................................................... 665 Failure code [DK30KX] Steering angle sensor: Out of input signal range............................................................................... 667 Failure code [DK30KZ] Steering angle sensor: Disconnection or short circuit.......................................................................... 668 Failure code [DK30L8] Steering angle sensor: Disagreement of analog signals.......................................................................... 669 Failure code [DK31KA] Steering angle sensor 2: Disconnection......................................................................................... 671 Failure code [DK31KB] Steering angle sensor 2: Short circuit......................................................................................... 673 Failure code [DK40KA] Brake pedal sensor: Disconnection.............................................................................................. 675 Failure code [DK40KB] Brake pedal sensor: Short circuit.............................................................................................. 677 Failure code [DK55KX] Directional potentiometer: Out of input signal range........................................................................... 679 Failure code [DK55KZ] Directional potentiometer: Disconnection or short circuit...................................................................... 680 Failure code [DK55L8] Directional potentiometer: Disagreement of analog signals...................................................................... 681 Failure code [DK56KA] Directional potentiometer 1: Disconnection..................................................................................... 683 Failure code [DK56KB] Directional potentiometer 1: Short circuit..................................................................................... 685 Failure code [DK57KA] Directional potentiometer 2: Disconnection..................................................................................... 687 Failure code [DK57KB] Directional potentiometer 2: Short circuit..................................................................................... 689 Failure code [DLM0KX] HST motor speed sensors: Out of input signal range............................................................................. 691 Failure code [DLM1KA] Left HST motor speed sensor: Disconnection..................................................................................... 693 Failure code [DLM1KB] Left HST motor speed sensor: Short circuit..................................................................................... 695 Failure code [DLM1MA] Left HST motor speed sensor: Malfunction....................................................................................... 697 Failure code [DLM2KA] Right HST motor speed sensor: Disconnection.................................................................................... 699 Failure code [DLM2KB] Right HST motor speed sensor: Short circuit.................................................................................... 701 Failure code [DLM2MA] Right HST motor speed sensor: Malfunction...................................................................................... 703 Failure code [DLM3KA] Fan speed sensor: Disconnection................................................................................................ 705 Failure code [DLM3KB] Fan speed sensor: Short circuit................................................................................................ 707 350 Troubleshooting by failure code (Display of code), Part 5............................................................................................ 710 Failure code [DN21FS] Brake pedal and proximity switch: Fixing....................................................................................... 713 Failure code [DV00KB] Caution buzzer: Short circuit.................................................................................................. 715 Failure code [DV20KB] Back alarm buzzer: Short circuit............................................................................................... 716 Failure code [DW4BKA] Parking brake solenoid valve: Disconnection.................................................................................... 717 Failure code [DW4BKB] Parking brake solenoid valve: Short circuit.................................................................................... 719 Failure code [DW4BKY] Parking brake solenoid valve: Short circuit with power supply line............................................................. 721 Failure code [DW7BKA] Fan reverse solenoid valve: Disconnection...................................................................................... 723 Failure code [DW7BKB] Fan reverse solenoid valve: Short circuit...................................................................................... 725 Failure code [DW7BKY] Fan reverse solenoid valve: Short circuit with power supply line............................................................... 726 Failure code [DW7EKA] Slow brake solenoid valve: Disconnection....................................................................................... 727 Failure code [DW7EKB] Slow brake solenoid valve: Short circuit....................................................................................... 731 Failure code [DW7EKY] Slow brake solenoid valve: Short circuit with power supply line................................................................ 733 Failure code [DWN5KA] Fan EPC solenoid valve: Disconnection.......................................................................................... 735 Failure code [DWN5KB] Fan EPC solenoid valve: Short circuit.......................................................................................... 737 Failure code [DWN5KY] Fan EPC solenoid valve: Short circuit with power supply line................................................................... 739 Failure code [DXA4KA] LF HST pump EPC solenoid valve: Disconnection.................................................................................. 741 Failure code [DXA4KB] LF HST pump EPC solenoid valve: Short circuit.................................................................................. 743 Failure code [DXA4KY] LF HST pump EPC solenoid valve: Short circuit with power supply line........................................................... 745 Failure code [DXA5KA] LR HST pump EPC solenoid valve: Disconnection.................................................................................. 747 Failure code [DXA5KB] LR HST pump EPC solenoid valve: Short circuit.................................................................................. 749 Failure code [DXA5KY] LR HST pump EPC solenoid valve: Short circuit with power supply line........................................................... 751 Failure code [DXA6KA] RF HST pump EPC solenoid valve: Disconnection.................................................................................. 753 Failure code [DXA6KB] RF HST pump EPC solenoid valve: Short circuit.................................................................................. 755 Failure code [DXA6KY] RF HST pump EPC solenoid valve: Short circuit with power supply line........................................................... 756 Failure code [DXA7KA] RR HST pump EPC solenoid valve: Disconnection.................................................................................. 757 Failure code [DXA7KB] RR HST pump EPC solenoid valve: Short circuit.................................................................................. 759 Failure code [DXA7KY] RR HST pump EPC solenoid valve: Short circuit with power supply line........................................................... 761 Failure code [DXK1KA] Left HST motor EPC solenoid valve: Disconnection............................................................................... 763 Failure code [DXK1KB] Left HST motor EPC solenoid valve: Short circuit............................................................................... 764 Failure code [DXK1KY] Left HST motor EPC solenoid valve: Short circuit with power supply line........................................................ 765 Failure code [DXK2KA] Right HST motor EPC solenoid valve: Disconnection.............................................................................. 766 Failure code [DXK2KB] Right HST motor EPC solenoid valve: Short circuit.............................................................................. 767 Failure code [DXK2KY] Right HST motor EPC solenoid valve: Short circuit with power supply line....................................................... 768 400 Troubleshooting of electrical system (E-mode)........................................................................................................ 770 E-1 Engine does not start (Starting motor does not rotate)........................................................................................... 773 E-2 Engine is not preheated.......................................................................................................................... 776 E-3 When starting switch is turned ON, any item does not light up.................................................................................... 779 E-4 Charge level caution flashes while engine is running............................................................................................. 781 E-5 Emergency warning items flash while engine is running............................................................................................ 783 E-6 Preheating pilot lamp does not light up during preheating operation.............................................................................. 789 E-7 The coolant temperature gauge does not indicate correctly........................................................................................ 791 E-8 The HST oil temperature gauge does not indicate correctly........................................................................................ 792 E-9 Fuel level gauge does not indicate properly...................................................................................................... 793 E-10 Gear speed, set travel speed, and shift mode indicator does not display normally................................................................ 795 E-11 Multi-information unit does not display normally................................................................................................ 795 E-12 Caution lamp does not flash or does not go off.................................................................................................. 796 E-13 Caution buzzer does not sound or does not stop.................................................................................................. 797 E-14 Reverse travel speed setting switch does not function........................................................................................... 799 E-15 Shift mode switch does not function............................................................................................................. 801 E-16 Buzzer cancel switch does not function.......................................................................................................... 803 E-17 Information switch does not function............................................................................................................ 805 E-18 The fan cleaning does not operate or cannot be reset............................................................................................ 807 E-19 Backup alarm does not sound..................................................................................................................... 809 E-20 The horn does not sound or does not stop........................................................................................................ 810 E-21 Work equipment does not move.................................................................................................................... 811 E-22 Headlamp or rear lamp does not light up......................................................................................................... 813 E-23 Foot heater does not operate.................................................................................................................... 816 E-24 Air conditioner does not operate................................................................................................................ 819 E-25 Windshield wiper and window washer do not operate............................................................................................... 824 E-26 KOMTRAX system does not operate normally........................................................................................................ 837 500 Troubleshooting of hydraulic and mechanical system (H-mode).......................................................................................... 840 Information in troubleshooting table................................................................................................................. 842 H-1 Right and left travel systems do not operate forward and in reverse (No travel systems operate).................................................. 843 H-2 Right or left travel system does not operate forward and in reverse (Only right or left travel system does not operate).......................... 845 H-3 Right or left travel system does not operate forward or in reverse (Only 1 system does not operate).............................................. 846 H-4 Speed or power of travel is low.................................................................................................................. 847 H-5 Gear is not shifted.............................................................................................................................. 848 H-6 Large shocks are made when machine starts and stops travel....................................................................................... 849 H-7 Machine deviates largely during travel........................................................................................................... 850 H-8 Hydraulic drift of travel is large............................................................................................................... 851 H-9 Engine stalls or engine speed lowers extremely during travel..................................................................................... 852 H-10 Abnormal sound comes out from around HST pump and motor......................................................................................... 853 H-11 Work equipment dose not operate at all.......................................................................................................... 854 H-12 Speed or power of whole work equipment is low................................................................................................... 855 H-13 Speed or power of lifting blade is low.......................................................................................................... 856 H-14 Speed or power of tilting blade is low.......................................................................................................... 857 H-15 Speed or power of angling blade is low.......................................................................................................... 858 H-16 Time lag in lifting blade is large.............................................................................................................. 859 H-17 Hydraulic drift of lifting blade is large....................................................................................................... 859 H-18 Hydraulic drift of tilting blade is large....................................................................................................... 859 H-19 Abnormal sound comes out from around work equipment pump and control valve...................................................................... 860 H-20 HST oil temperature (Hydraulic oil temperature) rises too high.................................................................................. 861 H-21 Fan speed is abnormal (High, low, or 0 rpm)..................................................................................................... 863 H-22 Abnormal sound is heard from around fan......................................................................................................... 864 600 Troubleshooting of engine (S-mode)................................................................................................................... 866 Method of using troubleshooting charts............................................................................................................... 868 S-1 Starting performance is poor..................................................................................................................... 871 S-2 Engine does not start............................................................................................................................ 872 S-3 Engine does not pick up smoothly................................................................................................................. 875 S-4 Engine stops during operations................................................................................................................... 876 S-5 Engine does not rotate smoothly.................................................................................................................. 877 S-6 Engine lacks output (or lacks power)............................................................................................................. 878 S-7 Exhaust smoke is black (imcomplete combustion)................................................................................................... 879 S-8 Oil consumption is excessive (or exhaust smoke is blue).......................................................................................... 880 S-9 Oil becomes contaminated quickly................................................................................................................. 881 S-10 Fuel consumption is excessive................................................................................................................... 882 S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down).......................................................................... 883 S-12 Oil pressure drops.............................................................................................................................. 884 S-13 Oil level rises (water, fuel in oil)............................................................................................................ 885 S-14 Coolant temperature becomes too high (overheating).............................................................................................. 886 S-15 Abnormal noise is made.......................................................................................................................... 887 S-16 Vibration is excessive.......................................................................................................................... 888 50 Disassembly and assembly.................................................................................................................................. 0 100 General information on disassembly and assembly...................................................................................................... 890 How to read this manual.............................................................................................................................. 891 Coating materials list............................................................................................................................... 893 Special tools list................................................................................................................................... 896 Sketches of special tools............................................................................................................................ 899 200 Engine and cooling system............................................................................................................................ 904 Removal and installation of fuel supply pump assembly................................................................................................ 905 Removal and installation of fuel injector assembly................................................................................................... 909 Removal and installation of cylinder head assembly................................................................................................... 917 Removal and installation of engine and HST pump assembly............................................................................................. 930 Removal and installation of engine front seal assembly............................................................................................... 933 Removal and installation of engine rear seal assembly................................................................................................ 935 Removal and installation of front guard assembly..................................................................................................... 939 Removal and installation of radiator assembly........................................................................................................ 941 Removal and installation of hydraulic oil cooler assembly............................................................................................ 943 Removal and installation of aftercooler assembly..................................................................................................... 945 Removal and installation of cooling fan and motor assembly........................................................................................... 947 Removal and installation of cooling fan drive motor assembly1........................................................................................ 949 Removal and installation of fuel tank assembly....................................................................................................... 951 300 Power train.......................................................................................................................................... 954 Removal and installation of HST pump assembly........................................................................................................ 955 Removal and installation of HST motor and final drive assembly....................................................................................... 957 Disassembly and assembly of final drive assembly..................................................................................................... 959 400 Undercarriage and frame.............................................................................................................................. 970 Spreading and installation of track shoe assembly.................................................................................................... 971 Removal and installation of idler and recoil spring assembly......................................................................................... 973 Disassembly and assembly of idler assembly........................................................................................................... 974 Disassembly and assembly of recoil spring assembly................................................................................................... 977 Disassembly and assembly of track roller assembly.................................................................................................... 981 Disassembly and assembly of carrier roller assembly.................................................................................................. 985 500 Hydraulic system..................................................................................................................................... 990 Removal and installation of hydraulic tank assembly.................................................................................................. 991 Removal and installation of control valve assembly................................................................................................... 993 Disassembly and assembly of control valve assembly................................................................................................... 994 Disassembly and assembly of hydraulic cylinder assembly.............................................................................................. 996 600 Work equipment.......................................................................................................................................1002 Removal and installation of work equipment assembly..................................................................................................1003 700 Cab and its attachments..............................................................................................................................1008 Removal and installation of ROPS canopy and operator seat frame assembly.............................................................................1009 Removal and installation of ROPS cab and operator seat frame assembly................................................................................1012 Removal and installation of operator’s cab glass (Stuck glass).......................................................................................1017 800 Electrical system....................................................................................................................................1024 Removal and installation of HST controller assembly..................................................................................................1025 Removal and installation of KOMTRAX terminal assembly................................................................................................1026 90 Diagrams and drawings..................................................................................................................................... 0 100 Hydraulic diagrams and drawings......................................................................................................................1028 Work equipment hydraulic circuit diagram.............................................................................................................1030 200 Electrical diagrams and drawings.....................................................................................................................1033 Electrical circuit diagram...........................................................................................................................1035 Cab electrical circuit diagram.......................................................................................................................1040 Air conditioner circuit diagram......................................................................................................................1043 Connector list and stereogram........................................................................................................................1044
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⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
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