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Summary of Contents for Komatsu D39EX-3001
- Page 1 SEN04041-05 BULLDOZER D39EX D39PX D39EX- 3001 SERIAL NUMBERS and up D39PX- 3001...
- Page 2 SEN04050-05 BULLDOZER D39EX-22 D39PX-22 Machine model Serial number D39EX-22 3001 and up D39PX-22 3001 and up 00 Index and foreword 100 Index Composition of shop manual..........................2 Table of contents ..............................4 D39EX-22, D39PX-22 00-100...
- Page 3 100 Index SEN04050-05 Composition of shop manual Composition of shop manual The contents of this shop manual are shown together with Form No. in a list. Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly. The marks shown to the right of Form No.
- Page 4 100 Index SEN04050-05 Composition of shop manual 600 Troubleshooting of engine (S-mode) ..................SEN04109-01 50 Disassembly and assembly ......................SEN04048-03 100 General information on disassembly and assembly............SEN04662-03 q 200 Engine and cooling system ....................SEN04663-02 300 Power train .........................SEN04664-01 400 Undercarriage and frame ....................SEN04665-01 500 Hydraulic system ........................SEN04666-01 600 Work equipment .........................SEN04667-01 700 Cab and its attachments.....................SEN04668-01...
- Page 5 100 Index SEN04050-05 Table of contents Table of contents 00 Index and foreword 100 Index ............................SEN04050-05 Composition of shop manual......................... Table of contents ............................200 Foreword and general information .....................SEN04051-02 Safety notice ..............................How to read the shop manual ........................Explanation of terms for maintenance standard....................
- Page 6 100 Index SEN04050-05 Table of contents CLSS ................................28 Functions and operation of each valve......................31 420 Hydraulic system, Part 2 ......................SEN04234-01 Blade PPC valve............................Accumulator..............................500 Work equipment ........................SEN04236-01 Work equipment ............................Cutting edge and end bit ..........................Ripper ................................
- Page 7 100 Index SEN04050-05 Table of contents Check of installed condition of cylinder head and manifolds................. 33 Check of engine piping for damage and looseness ..................33 Replacing alternator belt ..........................34 120 Testing and adjusting, Part 2......................SEN04098-00 Adjusting decelerator pedal........................... Testing and adjusting HST oil pressure......................
- Page 8 100 Index SEN04050-05 Table of contents 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 ....
- Page 9 100 Index SEN04050-05 Table of contents 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 ..
- Page 10 100 Index SEN04050-05 Table of contents 350 Troubleshooting by failure code (Display of code), Part 5............SEN04106-00 Failure code [DN21FS] Brake pedal and proximity switch: Fixing..............Failure code [DV00KB] Caution buzzer: Short circuit..................Failure code [DV20KB] Back alarm buzzer: Short circuit ................Failure code [DW4BKA] Parking brake solenoid valve: Disconnection ............
- Page 11 100 Index SEN04050-05 Table of contents 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 ......................
- Page 12 100 Index SEN04050-05 Table of contents 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 ....................
- Page 13 SEN04050-05 D39EX-22, D39PX-22 Bulldozer Form No. SEN04050-05 ©2011 KOMATSU All Rights Reserved Printed in Japan 02-11 00-100...
- Page 14 SEN04051-02 BULLDOZER D39EX-22 D39PX-22 Machine model Serial number D39EX-22 3001 and up D39PX-22 3001 and up 00 Index and foreword 200 Foreword and general information 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 ...................
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Page 15: Safety Notice
Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. - Page 16 200 Foreword and general information SEN04051-02 Safety notice Preparations for work When removing a cover which is under Before adding oil or making any repairs, internal pressure or under pressure from a park the machine on a hard and level spring, always leave 2 bolts in diagonal ground, and apply the parking brake and positions.
- Page 17 200 Foreword and general information SEN04051-02 Safety notice Precautions for sling work and making signs Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily.
- Page 18 200 Foreword and general information SEN04051-02 Safety notice If the load is unstable or the wire rope 13) If the hoist stops because of a power fail- or chains are twisted, lower the load ure, turn the power switch OFF. When and lift it up again.
- Page 19 200 Foreword and general information SEN04051-02 Safety notice a Example of O-ring (Fitted to every joint of Precautions for disconnecting and con- necting hoses and tubes in air conditioner hoses and tubes) circuit Disconnection For the environment, the air condi- tioner of this machine uses the refrigerant (air conditioner gas: R134a) which has fewer factors of...
- Page 20 This section explains the method of reproducing, repairing, and replacing parts. Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work. D39EX-22, D39PX-22...
- Page 21 200 Foreword and general information SEN04051-02 How to read the shop manual Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table. Revised edition mark When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1.
- Page 22 200 Foreword and general information SEN04051-02 Explanation of terms for maintenance standard Explanation of terms for maintenance standard The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the machine maintenance work. The following terms are used to explain the criteria. Standard size and tolerance To be accurate, the finishing size of parts is a little different from one to another.
- Page 23 200 Foreword and general information SEN04051-02 Explanation of terms for maintenance standard Standard clearance and standard value Clearance limit The clearance made when new parts are Parts can be used until the clearance assembled is called the “standard clear- between them is increased to a certain ance“, which is indicated by the range limit.
- Page 24 200 Foreword and general information SEN04051-02 Handling of electric equipment and hydraulic component Handling of electric equipment and hydraulic component To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be carried out.
- Page 25 200 Foreword and general information SEN04051-02 Handling of electric equipment and hydraulic component Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the sol- dering may be damaged, or the wiring...
- Page 26 200 Foreword and general information SEN04051-02 Handling of electric equipment and hydraulic component Removing, installing, and drying connec- tors and wiring harnesses Disconnecting connectors Hold the connectors when discon- necting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart.
- Page 27 200 Foreword and general information SEN04051-02 Handling of electric equipment and hydraulic component Connecting connectors Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or dam- age to the connector pins.
- Page 28 200 Foreword and general information SEN04051-02 Handling of electric equipment and hydraulic component Heavy duty wire connector (DT 8-pole, 12- Disconnection Connection (Example of pole) incomplete setting of (a)) Disconnection (Left of figure) While pressing both sides of locks (a) and (b), pull out female connector (2).
- Page 29 200 Foreword and general information SEN04051-02 Handling of electric equipment and hydraulic component Drying wiring harness If there is any oil or dirt on the wiring har- ness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness.
- Page 30 Download the full PDF manual instantly. Our customer service e-mail: aservicemanualpdf@yahoo.com...
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