Complete service repair manual with Electrical Wiring Diagrams for Komatsu Bulldozers D39EX, D39PX, with all the technical information to maintain, diagnose, repair, and service like professional mechanics.

Komatsu Bulldozers D39EX,PX workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

SEBM023809 - Bulldozer D39EX,PX-21 Shop Manual (SN1001&up).pdf
SEBM023810 - Bulldozer D39EX,PX-21 Shop Manual (SN1001&up).pdf
SEN04041-05 - Bulldozer D39EX,PX-22 Shop Manual (SN3001&up).pdf

PRODUCT DETAILS:
Total Pages: 1,920 pages
File Format: PDF
Language: English

TABLE OF CONTENTS
01 GENERAL ... 01-1
10 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD ... 10-1
20 TESTING AND ADJUSTING ... 20-1
30 DISASSEMBLY AND ASSEMBLY ... 30-1
90 OTHERS ...90-1

SEBM023809 - Bulldozer D39EX,PX-21 Shop Manual (SN1001&up)...2
  COVER...2
  CONTENTS...3
  SAFETY...8
    SAFETY NOTICE...8
  FOREWORD...10
    GENERAL...10
    HOW TO READ THE SHOP MANUAL...11
    HOISTING INSTRUCTIONS...12
    METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER...13
    COATING MATERIALS...15
    STANDARD TIGHTENING TORQUE...17
    ELECTRIC WIRE CODE...20
    CONVERSION TABLE...21
    UNITS...27
  01 GENERAL...28
    SPECIFICATION DRAWING...29
    SPECIFICATIONS...30
    WEIGHT TABLE...34
    TABLE OF FUEL, COOLANT AND LUBRICANTS...36
  10 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD...37
    COOLING SYSTEM...38
    ENGINE CONTROL...39
    POWER TRAIN...41
    POWER TRAIN SYSTEM...42
    HST HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAM...43
    STEERING, BRAKE CONTROL...44
    DAMPER...50
    SOLENOID VALVE...51
    FINAL DRIVE...53
    HST PUMP...57
    SAFETY-SUCTION VALVE...62
    CUT-OFF VALVE...65
    CHARGE SAFETY VALVE...66
    CHARGE PUMP...68
    HST BRAKE QUICK RETURN CIRCUIT...69
    TOWING  VALVE...70
    PARKING BRAKE VALVE...71
    AS VALVE...73
    HST MOTOR...75
    STEERING, DIRECTIONAL PPC VALVE...86
    INCHING VALVE...95
    AUTOMATIC GEARSHIFITING VALVE...97
    FRAME  ASSEMBLY...102
    TRACK FRAME, RECOIL SPRING...103
    IDLER...105
    TRACK ROLLER ...107
    CARRIER ROLLER...108
    SPROCKET...109
    TRACK SHOE...111
    ARRANGEMENT OF HYDRAULIC EQUIPMENT FOR WORK EQUIPMENT...115
    WORK EQUIPMENT CONTROL...116
    HYDRAULIC TANK, FILTER...118
    HYDRAULIC PUMP...119
    WORK EQUIPMENT  CYLINDER...120
    SUCTION VALVE...122
    CONTROL VALVE...124
    CLSS...132
    WORK EQUIPMENT PPC VALVE...142
    WORK EQUIPMENT ...149
    CUTTING EDGE, END BIT...152
    CAB RELATED...153
    SAFETY MECHANISM WHEN STARTING ENGINE...154
    GEARSHIFT CONTROL SYSTEM...155
    PARKING BRAKE CONTROL SYSTEM...156
    COMPONENT EQUIPMENT OF SYTEM...157
    MONITOR SYSTEM...159
    SENSORS...163
  20 TESTING AND ADJUSTING...166
    STANDARD VALUE TABLE...167
      STANDARD VALUE TABLE FOR ENGINE...167
      STANDARD VALUE FOR CHASSIS...168
      STANDARD VALUE TABLE FOR ELECTRICAL PARTS...172
    TESTING AND ADJUSTING...175
      TOOLS FOR TESTING AND ADJUSTING...176
      MEASURING ENGINE SPEED...177
      MEASURING EXHAUST COLOR...178
      MEASURING BLOW-BY PRESSURE...179
      MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)...180
      ADJUSTING VALVE CLEARANCE...181
      TESTING AND ADJUSTING FUEL INJECTION TIMING...183
      MEASURING COMPRESSION PRESSURE...184
      ADJUSTING ENGINE STOP SOLENOID LINKAGE...185
      MEASURING ENGINE OIL PRESSURE...186
      BLEEDING AIR FROM FUEL CIRCUIT...187
      TESTING AND ADJUSTING TENSION OF AIR CONDITIONER COMPRESSOR BELT...188
      MEASURING AND ADJUSTING HST OIL PRESSURE...189
      MEASURING SOLENOID VALVE OUTPUT PRESSURE...194
      MEASURING AND ADJUSTING WORK EQUIPMENT MAIN RELIEF PRESSURE...195
      MEASURING PPC VALVE OUTPUT PRESSURE...197
      MEASURING LEAKAGE INSIDE CYLINDER...198
      BLEEDING AIR FROM HYDRAULIC CYLINDERS...198
      TESTING AND ADJUSTING TRACK SHOE TENSION...199
      TESTING AND ADJUSTING TRAVEL DEVIATION...200
      ADJUSTING FUEL CONTROL LINKAGE...203
      ADJUSTING DECELERATION PEDAL LINKAGE...205
      ADJUSTING BRAKE PEDAL LINKAGE...206
      ADJUSTING STEERING/DIRECTIONAL/GEAR SHIFT LEVER AND LOCK LEVER...208
      ADJUSTING BLADE CONTROL LEVER AND LOCK LEVER...211
      ADJUSTING WORK EQUIPMENT PPC VALVE...212
      PROCEDURE FOR RELEASING PARKING BRAKE...213
      PROCEDURE FOR INSPECTING DIODE...215
    TROUBLESHOOTING...216
      POINTS TO REMEMBER WHEN TROUBLESHOOTING...217
      SEQUENCE OF EVENTS IN TROUBLESHOOTING...218
      POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...219
      CHECKS BEFORE TROUBLESHOOTING...227
      METHOD OF USING TROUBLESHOOTING CHARTS...228
      TYPES AND LOCATIONS OF CONNECTORS...229
      CONNECTOR ARRANGEMENT DIAGRAM...231
      CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...233
      TROUBLESHOOTING FOR ELECTRICAL SYSTEM (E-MODE)...255
        TABLE OF FAILURE MODES AND CAUSES (ELECTRICAL SYSTEM)...256
        ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM...258
        E-1 WHEN STARTING SWITCH IS TURNED ON, STARTING MOTOR DOES NOT ROTATE...260
        E-2 ENGINE DOES NOT START (ENGINE STOP SOLENOID DOES NOT OPERATE NORMALLY)...262
        E-3 HEADLAMP DOES NOT LIGHT UP...263
        E-4 WHEN STARTING SWITCH IS TURNED TO HEAT POSITION, ENGINE IS NOT HEATED...265
        E-5 WINDSHEILD WIPER DOES NOT OPERATE...266
        E-6 WASHING WATER DOES NOT SPOUT ...268
        E-7 AIR CONDITIONER DOES NOT WORK...270
          A) AIR DOES NOT BLOW OUT...270
          B) AIR IS NOT COOLED...273
        E-8 PARKING BRAKE CANNOT BE RELEASED (PARKING BRAKE SOLENOID DOES NOT OPERATE)...277
        E-9 TRAVEL SPEED CONTROL IS ABNORMAL...278
          A) WHEN GEAR SHIFT SWITCH IS PRESSED, GEAR SPEED DOES NOT CHANGE OR GEAR SPEED CHANGES BY ITSELF (GEAR SHIFT SWITCH OR CONTRO...278
          B) GEAR SPEED CANNOT BE SELECTED NORMALLY (TRAVEL SPEED CHANGEOVER SOLENOID IS ADNORMAL...279
        E-10 BACKUP ALARM DOES NOT SOUND DURING REVERSE TRAVEL...281
        E-11 HORN DOES NOT SOUND...283
      TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)...284
        TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC AND MECHANICAL SYSTEMS)...285
        H-1 MACHINE DOES NOT TRAVEL IN EITHER DIRECTION OR IT STOPS SUDDENLY...287
        H-2 MACHINE DOES NOT TRAVEL IN ONE DIRECTION...288
        H-3 MACHINE TRAVELS WHILE TRAVEL LEVER IS IN NEUTRAL...288
        H-5 MACHINE DEVIATES WHILE TRAVEL LEVER IS IN PARTIAL POSITION ...288
        H-7 MACHINE SWINGS MOMENTARILY WHEN IT STARTS ON FLAT GROUND...288
        H-11 TURNING TIME LAG IS LARGE...288
        H-12 WHEN OPERATOR INTENDS TO TURN GRADUALLY, MACHINE TURNS SHARPLY...288
        H-13 MACHINE DOES NOT RETURN QUICKLY TO STRAIGHT TRAVEL POSITION...288
        H-14 MACHINE IS NOT DECELERATED SMOOTHLY OR TRAVEL SPEED CANNOT BE CONTROLLED ON DOWNHILL GROUND...288
        H-15 MACHINE DEVIATES WHEN IT IS DECELERATED...288
        H-4 MACHINE DEVIATES WHEN TRAVEL LEVER IS MOVED TO STROKE END...289
        H-6 MACHINE MOVES BACK WHEN OPERATOR STARTS ON UPHILL GROUND...289
        H-8 MACHINE STARTS SHARPLY...289
        H-9 MACHINE SWINGS MOMENTARILY WHEN IT STARTS...290
        H-10 STARTING TIME LAG IS LARGE...291
        H-16 MAXIMUM TRAVEL SPEED IS LOW OR OUTPUT POWER IS INSUFFICIENT OR ACCELERATION IS LOW...292
        H-17 ENGINE STALLS...293
        H-18 HST NOISE IS LARGE...294
        H-19 HST OIL TEMPERATURE RISES TOO HIGH...295
        H-20 GEAR SPEED DOES NOT CHANGE...295
        H-21 ABNORMAL SOUND IS HEARD FROM AROUND WORK EQUIPMENT PUMP OR HST PUMP...296
        H-22 ANY WORK EQUIPMENT DOES NOT MOVE...296
        H-23 SPEED OR POWER OF EACH WORK EQUIPMENT IS LOW...297
        H-24 SPEED OR POWER OF BLADE LIFT OF BLADE TILT CYLINDER IS LOW...297
        H-25 SPEED OR POWER OF BLADE ANGLE CYLINDER IS LOW...298
        H-26 HYDRAULIC DRIFT OF BLADE LIFT CYLINDER IS LARGE...299
        H-27 HYDRAULIC DRIFT OF BLADE TILT CYLINDER IS LARGE...299
        H-28 HYDRAULIC DRIFT OF BLADE ANGLE CYLINDER IS LARGE...300
      TROUBLESHOOTING FOR MACHINE MONITOR SYSTEM (M-MODE)...301
        TABLE OF FAILURE MODES AND CAUSES ( MACHINE MONITOR SYSTEMS)...302
        ELECTRIC CIRCUIT DIAGRAM FOR EACH SYSTEM...303
        M-1 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL IS NOT TURNED ON...305
        M-2 TROUBLE IN PREHESTING CAUTION LAMP...306
          A) PREHEATING MONITOR DOES NOT LIGHT UP...306
          B) PREHEATING MONITOR KEEPS LIGHTING UP...306
        M-3 CAUTION ITEM LIGHTS UP...307
          A) CHARGE CAUTION LAMP LIGHTS UP WHILE ENGINE IS RUNNING...307
          B) OIL PRESSURE CAUTION LAMP LIGHTS UP WHILE ENGINE IS RUNNING...308
          C) HST FILTER CLOGGING LAMP LIGHTS UP (WHILE FILTER IS NOT CLOGGED)...308
        M-4 TROUBLE IS HST OIL TEMPERATURE GAUGE...309
          A) GAUGE DOES NOT RISE ABOVE C (LOWEST POINT)...309
          B) GAUGE DOES NOT LOWER BELOW H (HIGHEST POINT)...309
          C) HST OIL TEMPERATURE INDICATED BY GAUGE IS DIFFERENT FROM ACTUAL TEMPERATURE...310
        M-5 TROUBLE IN ENGINE WATER TEMPERATURE GAUGE...311
          A) GAUGE DOES NOT RISE ABOVE C (LOWEST POINT)...311
          B) GAUGE DOES NOT LOWER BELOW H (HIGHEST POINT)...311
          C) HST OIL TEMPERATURE INDICATED BY GAUGE IS DIFFERENT FROM ACTUAL TEMPERATURE...312
        M-6 TROUBLE IN FUEL LEVEL GAUGE...313
          A) GAUGE DOES NOT RISE ABOVE E (LOWEST POINT)...313
          B) GAUGE DOES NOT LOWER BELOW F (HIGHEST POINT)...313
          C) FUEL LEVEL INDICATED BY GAUGE IS DIFFERENT FROM ACTUAL LEVEL...314
        M-7 SERVICE METER DOES NOT OPERATE AFTER ENGINE IS STARTED...315
        M-8 MONITOR PANEL LAMP DOES NOT LIGHT UP (WHILE HEADLAMP IS NORMAL)...316
        M-9 TROUBLE IN DISPLAY OF TRAVEL SPEED (WHILE ACTUAL TRAVEL SPEED IS NORMAL)...317
          A) TRAVEL SPEED IS NOT DISPLAYED...317
          B) DISPLAYED SPEED IS DIFFERENT FROM ACTUAL TRAVEL SPEED...317
  30 DISASSEMBLY AND ASSEMBLY...321
    METHOD OF USING MANUAL...322
    PRECAUTIONS WHEN CARRYING OUT OPERATION...323
    SPECIAL TOOL LIST...325
    SKETCHES OF SPECIAL TOOLS...327
    REMOVAL OF FUEL INJECTION PUMP ASSEMBLY...328
    INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY...330
    REMOVAL OF CYLINDER HEAD ASSEMBLY...332
    INSTALLATION OF CYLINDER HEAD ASSEMBLY...337
    REMOVAL OF ENGINE FRONT SEAL...339
    INSTALLATION OF ENGINE FRONT SEAL...340
    REMOVAL OF ENGINE REAR SEAL...341
    INSTALLATION OF ENGINE REAR SEAL...342
    REMOVAL OF RADIATOR GUARD ASSEMBLY...343
    INSTALLATION OF RADIATOR GUARD ASSEMBLY...345
    DISASSEMBLY OF RADIATOR, OIL COOLER, AND CHARGE AIR COOLER ASSEMBLIES...346
    ASSEMBLY OF RADIATOR, OIL COOLER, AND CHARGE AIR COOLER ASSEMBLIES...348
    REMOVAL OF ENGINE ASSEMBLY...350
    INSTALLATION OF ENGINE ASSEMBLY...352
    REMOVAL OF DAMPER...353
    INSTALLATION OF DAMPER...353
    REMOVAL OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY...354
    INSTALLATION OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY...355
    DISASSEMBLY OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY...356
    ASSEMBLY OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY...360
    REMOVAL OF IDLER AND RECOIL SPRING ASSEMBLY...365
    INSTALLATION OF IDLER AND RECOIL SPRING ASSEMBLY...365
    DISASSEMBLY OF RECOIL SPRING ASSEMBLY...366
    ASSEMBLY OF RECOIL SPRING ASSEMBLY...367
    DISASSEMBLY OF IDER ASSEMBLY...369
    ASSEMBLY OF IDER ASSEMBLY...370
    DISASSEMBLY OF TRACK ROLLER ASSEMBLY...372
    ASSEMBLY OF TRACK ROLLER ASSEMBLY...373
    DISASSEMBLY OF CARRIER ROLLER ASSEMBLY...376
    ASSEMBLY OF CARRIER ROLLER ASSEMBLY...377
    SPREADING TRACK SHOE ASSEMBLY...378
    INSTALLATION OF TRACK SHOE ASSEMBLY...379
    REMOVAL OF HST PUMP ASSEMBLY...380
    INSTALLATION OF HST PUMP ASSEMBLY...381
    REMOVAL OF MAIN CONTROL VALVE ASSEMBLY...382
    INSTALLATION OF MAIN CONTROL VALVE ASSEMBLY...383
    DISASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY...384
    ASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY...388
    DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLIES...392
    ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLIES...393
    REMOVAL OF BLADE ASSEMBLY...395
    INSTALLATION OF BLADE ASSEMBLY...396
    REMOVAL OF OPERATOR'S CAB FRAME ASSEMBLY...397
    INSTALLATION OF OPERATOR'S CAB FRAME ASSEMBLY...400
    REMOVAL OF FUEL TANK ASSEMBLY...401
    INSTALLTION OF FUEL TANK ASSEMBLY...401
    REMOVAL OF HYDRAULIC TANK ASSEMBLY...402
    INSTALLATION OF HYDRAULIC TANK ASSEMBLY...403
  90 OTHERS ...405
    HYDRAULIC CIRCUIT DIAGRAM (1/2) D39EX-21: 1001-1200; D39PX-21: 1001-1208...406
    HYDRAULIC CIRCUIT DIAGRAM (1/2) D39EX-21: 1201 and up; D39PX-21: 1209 and up...407
    HYDRAULIC CIRCUIT DIAGRAM (2/2)...408
    ELECTRICAL CIRCUIT DIAGRAM (1/2)...409
    ELECTRICAL CIRCUIT DIAGRAM (2/2)...410
    ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER...411
SEBM023810 - Bulldozer D39EX,PX-21 Shop Manual (SN1001&up)...412
  COVER...412
  CONTENTS...413
  01 GENERAL...446
    SPECIFICATION DRAWING...447
    SPECIFICATIONS...448
    WEIGHT TABLE...452
    TABLE OF FUEL, COOLANT AND LUBRICANTS...454
  10 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD...455
    COOLING SYSTEM...456
    ENGINE CONTROL...457
    POWER TRAIN...458
    POWER TRAIN SYSTEM...459
    HST HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAM...460
    STEERING, BRAKE CONTROL...462
    DAMPER...468
    SOLENOID VALVE...469
    FINAL DRIVE...471
    HST PUMP...474
    SAFETY-SUCTION VALVE...479
    CUT-OFF VALVE...482
    CHARGE SAFETY VALVE...483
    CHARGE PUMP...485
    HST BRAKE QUICK RETURN CIRCUIT...486
    TOWING VALVE...487
    PARKING BRAKE VALVE...488
    AS VALVE...490
    HST MOTOR...492
    STEERING, DIRECTIONAL PPC VALVE...503
    INCHING VALVE...512
    AUTOMATIC GEARSHIFTING VALVE...514
    FRAME ASSEMBLY...519
    TRACK FRAME, RECOIL SPRING...520
    IDLER...522
    TRACK ROLLER...524
    CARRIER ROLLER...525
    SPROCKET...526
    TRACK SHOE...528
    ARRANGEMENT OF HYDRAULIC EQUIPMENT FOR WORK EQUIPMENT...532
    WORK EQUIPMENT CONTROL...533
    HYDRAULIC TANK, FILTER...535
    HYDRAULIC PUMP...536
    WORK EQUIPMENT CYLINDER...537
    SUCTION VALVE...539
    CONTROL VALVE...541
    CLSS...549
    WORK EQUIPMENT PPC VALVE...559
    WORK EQUIPMENT ...566
    CUTTING EDGE, END BIT...569
    CAB RELATED...570
    SAFETY MECHANISM WHEN STARTING ENGINE...571
    GEARSHIFT CONTROL SYSTEM...572
    PARKING BRAKE CONTROL SYSTEM...573
    COMPONENT EQUIPMENT OF SYSTEM...574
    MONITOR SYSTEM...576
    SENSORS...580
  20 TESTING AND ADJUSTING...583
    STANDARD VALUE TABLE FOR ENGINE...584
    STANDARD VALUE TABLE FOR CHASSIS...585
    STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM...590
    TESTING AND ADJUSTING...592
      TOOLS LIST FOR TESTING AND ADJUSTING...593
      MEASURING ENGINE SPEED...596
      MEASURING EXHAUST COLOR...597
      MEASURING BLOW-BY PRESSURE...598
      MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)...599
      ADJUSTING VALVE CLEARANCE...600
      TESTING ADJUSTING FUEL INJECTION TIMING...602
      MEASURING COMPRESSION PRESSURE...603
      ADJUSTING ENGINE STOP SOLENOIDE LINKAGE...604
      MEASURING ENGINE OIL PRESSURE...605
      BLEEDING AIR FROM FUEL CIRCUIT...606
      REPLACEMENT OF FAN BELT...607
      TESTING AND ADJUSTING TENSION OF AIR CONDITIONER COMPRESSOR BELT...609
      MEASURING AND ADJUSTING HST OIL PRESSURE...610
      MEASURING SOLENOID VALVE OUTPUT PRESSURE...615
      MEASURING AND ADJUSTING WORK EQUIPMENT MAIN RELIEF PRESSURE...616
      MEASURING PPC VALVE OUTPUT PRESSURE...618
      MEASURING LEAKAGE INSIED CYLINDER...619
      BLEEDING AIR FROM HYDRAULIC CYLINDERS...619
      TESTING AND ADJUSTING TRACK SHOE TENSION...620
      TESTING AND ADJUSTING TRAVEL DEVIATION...621
      ADJUSTING FUEL CONTROL LINKAGE...624
      ADJUSTING DECELERATOR PEDAL LINKAGE...626
      ADJUSTING BRAKE PEDAL LINKAGE...627
      ADJUSTING STEERING/DIRECTIONAL/GEAR SHIFT LEVER AND LOCK LEVER...629
      ADJUSTING BLADE CONTROL LEVER AND LOCK LEVER...632
      ADJUSTING WORK EQUIPMENT PPC VALVE...633
      PROCEDURE FOR RELEASING PARKING BRAKE...634
      PROCEDURE FOR INSPECTING DIODE...636
    TROUBLESHOOTING...637
      POINTS TO REMEMBER WHEN TROUBLESHOOTING...638
      SEQUENCE OF EVENTS IN TROUBLESHOOTING...639
      HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT...640
      CHECKS BEFORE TROUBLESHOOTING...650
      METHOD OF USING TROUBLESHOOTING CHARTS...651
      TYPES AND LOCATIONS OF CONNECTORS...652
      CONNECTOR ARRANGEMENT DIAGRAM...654
      CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...656
      T-BRANCH BOX AND T-BRANCH ADAPTER TABLE...692
      TROUBLESHOOTING FOR ELECTRICAL SYSTEM (E-MODE)...695
        TABLE OF FAILURE MODES AND CAUSES (ELECTRICAL SYSTEM)...696
        ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM...698
        E-1. WHEN STARTING SWITCH IS TURNED ON, STARTING MOTOR DOES NOT ROTATE...700
        E-2. ENGINE DOES NOT START (ENGINE STOP SOLENOID DOES NOT OPERATE NORMALLY)...702
        E-3. HEADLAMP DOES NOT LIGHT UP...703
        E-4. WHEN STARTING SWITCH IS TURNED TO HEAT POSITION, ENGINE IS NOT HEATED...705
        E-5. WINDSHIELD WIPER DOES NOT OPERATE...706
        E-6. WASHING WATER DOES NOT SPOUT...708
        E-7. AIR CONDITIONER DOES NOT WORK...710
          (a) AIR DOES NOT BLOW OUT...710
          (b) AIR IS NOT COOLED...713
        E-8. PARKING BRAKE CANNOT BE RELEASED (PARKING BRAKE SOLENOID DOES NOT OPERATE)...717
        E-9. TRAVEL SPEED CONTROL IS ABNORMAL...718
          (a) WHEN GEAR SHIFT SWITCH IS PRESSED, GEAR SPEED DOES NOT CHANGE OR GEAR SPEED CHANGES BY ITSELF (GEAR SHIFT SWITCH OR CONTROLLER IS ABNORMAL)...718
          (b) GEAR SPEED CANNOT BE SELECTED NORMALLY (TRAVEL SPEED CHANGEOVER SOLENOID IS ABNORMAL)...719
        E-10. BACKUP ALARM DOES NOT SOUND DURING REVERSE TRAVEL...721
        E-11. HORN DOES NOT SOUND...723
      TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)...724
        TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC AND MECHANICAL SYSTEMS)...725
        H-1. MACHINE DOES NOT TRAVEL IN EITHER DIRECTION OR IT STOPS SUDDENLY...727
        H-2. MACHINE DOES NOT TRAVEL IN ONE DIRECTION...728
        H-3. MACHINE TRAVELS WHILE TRAVEL LEVER IS IN NEUTRAL...728
        H-5. MACHINE DEVIATES WHILE TRAVEL LEVER IS IN PARTIAL POSITION...728
        H-7. MACHINE SWINGS MOMENTARILY WHEN IT STARTS ON FLAT GROUND...728
        H-11. TURNING TIME LAG IS LARGE...728
        H-12. WHEN OPERATOR INTENDS TO TURN GRADUALLY, MACHINE TURNS SHARPLY...728
        H-13. MACHINE DOES NOT RETURN QUICKLY TO STRAIGHT TRAVEL POSITION...728
        H-14. MACHINE IS NOT DECELERATED SMOOTHLY OR TRAVEL SPEED CANNOT BE CONTROLLED ON DOWNHILL GROUND...728
        H-15. MACHINE DEVIATES WHEN IT IS DECELERATED...728
        H-4. MACHINE DEVIATES WHEN TRAVEL LEVER IS MOVED TO STROKE END...729
        H-6. MACHINE MOVES BACK WHEN OPERATOR STARTS ON UPHILL GROUND...729
        H-8. MACHINE STARTS SHARPLY...729
        H-9. MACHINE SWINGS MOMENTARILY WHEN IT STARTS...730
        H-10. STARTING TIME LAG IS LARGE...731
        H-16. MAXIMUM TRAVEL SPEED IS LOW OR OUTPUT POWER IS INSUFFICIENT OR ACCELERATION IS LOW...732
        H-17. ENGINE STALLS...733
        H-18. HST NOISE IS LARGE...734
        H-19. HST OIL TEMPERATURE RISES TOO HIGH...735
        H-20. GEAR SPEED DOES NOT CHANGE...735
        H-21. ABNORMAL SOUND IS HEARD FROM AROUND WORK EQUIPMENT PUMP OR HST PUMP...736
        H-22. ANY WORK EQUIPMENT DOES NOT MOVE...736
        H-23. SPEED OR POWER OF EACH WORK EQUIPMENT IS LOW...737
        H-24. SPEED OR POWER OF BLADE LIFT OF BLADE TILT CYLINDER IS LOW...737
        H-25. SPEED OR POWER OF BLADE ANGLE CYLINDER IS LOW...738
        H-26. HYDRAULIC DRIFT OF BLADE LIFT CYLINDER IS LARGE...739
        H-27. HYDRAULIC DRIFT OF BLADE TILT CYLINDER IS LARGE...739
        H-28. HYDRAULIC DRIFT OF BLADE ANGLE CYLINDER IS LARGE...740
      TROUBLESHOOTING FOR MACHINE MONITOR SYSTEM (M-MODE)...741
        TABLE OF FAILURE MODES AND CAUSES (MACHINE MONITOR SYSTEM)...742
        ELECTRIC CIRCUIT DIAGRAM FOR EACH SYSTEM...743
        M-1. WHEN STARTING SWITCH IS TURNED ON , MONITOR PANEL IS NOT TURNED ON...745
        M-2. TROUBLE IN PREHEATING CAUTION LAMP...746
          (a) PREHEATING MONITOR DOES NOT LIGHT UP...746
          (b) PREHEATING MONITOR KEEPS LIGHTING UP...746
        M-3. CAUTION ITEM LIGHTS UP...747
          (a) CHARGE CAUTION LAMP LIGHTS UP WHILE ENGINE IS RUNNING...747
          (b) OIL PRESSURE CAUTION LAMP LIGHTS UP WHILE ENGINE IS RUNNING...748
          (c) HST FILTER CLOGGING CAUTION LAMP LIGHTS UP (WHILE FILTER IS NOT CLOGGED)...748
        M-4. TROUBLE IN HST OIL TEMPERATURE GAUGE...749
          (a) GAUGE DOES NOT RISE ABOVE C (LOWEST POINT)...749
          (b) GAUGE DOES NOT LOWER BELOW H (HIGHEST POINT)...749
          (c) HST OIL TEMPERATURE INDICATED BY GAUGE IS DIFFERENT FROM ACTUAL TEMPERATURE...750
        M-5. TROUBLE IN ENGINE WATER TEMPERATURE GAUGE...751
          (a) GAUGE DOES NOT RISE ABOVE C (LOWEST POINT)...751
          (b) GAUGE DOES NOT LOWER BELOW H (HIGHEST POINT)...751
          (c) ENGINE WATER TEMPERATURE INDICATED BY GAUGE IS DIFFERENT FROM ACTUAL TEMPERATURE...752
        M-6. TROUBLE IN FUEL LEVEL GAUGE...753
          (a) GAUGE DOES NOT RISE ABOVE E (LOWEST POINT)...753
          (b) GAUGE DOES NOT LOWER BELOW F (HIGHEST POINT)...753
          (c) FUEL LEVEL INDICATED BY GAUGE IS DIFFERENT FROM ACTUAL LEVEL...754
        M-7. SERVICE METER DOES NOT OPERATE AFTER ENGINE IS STARTED...755
        M-8. MONITOR PANEL LAMP DOES NOT LIGHT UP (WHILE HEADLAMP IS NORMAL)...756
        M-9. TROUBLE IN DISPLAY OF TRAVEL SPEED (WHILE ACTUAL TRAVEL SPEED IS NORMAL)...757
          (a) TRAVEL SPEED IS NOT DISPLAYED...757
          (b) DISPLAYED SPEED IS DIFFERENT FROM ACTUAL TRAVEL SPEED...757
      TROUBLESHOOTING FOR ENGINE SYSTEM (S-MODE)...759
        METHOD OF USING TROUBLESHOOTING CHARTS...760
        S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)...764
        S-2 ENGINE DOES NOT START ...765
        S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) ...768
        S-4 ENGINE STOPS DURING OPERATIONS...769
        S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...770
        S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)...771
        S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)...772
        S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)...773
        S-9 OIL BECOMES CONTAMINATED QUICKLY...774
        S-10 FUEL CONSUMPTION IS EXCESSIVE...775
        S-11 OIL IS IN COOLANT, OR COOLANT SPURTS BACK, OR COOLANT LEVEL GOES DOWN ...776
        S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)...777
        S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)...778
        S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...779
        S-15 ABNORMAL NOISE IS MADE...780
        S-16 VIBRATION IS EXCESSIVE...781
  30 DISASSEMBLY AND ASSEMBLY...783
    HOW TO READ THIS MANUAL...784
    COATING MATERIALS LIST...786
    SPECIAL TOOL LIST...789
    SKETCHES OF SPECIAL TOOLS...791
    REMOVAL OF FUEL INJECTION PUMP ASSEMBLY...792
    INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY...794
    REMOVAL OF CYLINDER HEAD ASSEMBLY...796
    INSTALLATION OF CYLINDER HEAD ASSEMBLY...801
    REMOVAL OF ENGINE FRONT SEAL...803
    INSTALLATION OF ENGINE FRONT SEAL...804
    REMOVAL OF ENGINE REAR SEAL...805
    INSTALLATION OF ENGINE REAR SEAL...806
    REMOVAL OF RADIATOR GUARD ASSEMBLY...807
    INSTALLATION OF RADIATOR GUARD ASSEMBLY...809
    DISASSEMBLY OF RADIATOR, OIL COOLER, AND CHARGE AIR COOLER ASSEMBLIES...810
    ASSEMBLY OF RADIATOR, OIL COOLER, AND CHARGE AIR COOLER ASSEMBLIES...812
    REMOVAL OF ENGINE ASSEMBLY...814
    INSTALLATION OF ENGINE ASSEMBLY...816
    REMOVAL OF DAMPER...817
    INSTALLATION OF DAMPER...817
    REMOVAL OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY...818
    INSTALLATION OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY...819
    DISASSEMBLY OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY...820
    ASSEMBLY OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY...824
    REMOVAL OF IDLER AND RECOIL SPRING ASSEMBLY...829
    INSTALLATION OF IDLER AND RECOIL SPRING ASSEMBLY...829
    DISASSEMBLY OF RECOIL SPRING ASSEMBLY...830
    ASSEMBLY OF RECOIL SPRING ASSEMBLY...831
    DISASSEMBLY OF IDLER ASSEMBLY...833
    ASSEMBLY OF IDLER ASSEMBLY...834
    DISASSEMBLY OF TRACK ROLLER ASSEMBLY...836
    ASSEMBLY OF TRACK ROLLER ASSEMBLY...837
    DISASSEMBLY OF CARRIER ROLLER ASSEMBLY...840
    ASSEMBLY OF CARRIER ROLLER ASSEMBLY...841
    SPREADING TRACK SHOE ASSEMBLY...842
    INSTALLATION OF TRACK SHOE ASSEMBLY...843
    REMOVAL OF HST PUMP ASSEMBLY...844
    INSTALLATION OF HST PUMP ASSEMBLY...845
    REMOVAL OF MAIN CONTROL VALVE ASSEMBLY...846
    INSTALLATION OF MAIN CONTROL VALVE ASSEMBLY...847
    DISASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY...848
    ASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY...852
    DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLIES...856
    ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLIES...857
    REMOVAL OF BALDE ASSEMBLY...859
    INSTALLATION OF BLADE ASSEMBLY...860
    REMOVAL OF OPERATOR'S CAB FRAME ASSEMBLY...861
    INSTALLATION OF OPERATO'S CAB FRAME ASSEMBLY...865
    REMOVAL OF FUEL TANK ASSEMBLY...866
    INSTALLATION OF FUEL TANK ASSEMBLY...866
    REMOVAL OF HYDRAULIC TANK ASSEMBLY...867
    INSTALLATION OF HYDRAULIC TANK ASSEMBLY...868
  90 OTHERS...869
    HYDRAULIC CIRCUIT DIAGRAM (1/2)(D39EX-21 SERIAL NO.1001-1200 D39PX-21 SERIAL NO.1001-1208)...870
    HYDRAULIC CIRCUIT DIAGRAM (1/2) (D39EX-21 SERIAL NO.1201 AND UP D39PX-21 SERIAL NO.1209 AND UP)...871
    HYDRAULIC CIRCUIT DIAGRAM (2/2)...872
    ELECTRICAL CIRCUIT DIAGRAM (1/2)...873
    ELECTRICAL CIRCUIT DIAGRAM (2/2)...874
    ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER...875
SEN04041-05 - Bulldozer D39EX,PX-22 Shop Manual (SN3001&up)...876
  COVER...876
  00 Index and foreword...0
    100 Index...877
      Composition of shop manual...878
      Table of contents...880
    200 Foreword and general information...889
      Safety notice...890
      How to read the shop manual...895
      Explanation of terms for maintenance standard...897
      Handling of electric equipment and hydraulic component...899
      Handling of connectors newly used for engines...908
      How to read electric wire code...911
      Precautions when carrying out operation...914
      Method of disassembling and connecting push-pull type coupler...917
      Standard tightening torque table...920
      Conversion table...924
  01 General...0
    100 Specification and technical data...931
      Specification dimensional drawing...932
      Specifications...933
      Weight table...937
      Table of fuel, coolant and lubricants...939
  10 Structure, function and maintenance standard...0
    100 Engine and cooling system...941
      Engine system parts...942
      Cooling system...943
      Cooling fan pump...944
      Cooling fan motor...945
      Oil cooler bypass valve...950
    200 Power train...955
      Power train...956
      Power train system...957
      Damper...958
      HST hydraulic equipment arrangement diagram...959
      Steering and brake control...960
      Solenoid valve...962
      Final drive...969
      HST pump...972
      HST motor...984
      Charge pump...994
    300 Undercarriage and frame...997
      Main frame...998
      Track frame and idler cushion...1000
      Idler...1002
      Track roller...1004
      Carrier roller...1006
      Sprocket...1008
      Track shoe...1010
    410 Hydraulic system, Part 1...1017
      Arrangement of hydraulic equipment for work equipment...1018
      Work equipment control...1020
      Hydraulic tank and filter...1022
      Work equipment and fan pump...1024
      Control valve...1032
      CLSS...1044
      Functions and operation of each valve...1047
    420 Hydraulic system, Part 2...1057
      Blade PPC valve...1058
      Accumulator...1064
    500 Work equipment...1067
      Work equipment...1068
      Cutting edge and end bit...1072
      Ripper...1073
      Work equipment cylinder...1074
      Piston valve...1077
    600 Cab and its attachments...1079
      ROPS cab...1080
      Cab mount...1081
      Canopy mount...1082
      Air conditioner...1083
    700 Electrical system...1087
      Monitor system...1088
      Engine control...1090
      Engine control system...1091
      Cooling control system...1092
      HST control system...1094
      Parking brake control system...1100
      KOMTRAX system...1102
      Component equipment of system...1104
      PCCS lever (for steering)...1112
      Sensor...1115
  20 Standard value table...0
    100 Standard service value table...1127
      Standard service value table for engine...1128
      Standard service value table for chassis...1129
  30 Testing and adjusting...0
    110 Testing and adjusting, Part 1...1137
      Tools for testing, adjusting, and troubleshooting...1139
      Sketches of special tools...1142
      Measuring engine speed...1143
      Measuring intake air pressure (boost pressure)...1144
      Measuring exhaust gas color (boost pressure)...1146
      Adjusting valve clearance...1147
      Measuring compression pressure...1149
      Measuring blow-by pressure...1152
      Testing engine oil pressure...1154
      Handling fuel system equipment...1155
      Releasing residual pressure in fuel system...1155
      Bleeding air from fuel circuit...1156
      Measuring fuel pressure...1157
      Measuring fuel discharge, return and leakage...1159
      Testing leakage in fuel system...1163
      Measurement of fan circuit pressure and fan speed...1164
      Adjustment of fan speed sensor...1165
      Handling reduced cylinder mode operation...1166
      Handling no-injection cranking operation...1166
      Handling controller voltage circuit...1167
      Check of muffler and muffler stack for looseness and damage...1168
      Check of muffler function...1168
      Check of installed condition of cylinder head and manifolds...1169
      Check of engine piping for damage and looseness...1169
      Replacing alternator belt...1170
    120 Testing and adjusting, Part 2...1173
      Adjusting decelerator pedal...1174
      Testing and adjusting HST oil pressure...1176
      Measuring solenoid valve outlet pressure...1181
      Testing travel deviation...1184
      Adjusting parking brake lever...1185
      Simple brake performance test procedure...1187
      Adjusting brake pedal...1188
      Method of releasing parking brake (Procedure for emergency escape)...1190
      Testing and adjusting idler clearance...1192
      Testing and adjusting track shoe tension...1193
      Testing work equipment pressure...1194
      Testing work equipment PPC valve...1196
      Adjusting play of work equipment PPC valve...1198
      Adjusting work equipment lock lever...1199
      Testing internal leakage of work equipment cylinder...1200
      Releasing residual pressure in hydraulic circuit...1202
      Bleeding air from hydraulic circuit...1203
      Adjusting play of blade center ball...1204
      Procedure for testing diodes...1205
      Preparation work for troubleshooting for electrical system...1206
      How to start operation of KOMTRAX terminal...1210
      Lamp display of KOMTRAX terminal...1213
    130 Testing and adjusting, Part 3...1217
      Special functions of monitor panel (EMMS)...1218
      Items to be adjusted when electric/hydraulic devices are adjusted/replaced...1280
      Adjustment procedure after replacement of HST controller...1281
      Adjustment procedure after replacement of monitor panel...1283
      Pm-clinic...1284
  40 Troubleshooting...0
    100 Failure code table and fuse locations...1295
      Failure code table...1296
      Before carrying out troubleshooting for electrical system (E-mode)...1302
    200 General information on troubleshooting...1305
      Points to remember when troubleshooting...1306
      Sequence of events in troubleshooting...1307
      Testing before troubleshooting...1308
      Classification and procedures of troubleshooting...1309
      Information contained in troubleshooting table...1312
      Connection table for connector pin numbers...1314
      T- branch box and T- branch adapter table...1350
    310 Troubleshooting by failure code (Display of code), Part 1...1355
      Failure code [6091NX] HST charge filter element: Clogging...1357
      Failure code [AA10NX] Air cleaner: Clogging...1358
      Failure code [AB00MA] Alternator: Malfunction...1360
      Failure code [B@BAZG] Engine oil: Lowering of oil pressure...1361
      Failure code [B@BCNS] Coolant: Overheat...1362
      Failure code [B@CRNS] HST oil: Overheating...1363
      Failure code [B@CRZG] HST oil: Lowering of oil pressure...1364
      Failure code [CA111] Engine controller: Abnormality in controller...1365
      Failure code [CA115] Abnormal engine Ne and Bkup speed sensors: Abnormal speed sensor signal...1365
      Failure code [CA122] Charge pressure sensor tool high: Excessively high voltage detected...1366
      Failure code [CA123] Charge pressure sensor too low: Excessively low voltage detected...1368
      Failure code [CA131] Decelerator pedal sensor tool high: Excessively high voltage detected...1370
      Failure code [CA132] Decelerator pedal sensor too low: Excessively low voltage detected...1372
      Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected...1374
      Failure code [CA145] Coolant temperature sensor too low: Excessively low voltage detected...1376
      Failure code [CA153] Charge air temperature sensor too high: Excessively high voltage detected...1378
      Failure code [CA154] Charge temperature sensor too low: Excessively low voltage detected...1380
      Failure code [CA187] Sensor power source 2 too low: Excessively low voltage detected...1382
      Failure code [CA221] Atmospheric pressure sensor too high: Excessively high voltage detected...1384
      Failure code [CA222] Atmospheric pressure sensor too low: Excessively low voltage detected...1386
      Failure code [CA227] Sensor power source 2 too high: Excessively high voltage detected...1388
      Failure code [CA234] Engine over speed: Excessively high speed...1390
      Failure code [CA238] Abnormal power source for Ne speed sensor: Excessively low voltage detected...1391
      Failure code [CA271] IMV/PCV1 short circuit: Short circuit...1392
      Failure code [CA272] IMV/PCV1 disconnection: Disconnection...1394
    320 Troubleshooting by failure code (Display of code), Part 2...1397
      Failure code [CA322] Injector No. 1 system disconnection or short circuit: disconnection, short circuit...1400
      Failure code [CA324] Injector No. 3 system disconnection or short circuit: disconnection, short circuit...1402
      Failure code [CA331] Injector No. 2 system disconnection or short circuit: disconnection, short circuit...1404
      Failure code [CA332] Injector No. 4 system disconnection or short circuit: disconnection, short circuit...1406
      Failure code [CA342] Engine controller data matching error: matching error...1408
      Failure code [CA351] Injector drive circuit abnormality: Abnormal circuit...1410
      Failure code [CA352] Sensor power source 1 too low: Excessively low voltage detected...1412
      Failure code [CA386] Sensor power source 1 too high: Excessively high voltage detected...1414
      Failure code [CA428] Water in fuel sensor too high: Excessively high voltage detected...1416
      Failure code [CA429] Water in fuel sensor too low: Excessively low voltage detected...1418
      Failure code [CA435] Abnormal engine oil pressure switch: Abnormal signal circuit...1420
      Failure code [CA441] Power source voltage too low: Excessively low voltage detected...1422
      Failure code [CA442] Power source voltage too high: Excessively high voltage has occurred in the controller power source circuit...1424
      Failure code [CA449] Common rail pressure too high (2): Excessively high pressure trouble occurred...1426
      Failure code [CA451] Common rail pressure sensor too high: Excessively high voltage detected...1428
      Failure code [CA452] Common rail pressure sensor too low: Excessively low voltage detected...1430
      Failure code [CA488] Charge temperature too high and torque derated: Exceeded upper control limit of temperature...1432
      Failure code [CA553] Common rail pressure too high (1): Excessively high pressure detected...1433
      Failure code [CA559] Loss of pressure feed from supply pump (1): Loss of pressure feed detected...1434
      Failure code [CA689] Abnormal engine Ne speed sensor: Abnormal signal...1436
      Failure code [CA731] Abnormal engine Bkup speed sensor phase: Abnormal phase...1438
      Failure code [CA757] Loss of all engine controller data: Loss of all data...1440
      Failure code [CA778] Abnormal engine Bkup speed sensor: Abnormal Bkup signal...1442
      Failure code [CA1633] Abnormal KOMNET: Abnormal communication...1444
      Failure code [CA2185] Decelerator pedal sensor power source too high: Excessively high voltage detected...1446
      Failure code [CA2186] Decelerator pedal sensor power source too low: Excessively low voltage detected...1448
      Failure code [CA2249] Loss of pressure feed from supply pump (2): Loss of pressure feed detected...1450
      Failure code [CA2311] Abnormal IMV solenoid: Abnormal resistance...1452
      Failure code [CA2555] Air intake heater relay disconnection: Disconnection...1454
      Failure code [CA2556] Air intake heater relay short circuit: Short circuit...1456
    330 Troubleshooting by failure code (Display of code), Part 3...1459
      Failure code [D130KA] Neutral safety relay: Disconnection...1462
      Failure code [D130KB] Neutral safety relay: Short circuit...1464
      Failure code [DAFRKR] CAN communication (Monitor panel - HST controller): Defective communication (Abnormality in objective component system)...1466
      Failure code [DAFRMC] CAN communication (Monitor panel - ENGINE controller): Defective communication (Abnormality in objective component system)...1469
      Failure code [DAJ000] HST controller: Memory error...1472
      Failure code [DAJ0KK] HST controller: Lowing of source voltage...1474
      Failure code [DAJ0KQ] HST controller: Machine code error...1476
      Failure code [DAJ0KT] HST controller: Memory error...1477
      Failure code [DAJ5KK] HST controller sensor 5 V power supply No.1: Lowing of source voltage/Input...1478
      Failure code [DAJ6KK] HST controller sensor 5 V power supply No.2: Lowing of source voltage/Input...1480
      Failure code [DAJRKR] CAN communication (HST controller - Monitor panel): Defective communication (Abnormality in objective component system)...1482
      Failure code [DB2RKR] CAN communication (HST controller - Engine controller): Defective communication (Abnormality in objective component system)...1485
      Failure code [DD12KA] Shift up switch: Disconnection...1488
      Failure code [DD12KB] Shift up switch: Short circuit...1490
      Failure code [DD13KA] Shift down switch: Disconnection...1492
      Failure code [DD13KB] Shift down switch: Short circuit...1494
      Failure code [DD14KB] Travel lock limit switch 1: Short circuit...1496
      Failure code [DD1NL4] Fan rotation selector switch: Disagreement of ON, OFF Signals...1498
      Failure code [DDDCKB] Reverse travel speed switch: Short circuit...1500
      Failure code [DDP6KA] Brake oil pressure sensor: Disconnection...1502
      Failure code [DDP6KB] Brake oil pressure sensor: Short circuit...1504
      Failure code [DDP6MA] Brake oil pressure sensor: Malfunction...1506
      Failure code [DDQ2KA] Travel lock limit switch 1: Disconnection...1508
      Failure code [DDT0L4] Shift mode switch: Disagreement of ON/ OFF Signals...1510
      Failure code [DDU1FS] Travel lock limit switches 1 and 2: Fixing...1512
      Failure code [DDU1KA] Travel lock limit switch 2: Disconnection...1514
      Failure code [DDU1KY] Travel lock limit switch 2: Short circuit with power supply line...1516
      Failure code [DGS1KA] HST oil temperature sensor: Disconnection...1518
      Failure code [DGS1KX] HST oil temperature sensor: Out of Input signal range...1520
    340 Troubleshooting by failure code (Display of code), Part 4...1523
      Failure code [DHH5KA] Left HST pump pressure sensor: Disconnection...1526
      Failure code [DHH5KB] Left HST pump pressure sensor: Short circuit...1528
      Failure code [DHH6KA] Right HST pump pressure sensor: Disconnection...1530
      Failure code [DHH6KB] Right HST pump pressure sensor: Short circuit...1532
      Failure code [DK10KA] Fuel dial sensor: Disconnection...1534
      Failure code [DK10KB] Fuel dial sensor: Short circuit...1536
      Failure code [DK30KA] Steering angle sensor 1: Disconnection...1538
      Failure code [DK30KB] Steering angle sensor 1: Short circuit...1540
      Failure code [DK30KX] Steering angle sensor: Out of input signal range...1542
      Failure code [DK30KZ] Steering angle sensor: Disconnection or short circuit...1543
      Failure code [DK30L8] Steering angle sensor: Disagreement of analog signals...1544
      Failure code [DK31KA] Steering angle sensor 2: Disconnection...1546
      Failure code [DK31KB] Steering angle sensor 2: Short circuit...1548
      Failure code [DK40KA] Brake pedal sensor: Disconnection...1550
      Failure code [DK40KB] Brake pedal sensor: Short circuit...1552
      Failure code [DK55KX] Directional potentiometer: Out of input signal range...1554
      Failure code [DK55KZ] Directional potentiometer: Disconnection or short circuit...1555
      Failure code [DK55L8] Directional potentiometer: Disagreement of analog signals...1556
      Failure code [DK56KA] Directional potentiometer 1: Disconnection...1558
      Failure code [DK56KB] Directional potentiometer 1: Short circuit...1560
      Failure code [DK57KA] Directional potentiometer 2: Disconnection...1562
      Failure code [DK57KB] Directional potentiometer 2: Short circuit...1564
      Failure code [DLM0KX] HST motor speed sensors: Out of input signal range...1566
      Failure code [DLM1KA] Left HST motor speed sensor: Disconnection...1568
      Failure code [DLM1KB] Left HST motor speed sensor: Short circuit...1570
      Failure code [DLM1MA] Left HST motor speed sensor: Malfunction...1572
      Failure code [DLM2KA] Right HST motor speed sensor: Disconnection...1574
      Failure code [DLM2KB] Right HST motor speed sensor: Short circuit...1576
      Failure code [DLM2MA] Right HST motor speed sensor: Malfunction...1578
      Failure code [DLM3KA] Fan speed sensor: Disconnection...1580
      Failure code [DLM3KB] Fan speed sensor: Short circuit...1582
    350 Troubleshooting by failure code (Display of code), Part 5...1585
      Failure code [DN21FS] Brake pedal and proximity switch: Fixing...1588
      Failure code [DV00KB] Caution buzzer: Short circuit...1590
      Failure code [DV20KB] Back alarm buzzer: Short circuit...1591
      Failure code [DW4BKA] Parking brake solenoid valve: Disconnection...1592
      Failure code [DW4BKB] Parking brake solenoid valve: Short circuit...1594
      Failure code [DW4BKY] Parking brake solenoid valve: Short circuit with power supply line...1596
      Failure code [DW7BKA] Fan reverse solenoid valve: Disconnection...1598
      Failure code [DW7BKB] Fan reverse solenoid valve: Short circuit...1600
      Failure code [DW7BKY] Fan reverse solenoid valve: Short circuit with power supply line...1601
      Failure code [DW7EKA] Slow brake solenoid valve: Disconnection...1602
      Failure code [DW7EKB] Slow brake solenoid valve: Short circuit...1606
      Failure code [DW7EKY] Slow brake solenoid valve: Short circuit with power supply line...1608
      Failure code [DWN5KA] Fan EPC solenoid valve: Disconnection...1610
      Failure code [DWN5KB] Fan EPC solenoid valve: Short circuit...1612
      Failure code [DWN5KY] Fan EPC solenoid valve: Short circuit with power supply line...1614
      Failure code [DXA4KA] LF HST pump EPC solenoid valve: Disconnection...1616
      Failure code [DXA4KB] LF HST pump EPC solenoid valve: Short circuit...1618
      Failure code [DXA4KY] LF HST pump EPC solenoid valve: Short circuit with power supply line...1620
      Failure code [DXA5KA] LR HST pump EPC solenoid valve: Disconnection...1622
      Failure code [DXA5KB] LR HST pump EPC solenoid valve: Short circuit...1624
      Failure code [DXA5KY] LR HST pump EPC solenoid valve: Short circuit with power supply line...1626
      Failure code [DXA6KA] RF HST pump EPC solenoid valve: Disconnection...1628
      Failure code [DXA6KB] RF HST pump EPC solenoid valve: Short circuit...1630
      Failure code [DXA6KY] RF HST pump EPC solenoid valve: Short circuit with power supply line...1631
      Failure code [DXA7KA] RR HST pump EPC solenoid valve: Disconnection...1632
      Failure code [DXA7KB] RR HST pump EPC solenoid valve: Short circuit...1634
      Failure code [DXA7KY] RR HST pump EPC solenoid valve: Short circuit with power supply line...1636
      Failure code [DXK1KA] Left HST motor EPC solenoid valve: Disconnection...1638
      Failure code [DXK1KB] Left HST motor EPC solenoid valve: Short circuit...1639
      Failure code [DXK1KY] Left HST motor EPC solenoid valve: Short circuit with power supply line...1640
      Failure code [DXK2KA] Right HST motor EPC solenoid valve: Disconnection...1641
      Failure code [DXK2KB] Right HST motor EPC solenoid valve: Short circuit...1642
      Failure code [DXK2KY] Right HST motor EPC solenoid valve: Short circuit with power supply line...1643
    400 Troubleshooting of electrical system (E-mode)...1645
      E-1 Engine does not start (Starting motor does not rotate)...1648
      E-2 Engine is not preheated...1651
      E-3 When starting switch is turned ON, any item does not light up...1654
      E-4 Charge level caution flashes while engine is running...1656
      E-5 Emergency warning items flash while engine is running...1658
      E-6 Preheating pilot lamp does not light up during preheating operation...1664
      E-7 The coolant temperature gauge does not indicate correctly...1666
      E-8 The HST oil temperature gauge does not indicate correctly...1667
      E-9 Fuel level gauge does not indicate properly...1668
      E-10 Gear speed, set travel speed, and shift mode indicator does not display normally...1670
      E-11 Multi-information unit does not display normally...1670
      E-12 Caution lamp does not flash or does not go off...1671
      E-13 Caution buzzer does not sound or does not stop...1672
      E-14 Reverse travel speed setting switch does not function...1674
      E-15 Shift mode switch does not function...1676
      E-16 Buzzer cancel switch does not function...1678
      E-17 Information switch does not function...1680
      E-18 The fan cleaning does not operate or cannot be reset...1682
      E-19 Backup alarm does not sound...1684
      E-20 The horn does not sound or does not stop...1685
      E-21 Work equipment does not move...1686
      E-22 Headlamp or rear lamp does not light up...1688
      E-23 Foot heater does not operate...1691
      E-24 Air conditioner does not operate...1694
      E-25 Windshield wiper and window washer do not operate...1699
      E-26 KOMTRAX system does not operate normally...1712
    500 Troubleshooting of hydraulic and mechanical system (H-mode)...1715
      Information in troubleshooting table...1717
      H-1 Right and left travel systems do not operate forward and in reverse (No travel systems operate)...1718
      H-2 Right or left travel system does not operate forward and in reverse (Only right or left travel system does not operate)...1720
      H-3 Right or left travel system does not operate forward or in reverse (Only 1 system does not operate)...1721
      H-4 Speed or power of travel is low...1722
      H-5 Gear is not shifted...1723
      H-6 Large shocks are made when machine starts and stops travel...1724
      H-7 Machine deviates largely during travel...1725
      H-8 Hydraulic drift of travel is large...1726
      H-9 Engine stalls or engine speed lowers extremely during travel...1727
      H-10 Abnormal sound comes out from around HST pump and motor...1728
      H-11 Work equipment dose not operate at all...1729
      H-12 Speed or power of whole work equipment is low...1730
      H-13 Speed or power of lifting blade is low...1731
      H-14 Speed or power of tilting blade is low...1732
      H-15 Speed or power of angling blade is low...1733
      H-16 Time lag in lifting blade is large...1734
      H-17 Hydraulic drift of lifting blade is large...1734
      H-18 Hydraulic drift of tilting blade is large...1734
      H-19 Abnormal sound comes out from around work equipment pump and control valve...1735
      H-20 HST oil temperature (Hydraulic oil temperature) rises too high...1736
      H-21 Fan speed is abnormal (High, low, or 0 rpm)...1738
      H-22 Abnormal sound is heard from around fan...1739
    600 Troubleshooting of engine (S-mode)...1741
      Method of using troubleshooting charts...1743
      S-1 Starting performance is poor...1746
      S-2 Engine does not start...1747
      S-3 Engine does not pick up smoothly...1750
      S-4 Engine stops during operations...1751
      S-5 Engine does not rotate smoothly...1752
      S-6 Engine lacks output (or lacks power)...1753
      S-7 Exhaust smoke is black (imcomplete combustion)...1754
      S-8 Oil consumption is excessive (or exhaust smoke is blue)...1755
      S-9 Oil becomes contaminated quickly...1756
      S-10 Fuel consumption is excessive...1757
      S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down)...1758
      S-12 Oil pressure drops...1759
      S-13 Oil level rises (water, fuel in oil)...1760
      S-14 Coolant temperature becomes too high (overheating)...1761
      S-15 Abnormal noise is made...1762
      S-16 Vibration is excessive...1763
  50 Disassembly and assembly...0
    100 General information on disassembly and assembly...1765
      How to read this manual...1766
      Coating materials list...1768
      Special tools list...1771
      Sketches of special tools...1774
    200 Engine and cooling system...1779
      Removal and installation of fuel supply pump assembly...1780
      Removal and installation of fuel injector assembly...1784
      Removal and installation of cylinder head assembly...1792
      Removal and installation of engine and HST pump assembly...1805
      Removal and installation of engine front seal assembly...1808
      Removal and installation of engine rear seal assembly...1810
      Removal and installation of front guard assembly...1814
      Removal and installation of radiator assembly...1816
      Removal and installation of hydraulic oil cooler assembly...1818
      Removal and installation of aftercooler assembly...1820
      Removal and installation of cooling fan and motor assembly...1822
      Removal and installation of cooling fan drive motor assembly1...1824
      Removal and installation of fuel tank assembly...1826
    300 Power train...1829
      Removal and installation of HST pump assembly...1830
      Removal and installation of HST motor and final drive assembly...1832
      Disassembly and assembly of final drive assembly...1834
    400 Undercarriage and frame...1845
      Spreading and installation of track shoe assembly...1846
      Removal and installation of idler and recoil spring assembly...1848
      Disassembly and assembly of idler assembly...1849
      Disassembly and assembly of recoil spring assembly...1852
      Disassembly and assembly of track roller assembly...1856
      Disassembly and assembly of carrier roller assembly...1860
    500 Hydraulic system...1865
      Removal and installation of hydraulic tank assembly...1866
      Removal and installation of control valve assembly...1868
      Disassembly and assembly of control valve assembly...1869
      Disassembly and assembly of hydraulic cylinder assembly...1871
    600 Work equipment...1877
      Removal and installation of work equipment assembly...1878
    700 Cab and its attachments...1883
      Removal and installation of ROPS canopy and operator seat frame assembly...1884
      Removal and installation of ROPS cab and operator seat frame assembly...1887
      Removal and installation of operator’s cab glass (Stuck glass)...1892
    800 Electrical system...1899
      Removal and installation of HST controller assembly...1900
      Removal and installation of KOMTRAX terminal assembly...1901
  90 Diagrams and drawings...0
    100 Hydraulic diagrams and drawings...1903
      Work equipment hydraulic circuit diagram...1905
    200 Electrical diagrams and drawings...1908
      Electrical circuit diagram...1910
      Cab electrical circuit diagram...1915
      Air conditioner circuit diagram...1918
      Connector list and stereogram...1919

Komatsu Bulldozers D39EX,PX Repair Service Manuals