Komatsu D39EX-22 D39PX-22 Bulldozer Official Workshop Service Repair Technical Manual
Komatsu D39EX-22 D39PX-22 Bulldozer Official Workshop Service Repair Technical Manual
The Best PDF Manuals Online Includes : Bookmarks + Searchable Text + Index = Fast Navigation And Best Organization !
This is the COMPLETE Official Service Repair Manual for the Komatsu Bulldozer.
This manual contains deep information about maintaining, assembly, disassembly and servicing your Komatsu.
This PDF file is Bookmarked and SEARCHABLE to make what you need easy to find.
Models And Serials :
D39EX-3001
D39PX-3001
and up
CONTENTS :
00 Index and foreword
100 Index ................................................................................SEN04050-05
Composition of shop manual.............................................................. 2
Table of contents ............................................................................................. 4
200 Foreword and general information ........................................SEN04051-02
Safety notice ........................................................................ 2
How to read the shop manual ............................. 7
Explanation of terms for maintenance standard...................... 9
Handling of electric equipment and hydraulic component............................... 11
Handling of connectors newly used for engines.................... 20
How to read electric wire code ............................................................ 23
Precautions when carrying out operation.......................................... 26
Method of disassembling and connecting push-pull type coupler........... 29
Standard tightening torque table ..................... 32
Conversion table ................................................................................ 36
01 General
100 Specification and technical data...................SEN04052-01
Specification dimensional drawing .............................................. 2
Specifications ...................................................................................... 3
Weight table ....................................................................... 7
Table of fuel, coolant and lubricants.................................................... 9
10 Structure, function and maintenance standard
100 Engine and cooling system ......................SEN04230-00
Engine system parts............................................................................ 2
Cooling system................................................................................................ 3
Cooling fan pump............................................................................................. 4
Cooling fan motor............................................................................ 5
Oil cooler bypass valve ................................................................................. 10
200 Power train...........................................SEN04231-01
Power train .............................................................................................. 2
Power train system............................................................................................ 3
Damper .................................................... 4
HST hydraulic equipment arrangement diagram ......................................... 5
Steering and brake control ................................................................... 6
Solenoid valve.................................................................................................. 8
Final drive.................................................................................. 15
HST pump................................................................................................... 18
HST motor...................................................................................................... 30
Charge pump ....................................................................................... 40
300 Undercarriage and frame......................................................SEN04232-01
Main frame ................................................................................... 2
Track frame and idler cushion ........................................................ 4
Idler ................................................................. 6
Track roller ...................................... 8
Carrier roller ................................................................................. 10
Sprocket ........................................................................................... 12
Track shoe....................................................................................................... 14
410 Hydraulic system, Part 1 ...................................................SEN04233-01
Arrangement of hydraulic equipment for work equipment................................. 2
Work equipment control ...................................... 4
Hydraulic tank and filter......................................................... 6
Work equipment and fan pump ................................ 8
Control valve ......................................................................................... 16
CLSS ...................................................................................................... 28
Functions and operation of each valve.......................................................... 31
420 Hydraulic system, Part 2 .................................................. SEN04234-01
Blade PPC valve....................................................................................... 2
Accumulator..................................................................................................... 8
500 Work equipment .............................................. SEN04236-01
Work equipment .............................................................................. 2
Cutting edge and end bit ............................................................ 6
Ripper ............................................................................................... 7
Work equipment cylinder ................................................................... 8
Piston valve ............................................................................... 11
600 Cab and its attachments....................................................... SEN04237-00
ROPS cab.................................................................................................. 2
Cab mount ................................................................................................ 3
Canopy mount .............................................................................................. 4
Air conditioner....................................................................................... 5
700 Electrical system .............................................................. SEN04238-01
Monitor system .............................................................................. 2
Engine control............................................................................................ 4
Engine control system ................................................................... 5
Cooling control system ................................................................................ 6
HST control system ................................................................................ 8
Parking brake control system .............................................................. 14
KOMTRAX system ................................................................. 16
Component equipment of system............................................................... 18
PCCS lever (for steering) .............................................................................. 26
Sensor ........................................................................................ 29
20 Standard value table
100 Standard service value table ................................................ SEN04096-00
Standard service value table for engine ......................................................... 2
Standard service value table for chassis ............................................. 3
30 Testing and adjusting
110 Testing and adjusting, Part 1 ......... SEN04097-02
Tools for testing, adjusting, and troubleshooting .................... 3
Sketches of special tools ...................................................................... 6
Measuring engine speed ............................................................... 7
Measuring intake air pressure (boost pressure) ...................................... 8
Measuring exhaust gas color (boost pressure) .............................................. 10
Adjusting valve clearance...................................................................... 11
Measuring compression pressure ................................................................. 13
Measuring blow-by pressure ................................................. 16
Testing engine oil pressure.............................................................................. 18
Handling fuel system equipment .................................................. 19
Releasing residual pressure in fuel system .................................................... 19
Bleeding air from fuel circuit .......................................................................... 20
Measuring fuel pressure ............................................................................ 21
Measuring fuel discharge, return and leakage ............................................... 23
Testing leakage in fuel system.................................................................... 27
Measurement of fan circuit pressure and fan speed ............................ 28
Adjustment of fan speed sensor ............................................................. 29
Handling reduced cylinder mode operation .................................................... 30
Handling no-injection cranking operation ...................................................... 30
Handling controller voltage circuit................................................................... 31
Check of muffler and muffler stack for looseness and damage....................... 32
Check of muffler function.............................................................................. 32
Check of installed condition of cylinder head and manifolds........................... 33
Check of engine piping for damage and loosenes.......................................... 33
Replacing alternator belt .......................................................... 34
120 Testing and adjusting, Part 2...................................................SEN04098-00
Adjusting decelerator pedal............................................................................ 2
Testing and adjusting HST oil pressure.......................................................... 4
Measuring solenoid valve outlet pressure.......................................... 9
Testing travel deviation...................................................................................... 12
Adjusting parking brake lever........................................................................... 13
Simple brake performance test procedure ...................................................... 15
Adjusting brake pedal............................................................ 16
Method of releasing parking brake (Procedure for emergency escape) ......... 18
Testing and adjusting idler clearance ............................................ 20
Testing and adjusting track shoe tension .......................................... 21
Testing work equipment pressure ................................................................... 22
Testing work equipment PPC valve......................................................... 24
Adjusting play of work equipment PPC valve................................................... 26
Adjusting work equipment lock lever................................................ 27
Testing internal leakage of work equipment cylinder.......................... 28
Releasing residual pressure in hydraulic circuit ............................................. 30
Bleeding air from hydraulic circuit .......................................................... 31
Adjusting play of blade center ball ................................................................. 32
Procedure for testing diodes ........................................................................... 33
Preparation work for troubleshooting for electrical system .......................... 34
How to start operation of KOMTRAX terminal .................................. 38
Lamp display of KOMTRAX terminal ....................................................... 41
130 Testing and adjusting, Part 3................................................SEN04099-00
Special functions of monitor panel (EMMS) ................................................ 2
Items to be adjusted when electric/hydraulic devices are adjusted/replaced.. 64
Adjustment procedure after replacement of HST controller .... 65
Adjustment procedure after replacement of monitor panel ........ 67
Pm-clinic.................................................................................. 68
40 Troubleshooting
100 Failure code table and fuse locations .....................SEN04100-00
Failure code table........................................................................ 2
Before carrying out troubleshooting for electrical system (E-mode) .... 8
200 General information on troubleshooting.................................SEN04101-02
Points to remember when troubleshooting............................................... 2
Sequence of events in troubleshooting ............................................................ 3
Testing before troubleshooting ............................................................... 4
Classification and procedures of troubleshooting ............................... 5
Information contained in troubleshooting table ................................................ 8
Connection table for connector pin numbers .......................................... 10
T- branch box and T- branch adapter table ................................................... 46
310 Troubleshooting by failure code (Display of code), Part 1 ......SEN04102-00
Failure code [6091NX] HST charge filter element: Clogging ............. 3
Failure code [AA10NX] Air cleaner: Clogging ............................... 4
Failure code [AB00MA] Alternator: Malfunction .................. 6
Failure code [B@BAZG] Engine oil: Lowering of oil pressure.. 7
Failure code [B@BCNS] Coolant: Overheat ............... 8
Failure code [B@CRNS] HST oil: Overheating.................................. 9
Failure code [B@CRZG] HST oil: Lowering of oil pressure ....... 10
Failure code [CA111] Engine controller: Abnormality in controller ........ 11
Failure code [CA115] Abnormal engine Ne and Bkup speed sensors: Abnormal speed sensor signal.. 11
Failure code [CA122] Charge pressure sensor tool high: Excessively high voltage detected ...... 12
Failure code [CA123] Charge pressure sensor too low: Excessively low voltage detected.. 14
Failure code [CA131] Decelerator pedal sensor tool high: Excessively high voltage detected . 16
Failure code [CA132] Decelerator pedal sensor too low: Excessively low voltage detected.......... 18
Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected ................. 20
Failure code [CA145] Coolant temperature sensor too low: Excessively low voltage detected .................... 22
Failure code [CA153] Charge air temperature sensor too high: Excessively high voltage detected ............. 24
Failure code [CA154] Charge temperature sensor too low: Excessively low voltage detected..................... 26
Failure code [CA187] Sensor power source 2 too low: Excessively low voltage detected............................ 28
Failure code [CA221] Atmospheric pressure sensor too high: Excessively high voltage detected ............... 30
Failure code [CA222] Atmospheric pressure sensor too low: Excessively low voltage detected .................. 32
Failure code [CA227] Sensor power source 2 too high: Excessively high voltage detected ......... 34
Failure code [CA234] Engine over speed: Excessively high speed .............. 36
Failure code [CA238] Abnormal power source for Ne speed sensor: Excessively low voltage detected...... 37
Failure code [CA271] IMV/PCV1 short circuit: Short circuit....................... 38
Failure code [CA272] IMV/PCV1 disconnection: Disconnection ............ 40
320 Troubleshooting by failure code (Display of code), Part 2......................................................... SEN04103-01
Failure code [CA322] Injector No. 1 system disconnection or short circuit: disconnection, short circuit ....... 4
Failure code [CA324] Injector No. 3 system disconnection or short circuit: disconnection, short circuit ....... 6
Failure code [CA331] Injector No. 2 system disconnection or short circuit: disconnection, short circuit ....... 8
Failure code [CA332] Injector No. 4 system disconnection or short circuit: disconnection, short circuit ....... 10
Failure code [CA342] Engine controller data matching error: matching error ............................................... 12
Failure code [CA351] Injector drive circuit abnormality: Abnormal circuit ..... 14
Failure code [CA352] Sensor power source 1 too low: Excessively low voltage detected............................ 16
Failure code [CA386] Sensor power source 1 too high: Excessively high voltage detected ......................... 18
Failure code [CA428] Water in fuel sensor too high: Excessively high voltage detected .............................. 20
Failure code [CA429] Water in fuel sensor too low: Excessively low voltage detected ................................. 22
Failure code [CA435] Abnormal engine oil pressure switch: Abnormal signal circuit.................................... 24
Failure code [CA441] Power source voltage too low: Excessively low voltage detected .............................. 26
Failure code [CA442] Power source voltage too high:
Excessively high voltage has occurred in the controller power source circuit .. 28
Failure code [CA449] Common rail pressure too high (2): Excessively high pressure trouble occurred....... 30
Failure code [CA451] Common rail pressure sensor too high: Excessively high voltage detected............... 32
Failure code [CA452] Common rail pressure sensor too low: Excessively low voltage detected.................. 34
Failure code [CA488] Charge temperature too high and torque derated:
Exceeded upper control limit of temperature .......... 36
Failure code [CA553] Common rail pressure too high (1): Excessively high pressure detected................... 37
Failure code [CA559] Loss of pressure feed from supply pump (1): Loss of pressure feed detected........... 38
Failure code [CA689] Abnormal engine Ne speed sensor: Abnormal signal................................................. 40
Failure code [CA731] Abnormal engine Bkup speed sensor phase: Abnormal phase.................................. 42
Failure code [CA757] Loss of all engine controller data: Loss of all data........ 44
Failure code [CA778] Abnormal engine Bkup speed sensor: Abnormal Bkup signal.. 46
Failure code [CA1633] Abnormal KOMNET: Abnormal communication..... 48
Failure code [CA2185] Decelerator pedal sensor power source too high:
Excessively high voltage detected ................... 50
Failure code [CA2186] Decelerator pedal sensor power source too low:
Excessively low voltage detected ......................................... 52
Failure code [CA2249] Loss of pressure feed from supply pump (2): Loss of pressure feed detected......... 54
Failure code [CA2311] Abnormal IMV solenoid: Abnormal resistance ........ 56
Failure code [CA2555] Air intake heater relay disconnection: Disconnection .. 58
Failure code [CA2556] Air intake heater relay short circuit: Short circuit ....... 60
330 Troubleshooting by failure code (Display of code), Part 3....... SEN04104-00
Failure code [D130KA] Neutral safety relay: Disconnection............. 4
Failure code [D130KB] Neutral safety relay: Short circuit ................... 6
Failure code [DAFRKR] CAN communication (Monitor panel – HST controller):
Defective communication (Abnormality in objective component system) ..... 8
Failure code [DAFRMC] CAN communication (Monitor panel – ENGINE controller):
Defective communication (Abnormality in objective component system) ... 11
Failure code [DAJ000] HST controller: Memory error ............................ 14
Failure code [DAJ0KK] HST controller: Lowing of source voltage ..... 16
Failure code [DAJ0KQ] HST controller: Machine code error ................. 18
Failure code [DAJ0KT] HST controller: Memory error ..................... 19
Failure code [DAJ5KK] HST controller sensor 5 V power supply No.1: Lowing of source voltage/Input ...... 20
Failure code [DAJ6KK] HST controller sensor 5 V power supply No.2: Lowing of source voltage/Input ...... 22
Failure code [DAJRKR] CAN communication (HST controller – Monitor panel):
Defective communication (Abnormality in objective component system)..... 24
Failure code [DB2RKR] CAN communication (HST controller – Engine controller):
Defective communication (Abnormality in objective component system)......... 27
Failure code [DD12KA] Shift up switch: Disconnection................... 30
Failure code [DD12KB] Shift up switch: Short circuit .................. 32
Failure code [DD13KA] Shift down switch: Disconnection ......................... 34
Failure code [DD13KB] Shift down switch: Short circuit................................... 36
Failure code [DD14KB] Travel lock limit switch 1: Short circuit...................... 38
Failure code [DD1NL4] Fan rotation selector switch: Disagreement of ON, OFF Signals .......... 40
Failure code [DDDCKB] Reverse travel speed switch: Short circuit .............. 42
Failure code [DDP6KA] Brake oil pressure sensor: Disconnection................. 44
Failure code [DDP6KB] Brake oil pressure sensor: Short circuit ........... 46
Failure code [DDP6MA] Brake oil pressure sensor: Malfunction ................. 48
Failure code [DDQ2KA] Travel lock limit switch 1: Disconnection ................... 50
Failure code [DDT0L4] Shift mode switch: Disagreement of ON/ OFF Signals 52
Failure code [DDU1FS] Travel lock limit switches 1 and 2: Fixing............... 54
Failure code [DDU1KA] Travel lock limit switch 2: Disconnection.............. 56
Failure code [DDU1KY] Travel lock limit switch 2: Short circuit with power supply line . 58
Failure code [DGS1KA] HST oil temperature sensor: Disconnection .............. 60
Failure code [DGS1KX] HST oil temperature sensor: Out of Input signal range.... 62
340 Troubleshooting by failure code (Display of code), Part 4 ......SEN04105-00
Failure code [DHH5KA] Left HST pump pressure sensor: Disconnection ..... 4
Failure code [DHH5KB] Left HST pump pressure sensor: Short circuit.. 6
Failure code [DHH6KA] Right HST pump pressure sensor: Disconnection...... 8
Failure code [DHH6KB] Right HST pump pressure sensor: Short circuit ... 10
Failure code [DK10KA] Fuel dial sensor: Disconnection................. 12
Failure code [DK10KB] Fuel dial sensor: Short circuit ............. 14
Failure code [DK30KA] Steering angle sensor 1: Disconnection .... 16
Failure code [DK30KB] Steering angle sensor 1: Short circuit................... 18
Failure code [DK30KX] Steering angle sensor: Out of input signal range........ 20
Failure code [DK30KX] Steering angle sensor: Out of input signal range.... 20
Failure code [DK30KZ] Steering angle sensor: Disconnection or short circuit.. 21
Failure code [DK30L8] Steering angle sensor: Disagreement of analog signals ... 22
Failure code [DK31KA] Steering angle sensor 2: Disconnection ............ 24
Failure code [DK31KB] Steering angle sensor 2: Short circuit.............. 26
Failure code [DK40KA] Brake pedal sensor: Disconnection .............. 28
Failure code [DK40KB] Brake pedal sensor: Short circuit.......................... 30
Failure code [DK55KX] Directional potentiometer: Out of input signal range .. 32
Failure code [DK55KZ] Directional potentiometer: Disconnection or short circuit........ 33
Failure code [DK55L8] Directional potentiometer: Disagreement of analog signals.... 34
Failure code [DK56KA] Directional potentiometer 1: Disconnection ... 36
Failure code [DK56KB] Directional potentiometer 1: Short circuit................ 38
Failure code [DK57KA] Directional potentiometer 2: Disconnection .......... 40
Failure code [DK57KB] Directional potentiometer 2: Short circuit.................... 42
Failure code [DLM0KX] HST motor speed sensors: Out of input signal range 44
Failure code [DLM1KA] Left HST motor speed sensor: Disconnection ........ 46
Failure code [DLM1KB] Left HST motor speed sensor: Short circuit .............. 48
Failure code [DLM1MA] Left HST motor speed sensor: Malfunction .............. 50
Failure code [DLM2KA] Right HST motor speed sensor: Disconnection ........ 52
Failure code [DLM2KB] Right HST motor speed sensor: Short circuit............. 54
Failure code [DLM2MA] Right HST motor speed sensor: Malfunction............. 56
Failure code [DLM3KA] Fan speed sensor: Disconnection............................. 58
Failure code [DLM3KB] Fan speed sensor: Short circuit ................................ 60
350 Troubleshooting by failure code (Display of code), Part 5....... SEN04106-00
Failure code [DN21FS] Brake pedal and proximity switch: Fixing............... 4
Failure code [DV00KB] Caution buzzer: Short circuit.............................. 6
Failure code [DV20KB] Back alarm buzzer: Short circuit ............................... 7
Failure code [DW4BKA] Parking brake solenoid valve: Disconnection ........ 8
Failure code [DW4BKB] Parking brake solenoid valve: Short circuit.............. 10
Failure code [DW4BKY] Parking brake solenoid valve: Short circuit with power supply line.. 12
Failure code [DW7BKA] Fan reverse solenoid valve: Disconnection ...... 14
Failure code [DW7BKB] Fan reverse solenoid valve: Short circuit........ 16
Failure code [DW7BKY] Fan reverse solenoid valve: Short circuit with power supply line ........................... 17
Failure code [DW7EKA] Slow brake solenoid valve: Disconnection ......... 18
Failure code [DW7EKB] Slow brake solenoid valve: Short circuit ..... 22
Failure code [DW7EKY] Slow brake solenoid valve: Short circuit with power supply line..... 24
Failure code [DWN5KA] Fan EPC solenoid valve: Disconnection .................. 26
Failure code [DWN5KB] Fan EPC solenoid valve: Short circuit .............. 28
Failure code [DWN5KY] Fan EPC solenoid valve: Short circuit with power supply line............... 30
Failure code [DXA4KA] LF HST pump EPC solenoid valve: Disconnection .... 32
Failure code [DXA4KB] LF HST pump EPC solenoid valve: Short circuit ....... 34
Failure code [DXA4KY] LF HST pump EPC solenoid valve: Short circuit with power supply line................. 36
Failure code [DXA5KA] LR HST pump EPC solenoid valve: Disconnection .... 38
Failure code [DXA5KB] LR HST pump EPC solenoid valve: Short circuit........ 40
Failure code [DXA5KY] LR HST pump EPC solenoid valve: Short circuit with power supply line ................ 42
Failure code [DXA6KA] RF HST pump EPC solenoid valve: Disconnection. 44
Failure code [DXA6KB] RF HST pump EPC solenoid valve: Short circuit ...... 46
Failure code [DXA6KY] RF HST pump EPC solenoid valve: Short circuit with power supply line ................ 47
Failure code [DXA7KA] RR HST pump EPC solenoid valve: Disconnection . 48
Failure code [DXA7KB] RR HST pump EPC solenoid valve: Short circuit .. 50
Failure code [DXA7KY] RR HST pump EPC solenoid valve: Short circuit with power supply line................ 52
Failure code [DXK1KA] Left HST motor EPC solenoid valve: Disconnection .. 54
Failure code [DXK1KB] Left HST motor EPC solenoid valve: Short circuit .. 55
Failure code [DXK1KY] Left HST motor EPC solenoid valve: Short circuit with power supply line.....56
Failure code [DXK2KA] Right HST motor EPC solenoid valve: Disconnection .57
Failure code [DXK2KB] Right HST motor EPC solenoid valve: Short circuit.....58
Failure code [DXK2KY] Right HST motor EPC solenoid valve: Short circuit with power supply line ............ 59
400 Troubleshooting of electrical system (E-mode) ................. SEN04107-00
E-1 Engine does not start (Starting motor does not rotate) ......... 4
E-2 Engine is not preheated ....................................... 7
E-3 When starting switch is turned ON, any item does not light up......... 10
E-4 Charge level caution flashes while engine is running ........ 12
E-5 Emergency warning items flash while engine is running .................. 14
E-6 Preheating pilot lamp does not light up during preheating operation......... 20
E-7 The coolant temperature gauge does not indicate correctly. ...... 22
E-8 The HST oil temperature gauge does not indicate correctly. ................ 23
E-9 Fuel level gauge does not indicate properly ........................................ 24
E-10 Gear speed, set travel speed, and shift mode indicator does not display normally .............................. 26
E-11 Multi-information unit does not display normally ......................... 26
E-12 Caution lamp does not flash or does not go off ....................................... 27
E-13 Caution buzzer does not sound or does not stop ............. 28
E-14 Reverse travel speed setting switch does not function ..... 30
E-15 Shift mode switch does not function .............................. 32
E-16 Buzzer cancel switch does not function .................................................. 34
E-17 Information switch does not function................................................ 36
E-18 The fan cleaning does not operate or cannot be reset .................. 38
E-19 Backup alarm does not sound .................................... 40
E-20 The horn does not sound or does not stop ...................................... 41
E-21 Work equipment does not move ..................................................... 42
E-22 Headlamp or rear lamp does not light up........................................ 44
E-23 Foot heater does not operate.................................... 47
E-24 Air conditioner does not operate..................................... 50
E-25 Windshield wiper and window washer do not operate............... 55
E-26 KOMTRAX system does not operate normally............................... 68
500 Troubleshooting of hydraulic and mechanical system (H-mode) .....SEN04108-01
Information in troubleshooting table ............... 3
H-1 Right and left travel systems do not operate forward and in reverse (No travel systems operate) ........ 4
H-2 Right or left travel system does not operate forward and in reverse
(Only right or left travel system does not operate).......... 6
H-3 Right or left travel system does not operate forward or in reverse (Only 1 system does not operate)... 7
H-4 Speed or power of travel is low ............................................... 8
H-5 Gear is not shifted ............................................... 9
H-6 Large shocks are made when machine starts and stops travel.... 10
H-7 Machine deviates largely during travel ........ 11
H-8 Hydraulic drift of travel is large ............................... 12
H-9 Engine stalls or engine speed lowers extremely during travel ......... 13
H-10 Abnormal sound comes out from around HST pump and motor.......... 14
H-11 Work equipment dose not operate at all .................. 15
H-12 Speed or power of whole work equipment is low ............. 16
H-13 Speed or power of lifting blade is low................... 17
H-14 Speed or power of tilting blade is low ..................... 18
H-15 Speed or power of angling blade is low.................... 19
H-16 Time lag in lifting blade is large .................................... 20
H-17 Hydraulic drift of lifting blade is large...................................... 20
H-18 Hydraulic drift of tilting blade is large.............................. 20
H-19 Abnormal sound comes out from around work equipment pump and control valve...... 21
H-20 HST oil temperature (Hydraulic oil temperature) rises too high ............ 22
H-21 Fan speed is abnormal (High, low, or 0 rpm) ......................... 24
H-22 Abnormal sound is heard from around fan ...................... 25
600 Troubleshooting of engine (S-mode)...........................SEN04109-01
Method of using troubleshooting charts ......................................... 3
S-1 Starting performance is poor ................................................ 6
S-2 Engine does not start............................................................... 7
S-3 Engine does not pick up smoothly............................................... 10
S-4 Engine stops during operations ................................................. 11
S-5 Engine does not rotate smoothly ................................... 12
S-6 Engine lacks output (or lacks power).................................................. 13
S-7 Exhaust smoke is black (imcomplete combustion)..................... 14
S-8 Oil consumption is excessive (or exhaust smoke is blue) ......... 15
S-9 Oil becomes contaminated quickly ................... 16
S-10 Fuel consumption is excessive.......................................... 17
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down) ..... 18
S-12 Oil pressure drops ..................................................... 19
S-13 Oil level rises (water, fuel in oil) .................................... 20
S-14 Coolant temperature becomes too high (overheating) ................ 21
S-15 Abnormal noise is made....................................................... 22
S-16 Vibration is excessive ................................................................ 23
50 Disassembly and assembly
100 General information on disassembly and assembly ........SEN04662-03
How to read this manual .................. 2
Coating materials list.............................................. 4
Special tools list................................................... 7
Sketches of special tools................................................... 10
200 Engine and cooling system .................................................SEN04663-02
Removal and installation of fuel supply pump assembly................................ 2
Removal and installation of fuel injector assembly ............................... 6
Removal and installation of cylinder head assembly ....................................... 14
Removal and installation of engine and HST pump assembly ........................ 27
Removal and installation of engine front seal assembly................................... 30
Removal and installation of engine rear seal assembly ......................... 32
Removal and installation of front guard assembly................................... 36
Removal and installation of radiator assembly ................................... 38
Removal and installation of hydraulic oil cooler assembly ............................. 40
Removal and installation of aftercooler assembly ........................................... 42
Removal and installation of cooling fan and motor assembly............... 44
Removal and installation of cooling fan drive motor assembly......................... 46
Removal and installation of fuel tank assembly............................................ 48
300 Power train .............................................................. SEN04664-01
Removal and installation of HST pump assembly .............................................. 2
Removal and installation of HST motor and final drive assembly .................. 4
Disassembly and assembly of final drive assembly ............................. 6
400 Undercarriage and frame ............................ SEN04665-01
Spreading and installation of track shoe assembly....................................... 2
Removal and installation of idler and recoil spring assembly ............. 4
Disassembly and assembly of idler assembly ........................ 5
Disassembly and assembly of recoil spring assembly ...... 8
Disassembly and assembly of track roller assembly ... 12
Disassembly and assembly of carrier roller assembly............. 16
500 Hydraulic system ........................................ SEN04666-01
Removal and installation of hydraulic tank assembly ..........3
Removal and installation of control valve assembly ....................... 4
Disassembly and assembly of control valve assembly............................ 5
Disassembly and assembly of hydraulic cylinder assembly .......................... 7
600 Work equipment .............................................................. SEN04667-01
Removal and installation of work equipment assembly............................................... 2
700 Cab and its attachments....................... SEN04668-01
Removal and installation of ROPS canopy and operator seat frame assembly.. 2
Removal and installation of ROPS cab and operator seat frame assembly...... 5
Removal and installation of operator’s cab glass (Stuck glass).......... 10
800 Electrical system ....................... SEN04669-01
Removal and installation of HST controller assembly ....................... 2
Removal and installation of KOMTRAX terminal assembly......................... 3
90 Diagrams and drawings
100 Hydraulic diagrams and drawings ........................ SEN04053-00
Work equipment hydraulic circuit diagram........................................................ 3
200 Electrical diagrams and drawings......................................... SEN04054-01
Electrical circuit diagram............................................................................ 3
Cab electrical circuit diagram ..................................................................... 13
Air conditioner circuit diagram ............................................ 17
Connector list and stereogram ......................................... 19
Komatsu D39EX-22 D39PX-22 Bulldozer Official Workshop Service Repair Technical Manual
Komatsu D39EX-22 D39PX-22 Bulldozer Official Workshop Service Repair Technical Manual
The Best PDF Manuals Online Includes : Bookmarks + Searchable Text + Index = Fast Navigation And Best Organization !
This is the COMPLETE Official Service Repair Manual for the Komatsu Bulldozer.
This manual contains deep information about maintaining, assembly, disassembly and servicing your Komatsu.
This PDF file is Bookmarked and SEARCHABLE to make what you need easy to find.
Models And Serials :
D39EX-3001
D39PX-3001
and up
CONTENTS :
00 Index and foreword
100 Index ................................................................................SEN04050-05
Composition of shop manual.............................................................. 2
Table of contents ............................................................................................. 4
200 Foreword and general information ........................................SEN04051-02
Safety notice ........................................................................ 2
How to read the shop manual ............................. 7
Explanation of terms for maintenance standard...................... 9
Handling of electric equipment and hydraulic component............................... 11
Handling of connectors newly used for engines.................... 20
How to read electric wire code ............................................................ 23
Precautions when carrying out operation.......................................... 26
Method of disassembling and connecting push-pull type coupler........... 29
Standard tightening torque table ..................... 32
Conversion table ................................................................................ 36
01 General
100 Specification and technical data...................SEN04052-01
Specification dimensional drawing .............................................. 2
Specifications ...................................................................................... 3
Weight table ....................................................................... 7
Table of fuel, coolant and lubricants.................................................... 9
10 Structure, function and maintenance standard
100 Engine and cooling system ......................SEN04230-00
Engine system parts............................................................................ 2
Cooling system................................................................................................ 3
Cooling fan pump............................................................................................. 4
Cooling fan motor............................................................................ 5
Oil cooler bypass valve ................................................................................. 10
200 Power train...........................................SEN04231-01
Power train .............................................................................................. 2
Power train system............................................................................................ 3
Damper .................................................... 4
HST hydraulic equipment arrangement diagram ......................................... 5
Steering and brake control ................................................................... 6
Solenoid valve.................................................................................................. 8
Final drive.................................................................................. 15
HST pump................................................................................................... 18
HST motor...................................................................................................... 30
Charge pump ....................................................................................... 40
300 Undercarriage and frame......................................................SEN04232-01
Main frame ................................................................................... 2
Track frame and idler cushion ........................................................ 4
Idler ................................................................. 6
Track roller ...................................... 8
Carrier roller ................................................................................. 10
Sprocket ........................................................................................... 12
Track shoe....................................................................................................... 14
410 Hydraulic system, Part 1 ...................................................SEN04233-01
Arrangement of hydraulic equipment for work equipment................................. 2
Work equipment control ...................................... 4
Hydraulic tank and filter......................................................... 6
Work equipment and fan pump ................................ 8
Control valve ......................................................................................... 16
CLSS ...................................................................................................... 28
Functions and operation of each valve.......................................................... 31
420 Hydraulic system, Part 2 .................................................. SEN04234-01
Blade PPC valve....................................................................................... 2
Accumulator..................................................................................................... 8
500 Work equipment .............................................. SEN04236-01
Work equipment .............................................................................. 2
Cutting edge and end bit ............................................................ 6
Ripper ............................................................................................... 7
Work equipment cylinder ................................................................... 8
Piston valve ............................................................................... 11
600 Cab and its attachments....................................................... SEN04237-00
ROPS cab.................................................................................................. 2
Cab mount ................................................................................................ 3
Canopy mount .............................................................................................. 4
Air conditioner....................................................................................... 5
700 Electrical system .............................................................. SEN04238-01
Monitor system .............................................................................. 2
Engine control............................................................................................ 4
Engine control system ................................................................... 5
Cooling control system ................................................................................ 6
HST control system ................................................................................ 8
Parking brake control system .............................................................. 14
KOMTRAX system ................................................................. 16
Component equipment of system............................................................... 18
PCCS lever (for steering) .............................................................................. 26
Sensor ........................................................................................ 29
20 Standard value table
100 Standard service value table ................................................ SEN04096-00
Standard service value table for engine ......................................................... 2
Standard service value table for chassis ............................................. 3
30 Testing and adjusting
110 Testing and adjusting, Part 1 ......... SEN04097-02
Tools for testing, adjusting, and troubleshooting .................... 3
Sketches of special tools ...................................................................... 6
Measuring engine speed ............................................................... 7
Measuring intake air pressure (boost pressure) ...................................... 8
Measuring exhaust gas color (boost pressure) .............................................. 10
Adjusting valve clearance...................................................................... 11
Measuring compression pressure ................................................................. 13
Measuring blow-by pressure ................................................. 16
Testing engine oil pressure.............................................................................. 18
Handling fuel system equipment .................................................. 19
Releasing residual pressure in fuel system .................................................... 19
Bleeding air from fuel circuit .......................................................................... 20
Measuring fuel pressure ............................................................................ 21
Measuring fuel discharge, return and leakage ............................................... 23
Testing leakage in fuel system.................................................................... 27
Measurement of fan circuit pressure and fan speed ............................ 28
Adjustment of fan speed sensor ............................................................. 29
Handling reduced cylinder mode operation .................................................... 30
Handling no-injection cranking operation ...................................................... 30
Handling controller voltage circuit................................................................... 31
Check of muffler and muffler stack for looseness and damage....................... 32
Check of muffler function.............................................................................. 32
Check of installed condition of cylinder head and manifolds........................... 33
Check of engine piping for damage and loosenes.......................................... 33
Replacing alternator belt .......................................................... 34
120 Testing and adjusting, Part 2...................................................SEN04098-00
Adjusting decelerator pedal............................................................................ 2
Testing and adjusting HST oil pressure.......................................................... 4
Measuring solenoid valve outlet pressure.......................................... 9
Testing travel deviation...................................................................................... 12
Adjusting parking brake lever........................................................................... 13
Simple brake performance test procedure ...................................................... 15
Adjusting brake pedal............................................................ 16
Method of releasing parking brake (Procedure for emergency escape) ......... 18
Testing and adjusting idler clearance ............................................ 20
Testing and adjusting track shoe tension .......................................... 21
Testing work equipment pressure ................................................................... 22
Testing work equipment PPC valve......................................................... 24
Adjusting play of work equipment PPC valve................................................... 26
Adjusting work equipment lock lever................................................ 27
Testing internal leakage of work equipment cylinder.......................... 28
Releasing residual pressure in hydraulic circuit ............................................. 30
Bleeding air from hydraulic circuit .......................................................... 31
Adjusting play of blade center ball ................................................................. 32
Procedure for testing diodes ........................................................................... 33
Preparation work for troubleshooting for electrical system .......................... 34
How to start operation of KOMTRAX terminal .................................. 38
Lamp display of KOMTRAX terminal ....................................................... 41
130 Testing and adjusting, Part 3................................................SEN04099-00
Special functions of monitor panel (EMMS) ................................................ 2
Items to be adjusted when electric/hydraulic devices are adjusted/replaced.. 64
Adjustment procedure after replacement of HST controller .... 65
Adjustment procedure after replacement of monitor panel ........ 67
Pm-clinic.................................................................................. 68
40 Troubleshooting
100 Failure code table and fuse locations .....................SEN04100-00
Failure code table........................................................................ 2
Before carrying out troubleshooting for electrical system (E-mode) .... 8
200 General information on troubleshooting.................................SEN04101-02
Points to remember when troubleshooting............................................... 2
Sequence of events in troubleshooting ............................................................ 3
Testing before troubleshooting ............................................................... 4
Classification and procedures of troubleshooting ............................... 5
Information contained in troubleshooting table ................................................ 8
Connection table for connector pin numbers .......................................... 10
T- branch box and T- branch adapter table ................................................... 46
310 Troubleshooting by failure code (Display of code), Part 1 ......SEN04102-00
Failure code [6091NX] HST charge filter element: Clogging ............. 3
Failure code [AA10NX] Air cleaner: Clogging ............................... 4
Failure code [AB00MA] Alternator: Malfunction .................. 6
Failure code [B@BAZG] Engine oil: Lowering of oil pressure.. 7
Failure code [B@BCNS] Coolant: Overheat ............... 8
Failure code [B@CRNS] HST oil: Overheating.................................. 9
Failure code [B@CRZG] HST oil: Lowering of oil pressure ....... 10
Failure code [CA111] Engine controller: Abnormality in controller ........ 11
Failure code [CA115] Abnormal engine Ne and Bkup speed sensors: Abnormal speed sensor signal.. 11
Failure code [CA122] Charge pressure sensor tool high: Excessively high voltage detected ...... 12
Failure code [CA123] Charge pressure sensor too low: Excessively low voltage detected.. 14
Failure code [CA131] Decelerator pedal sensor tool high: Excessively high voltage detected . 16
Failure code [CA132] Decelerator pedal sensor too low: Excessively low voltage detected.......... 18
Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected ................. 20
Failure code [CA145] Coolant temperature sensor too low: Excessively low voltage detected .................... 22
Failure code [CA153] Charge air temperature sensor too high: Excessively high voltage detected ............. 24
Failure code [CA154] Charge temperature sensor too low: Excessively low voltage detected..................... 26
Failure code [CA187] Sensor power source 2 too low: Excessively low voltage detected............................ 28
Failure code [CA221] Atmospheric pressure sensor too high: Excessively high voltage detected ............... 30
Failure code [CA222] Atmospheric pressure sensor too low: Excessively low voltage detected .................. 32
Failure code [CA227] Sensor power source 2 too high: Excessively high voltage detected ......... 34
Failure code [CA234] Engine over speed: Excessively high speed .............. 36
Failure code [CA238] Abnormal power source for Ne speed sensor: Excessively low voltage detected...... 37
Failure code [CA271] IMV/PCV1 short circuit: Short circuit....................... 38
Failure code [CA272] IMV/PCV1 disconnection: Disconnection ............ 40
320 Troubleshooting by failure code (Display of code), Part 2......................................................... SEN04103-01
Failure code [CA322] Injector No. 1 system disconnection or short circuit: disconnection, short circuit ....... 4
Failure code [CA324] Injector No. 3 system disconnection or short circuit: disconnection, short circuit ....... 6
Failure code [CA331] Injector No. 2 system disconnection or short circuit: disconnection, short circuit ....... 8
Failure code [CA332] Injector No. 4 system disconnection or short circuit: disconnection, short circuit ....... 10
Failure code [CA342] Engine controller data matching error: matching error ............................................... 12
Failure code [CA351] Injector drive circuit abnormality: Abnormal circuit ..... 14
Failure code [CA352] Sensor power source 1 too low: Excessively low voltage detected............................ 16
Failure code [CA386] Sensor power source 1 too high: Excessively high voltage detected ......................... 18
Failure code [CA428] Water in fuel sensor too high: Excessively high voltage detected .............................. 20
Failure code [CA429] Water in fuel sensor too low: Excessively low voltage detected ................................. 22
Failure code [CA435] Abnormal engine oil pressure switch: Abnormal signal circuit.................................... 24
Failure code [CA441] Power source voltage too low: Excessively low voltage detected .............................. 26
Failure code [CA442] Power source voltage too high:
Excessively high voltage has occurred in the controller power source circuit .. 28
Failure code [CA449] Common rail pressure too high (2): Excessively high pressure trouble occurred....... 30
Failure code [CA451] Common rail pressure sensor too high: Excessively high voltage detected............... 32
Failure code [CA452] Common rail pressure sensor too low: Excessively low voltage detected.................. 34
Failure code [CA488] Charge temperature too high and torque derated:
Exceeded upper control limit of temperature .......... 36
Failure code [CA553] Common rail pressure too high (1): Excessively high pressure detected................... 37
Failure code [CA559] Loss of pressure feed from supply pump (1): Loss of pressure feed detected........... 38
Failure code [CA689] Abnormal engine Ne speed sensor: Abnormal signal................................................. 40
Failure code [CA731] Abnormal engine Bkup speed sensor phase: Abnormal phase.................................. 42
Failure code [CA757] Loss of all engine controller data: Loss of all data........ 44
Failure code [CA778] Abnormal engine Bkup speed sensor: Abnormal Bkup signal.. 46
Failure code [CA1633] Abnormal KOMNET: Abnormal communication..... 48
Failure code [CA2185] Decelerator pedal sensor power source too high:
Excessively high voltage detected ................... 50
Failure code [CA2186] Decelerator pedal sensor power source too low:
Excessively low voltage detected ......................................... 52
Failure code [CA2249] Loss of pressure feed from supply pump (2): Loss of pressure feed detected......... 54
Failure code [CA2311] Abnormal IMV solenoid: Abnormal resistance ........ 56
Failure code [CA2555] Air intake heater relay disconnection: Disconnection .. 58
Failure code [CA2556] Air intake heater relay short circuit: Short circuit ....... 60
330 Troubleshooting by failure code (Display of code), Part 3....... SEN04104-00
Failure code [D130KA] Neutral safety relay: Disconnection............. 4
Failure code [D130KB] Neutral safety relay: Short circuit ................... 6
Failure code [DAFRKR] CAN communication (Monitor panel – HST controller):
Defective communication (Abnormality in objective component system) ..... 8
Failure code [DAFRMC] CAN communication (Monitor panel – ENGINE controller):
Defective communication (Abnormality in objective component system) ... 11
Failure code [DAJ000] HST controller: Memory error ............................ 14
Failure code [DAJ0KK] HST controller: Lowing of source voltage ..... 16
Failure code [DAJ0KQ] HST controller: Machine code error ................. 18
Failure code [DAJ0KT] HST controller: Memory error ..................... 19
Failure code [DAJ5KK] HST controller sensor 5 V power supply No.1: Lowing of source voltage/Input ...... 20
Failure code [DAJ6KK] HST controller sensor 5 V power supply No.2: Lowing of source voltage/Input ...... 22
Failure code [DAJRKR] CAN communication (HST controller – Monitor panel):
Defective communication (Abnormality in objective component system)..... 24
Failure code [DB2RKR] CAN communication (HST controller – Engine controller):
Defective communication (Abnormality in objective component system)......... 27
Failure code [DD12KA] Shift up switch: Disconnection................... 30
Failure code [DD12KB] Shift up switch: Short circuit .................. 32
Failure code [DD13KA] Shift down switch: Disconnection ......................... 34
Failure code [DD13KB] Shift down switch: Short circuit................................... 36
Failure code [DD14KB] Travel lock limit switch 1: Short circuit...................... 38
Failure code [DD1NL4] Fan rotation selector switch: Disagreement of ON, OFF Signals .......... 40
Failure code [DDDCKB] Reverse travel speed switch: Short circuit .............. 42
Failure code [DDP6KA] Brake oil pressure sensor: Disconnection................. 44
Failure code [DDP6KB] Brake oil pressure sensor: Short circuit ........... 46
Failure code [DDP6MA] Brake oil pressure sensor: Malfunction ................. 48
Failure code [DDQ2KA] Travel lock limit switch 1: Disconnection ................... 50
Failure code [DDT0L4] Shift mode switch: Disagreement of ON/ OFF Signals 52
Failure code [DDU1FS] Travel lock limit switches 1 and 2: Fixing............... 54
Failure code [DDU1KA] Travel lock limit switch 2: Disconnection.............. 56
Failure code [DDU1KY] Travel lock limit switch 2: Short circuit with power supply line . 58
Failure code [DGS1KA] HST oil temperature sensor: Disconnection .............. 60
Failure code [DGS1KX] HST oil temperature sensor: Out of Input signal range.... 62
340 Troubleshooting by failure code (Display of code), Part 4 ......SEN04105-00
Failure code [DHH5KA] Left HST pump pressure sensor: Disconnection ..... 4
Failure code [DHH5KB] Left HST pump pressure sensor: Short circuit.. 6
Failure code [DHH6KA] Right HST pump pressure sensor: Disconnection...... 8
Failure code [DHH6KB] Right HST pump pressure sensor: Short circuit ... 10
Failure code [DK10KA] Fuel dial sensor: Disconnection................. 12
Failure code [DK10KB] Fuel dial sensor: Short circuit ............. 14
Failure code [DK30KA] Steering angle sensor 1: Disconnection .... 16
Failure code [DK30KB] Steering angle sensor 1: Short circuit................... 18
Failure code [DK30KX] Steering angle sensor: Out of input signal range........ 20
Failure code [DK30KX] Steering angle sensor: Out of input signal range.... 20
Failure code [DK30KZ] Steering angle sensor: Disconnection or short circuit.. 21
Failure code [DK30L8] Steering angle sensor: Disagreement of analog signals ... 22
Failure code [DK31KA] Steering angle sensor 2: Disconnection ............ 24
Failure code [DK31KB] Steering angle sensor 2: Short circuit.............. 26
Failure code [DK40KA] Brake pedal sensor: Disconnection .............. 28
Failure code [DK40KB] Brake pedal sensor: Short circuit.......................... 30
Failure code [DK55KX] Directional potentiometer: Out of input signal range .. 32
Failure code [DK55KZ] Directional potentiometer: Disconnection or short circuit........ 33
Failure code [DK55L8] Directional potentiometer: Disagreement of analog signals.... 34
Failure code [DK56KA] Directional potentiometer 1: Disconnection ... 36
Failure code [DK56KB] Directional potentiometer 1: Short circuit................ 38
Failure code [DK57KA] Directional potentiometer 2: Disconnection .......... 40
Failure code [DK57KB] Directional potentiometer 2: Short circuit.................... 42
Failure code [DLM0KX] HST motor speed sensors: Out of input signal range 44
Failure code [DLM1KA] Left HST motor speed sensor: Disconnection ........ 46
Failure code [DLM1KB] Left HST motor speed sensor: Short circuit .............. 48
Failure code [DLM1MA] Left HST motor speed sensor: Malfunction .............. 50
Failure code [DLM2KA] Right HST motor speed sensor: Disconnection ........ 52
Failure code [DLM2KB] Right HST motor speed sensor: Short circuit............. 54
Failure code [DLM2MA] Right HST motor speed sensor: Malfunction............. 56
Failure code [DLM3KA] Fan speed sensor: Disconnection............................. 58
Failure code [DLM3KB] Fan speed sensor: Short circuit ................................ 60
350 Troubleshooting by failure code (Display of code), Part 5....... SEN04106-00
Failure code [DN21FS] Brake pedal and proximity switch: Fixing............... 4
Failure code [DV00KB] Caution buzzer: Short circuit.............................. 6
Failure code [DV20KB] Back alarm buzzer: Short circuit ............................... 7
Failure code [DW4BKA] Parking brake solenoid valve: Disconnection ........ 8
Failure code [DW4BKB] Parking brake solenoid valve: Short circuit.............. 10
Failure code [DW4BKY] Parking brake solenoid valve: Short circuit with power supply line.. 12
Failure code [DW7BKA] Fan reverse solenoid valve: Disconnection ...... 14
Failure code [DW7BKB] Fan reverse solenoid valve: Short circuit........ 16
Failure code [DW7BKY] Fan reverse solenoid valve: Short circuit with power supply line ........................... 17
Failure code [DW7EKA] Slow brake solenoid valve: Disconnection ......... 18
Failure code [DW7EKB] Slow brake solenoid valve: Short circuit ..... 22
Failure code [DW7EKY] Slow brake solenoid valve: Short circuit with power supply line..... 24
Failure code [DWN5KA] Fan EPC solenoid valve: Disconnection .................. 26
Failure code [DWN5KB] Fan EPC solenoid valve: Short circuit .............. 28
Failure code [DWN5KY] Fan EPC solenoid valve: Short circuit with power supply line............... 30
Failure code [DXA4KA] LF HST pump EPC solenoid valve: Disconnection .... 32
Failure code [DXA4KB] LF HST pump EPC solenoid valve: Short circuit ....... 34
Failure code [DXA4KY] LF HST pump EPC solenoid valve: Short circuit with power supply line................. 36
Failure code [DXA5KA] LR HST pump EPC solenoid valve: Disconnection .... 38
Failure code [DXA5KB] LR HST pump EPC solenoid valve: Short circuit........ 40
Failure code [DXA5KY] LR HST pump EPC solenoid valve: Short circuit with power supply line ................ 42
Failure code [DXA6KA] RF HST pump EPC solenoid valve: Disconnection. 44
Failure code [DXA6KB] RF HST pump EPC solenoid valve: Short circuit ...... 46
Failure code [DXA6KY] RF HST pump EPC solenoid valve: Short circuit with power supply line ................ 47
Failure code [DXA7KA] RR HST pump EPC solenoid valve: Disconnection . 48
Failure code [DXA7KB] RR HST pump EPC solenoid valve: Short circuit .. 50
Failure code [DXA7KY] RR HST pump EPC solenoid valve: Short circuit with power supply line................ 52
Failure code [DXK1KA] Left HST motor EPC solenoid valve: Disconnection .. 54
Failure code [DXK1KB] Left HST motor EPC solenoid valve: Short circuit .. 55
Failure code [DXK1KY] Left HST motor EPC solenoid valve: Short circuit with power supply line.....56
Failure code [DXK2KA] Right HST motor EPC solenoid valve: Disconnection .57
Failure code [DXK2KB] Right HST motor EPC solenoid valve: Short circuit.....58
Failure code [DXK2KY] Right HST motor EPC solenoid valve: Short circuit with power supply line ............ 59
400 Troubleshooting of electrical system (E-mode) ................. SEN04107-00
E-1 Engine does not start (Starting motor does not rotate) ......... 4
E-2 Engine is not preheated ....................................... 7
E-3 When starting switch is turned ON, any item does not light up......... 10
E-4 Charge level caution flashes while engine is running ........ 12
E-5 Emergency warning items flash while engine is running .................. 14
E-6 Preheating pilot lamp does not light up during preheating operation......... 20
E-7 The coolant temperature gauge does not indicate correctly. ...... 22
E-8 The HST oil temperature gauge does not indicate correctly. ................ 23
E-9 Fuel level gauge does not indicate properly ........................................ 24
E-10 Gear speed, set travel speed, and shift mode indicator does not display normally .............................. 26
E-11 Multi-information unit does not display normally ......................... 26
E-12 Caution lamp does not flash or does not go off ....................................... 27
E-13 Caution buzzer does not sound or does not stop ............. 28
E-14 Reverse travel speed setting switch does not function ..... 30
E-15 Shift mode switch does not function .............................. 32
E-16 Buzzer cancel switch does not function .................................................. 34
E-17 Information switch does not function................................................ 36
E-18 The fan cleaning does not operate or cannot be reset .................. 38
E-19 Backup alarm does not sound .................................... 40
E-20 The horn does not sound or does not stop ...................................... 41
E-21 Work equipment does not move ..................................................... 42
E-22 Headlamp or rear lamp does not light up........................................ 44
E-23 Foot heater does not operate.................................... 47
E-24 Air conditioner does not operate..................................... 50
E-25 Windshield wiper and window washer do not operate............... 55
E-26 KOMTRAX system does not operate normally............................... 68
500 Troubleshooting of hydraulic and mechanical system (H-mode) .....SEN04108-01
Information in troubleshooting table ............... 3
H-1 Right and left travel systems do not operate forward and in reverse (No travel systems operate) ........ 4
H-2 Right or left travel system does not operate forward and in reverse
(Only right or left travel system does not operate).......... 6
H-3 Right or left travel system does not operate forward or in reverse (Only 1 system does not operate)... 7
H-4 Speed or power of travel is low ............................................... 8
H-5 Gear is not shifted ............................................... 9
H-6 Large shocks are made when machine starts and stops travel.... 10
H-7 Machine deviates largely during travel ........ 11
H-8 Hydraulic drift of travel is large ............................... 12
H-9 Engine stalls or engine speed lowers extremely during travel ......... 13
H-10 Abnormal sound comes out from around HST pump and motor.......... 14
H-11 Work equipment dose not operate at all .................. 15
H-12 Speed or power of whole work equipment is low ............. 16
H-13 Speed or power of lifting blade is low................... 17
H-14 Speed or power of tilting blade is low ..................... 18
H-15 Speed or power of angling blade is low.................... 19
H-16 Time lag in lifting blade is large .................................... 20
H-17 Hydraulic drift of lifting blade is large...................................... 20
H-18 Hydraulic drift of tilting blade is large.............................. 20
H-19 Abnormal sound comes out from around work equipment pump and control valve...... 21
H-20 HST oil temperature (Hydraulic oil temperature) rises too high ............ 22
H-21 Fan speed is abnormal (High, low, or 0 rpm) ......................... 24
H-22 Abnormal sound is heard from around fan ...................... 25
600 Troubleshooting of engine (S-mode)...........................SEN04109-01
Method of using troubleshooting charts ......................................... 3
S-1 Starting performance is poor ................................................ 6
S-2 Engine does not start............................................................... 7
S-3 Engine does not pick up smoothly............................................... 10
S-4 Engine stops during operations ................................................. 11
S-5 Engine does not rotate smoothly ................................... 12
S-6 Engine lacks output (or lacks power).................................................. 13
S-7 Exhaust smoke is black (imcomplete combustion)..................... 14
S-8 Oil consumption is excessive (or exhaust smoke is blue) ......... 15
S-9 Oil becomes contaminated quickly ................... 16
S-10 Fuel consumption is excessive.......................................... 17
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down) ..... 18
S-12 Oil pressure drops ..................................................... 19
S-13 Oil level rises (water, fuel in oil) .................................... 20
S-14 Coolant temperature becomes too high (overheating) ................ 21
S-15 Abnormal noise is made....................................................... 22
S-16 Vibration is excessive ................................................................ 23
50 Disassembly and assembly
100 General information on disassembly and assembly ........SEN04662-03
How to read this manual .................. 2
Coating materials list.............................................. 4
Special tools list................................................... 7
Sketches of special tools................................................... 10
200 Engine and cooling system .................................................SEN04663-02
Removal and installation of fuel supply pump assembly................................ 2
Removal and installation of fuel injector assembly ............................... 6
Removal and installation of cylinder head assembly ....................................... 14
Removal and installation of engine and HST pump assembly ........................ 27
Removal and installation of engine front seal assembly................................... 30
Removal and installation of engine rear seal assembly ......................... 32
Removal and installation of front guard assembly................................... 36
Removal and installation of radiator assembly ................................... 38
Removal and installation of hydraulic oil cooler assembly ............................. 40
Removal and installation of aftercooler assembly ........................................... 42
Removal and installation of cooling fan and motor assembly............... 44
Removal and installation of cooling fan drive motor assembly......................... 46
Removal and installation of fuel tank assembly............................................ 48
300 Power train .............................................................. SEN04664-01
Removal and installation of HST pump assembly .............................................. 2
Removal and installation of HST motor and final drive assembly .................. 4
Disassembly and assembly of final drive assembly ............................. 6
400 Undercarriage and frame ............................ SEN04665-01
Spreading and installation of track shoe assembly....................................... 2
Removal and installation of idler and recoil spring assembly ............. 4
Disassembly and assembly of idler assembly ........................ 5
Disassembly and assembly of recoil spring assembly ...... 8
Disassembly and assembly of track roller assembly ... 12
Disassembly and assembly of carrier roller assembly............. 16
500 Hydraulic system ........................................ SEN04666-01
Removal and installation of hydraulic tank assembly ..........3
Removal and installation of control valve assembly ....................... 4
Disassembly and assembly of control valve assembly............................ 5
Disassembly and assembly of hydraulic cylinder assembly .......................... 7
600 Work equipment .............................................................. SEN04667-01
Removal and installation of work equipment assembly............................................... 2
700 Cab and its attachments....................... SEN04668-01
Removal and installation of ROPS canopy and operator seat frame assembly.. 2
Removal and installation of ROPS cab and operator seat frame assembly...... 5
Removal and installation of operator’s cab glass (Stuck glass).......... 10
800 Electrical system ....................... SEN04669-01
Removal and installation of HST controller assembly ....................... 2
Removal and installation of KOMTRAX terminal assembly......................... 3
90 Diagrams and drawings
100 Hydraulic diagrams and drawings ........................ SEN04053-00
Work equipment hydraulic circuit diagram........................................................ 3
200 Electrical diagrams and drawings......................................... SEN04054-01
Electrical circuit diagram............................................................................ 3
Cab electrical circuit diagram ..................................................................... 13
Air conditioner circuit diagram ............................................ 17
Connector list and stereogram ......................................... 19