Komatsu D37EX -23 Install guide
BULLDOZER
SEN06061-03
D37EX -23
D37PX-23
D39EX -23
D39PX-23
SERIAL NUMBERS
D37EX-80001
D37PX-80001
D39EX-90001
D39PX-90001
and up
00 Index and foreword
Index
Index
(ALL-0310-001-A-00-A)
00 Index and foreword .......................................................................................................................00-1
Index .........................................................................................................................................00-2
Foreword, safety and general information ................................................................................... 00-14
Important safety notice .......................................................................................................00-14
How to read the shop manual..............................................................................................00-21
Explanation of terms for maintenance standard .................................................................... 00-23
Handling equipment of fuel system devices .......................................................................... 00-25
Handling of intake system parts........................................................................................... 00-26
Handling of hydraulic equipment.......................................................................................... 00-27
Method of disconnecting and connecting of push-pull type coupler ......................................... 00-29
Handling of electrical equipment.......................................................................................... 00-32
How to read electric wire code............................................................................................. 00-40
Precautions when performing operation ............................................................................... 00-43
Practical use of KOMTRAX................................................................................................. 00-48
Standard tightening torque table.......................................................................................... 00-49
List of abbreviation ............................................................................................................. 00-55
Conversion table................................................................................................................ 00-60
01 Specification.................................................................................................................................01-1
Table of contents ........................................................................................................................01-2
Specifications.............................................................................................................................01-3
Specification drawing ...........................................................................................................01-3
Specifications ......................................................................................................................01-7
Weight table ...................................................................................................................... 01-27
Table of fuel, coolant, and lubricants .................................................................................... 01-35
10 Structure and function ...................................................................................................................10-1
Table of contents ........................................................................................................................10-2
Engine and cooling system..........................................................................................................10-3
Engine related parts .............................................................................................................10-3
VFT ....................................................................................................................................10-5
EGR system piping drawing..................................................................................................10-9
EGR system circuit diagram................................................................................................ 10-11
EGR valve......................................................................................................................... 10-12
EGR cooler........................................................................................................................ 10-14
KCCV layout drawing ......................................................................................................... 10-16
KCCV ventilator ................................................................................................................. 10-18
KDOC muffler .................................................................................................................... 10-22
Cooling system .................................................................................................................. 10-24
Cooling fan motor............................................................................................................... 10-26
Oil cooler bypass and HST charge safety valve..................................................................... 10-34
Power train............................................................................................................................... 10-41
Power train system............................................................................................................. 10-41
Damper............................................................................................................................. 10-44
Hydraulic component layout of HST..................................................................................... 10-45
Steering and brake control .................................................................................................. 10-46
HST pump......................................................................................................................... 10-48
HST motor......................................................................................................................... 10-62
Charge pump..................................................................................................................... 10-78
Solenoid valve ................................................................................................................... 10-79
Final drive ......................................................................................................................... 10-89
Undercarriage and frame........................................................................................................... 10-93
Main frame ........................................................................................................................ 10-93
Track frame and idler cushion ............................................................................................. 10-94
Hydraulic system ...................................................................................................................... 10-96
Hydraulic component layout................................................................................................ 10-96
Work equipment control system........................................................................................... 10-98
Hydraulic tank.................................................................................................................. 10-100
CLSS.............................................................................................................................. 10-102
00-2 D37, 39-23
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00 Index and foreword
Index
Work equipment and cooling fan pump .............................................................................. 10-105
Control valve ................................................................................................................... 10-116
Ripper PPC valve............................................................................................................. 10-133
Angle control EPC valve ................................................................................................... 10-138
Accumulator .................................................................................................................... 10-143
Work equipment ..................................................................................................................... 10-145
Blade .............................................................................................................................. 10-145
Ripper............................................................................................................................. 10-146
Piston valve..................................................................................................................... 10-147
Cab and its attachments.......................................................................................................... 10-148
ROPS cab ....................................................................................................................... 10-148
Cab mount ...................................................................................................................... 10-150
Electrical system .................................................................................................................... 10-151
Electrical control system ................................................................................................... 10-151
Machine monitor system................................................................................................... 10-173
KOMTRAX system........................................................................................................... 10-195
System component parts .................................................................................................. 10-198
Sensor ............................................................................................................................ 10-215
20 Standard value tables....................................................................................................................20-1
Table of contents ........................................................................................................................20-2
Standard service value table........................................................................................................20-3
Standard value table for engine.............................................................................................20-3
Standard value table for machine ..........................................................................................20-4
Standard value table for electrical system............................................................................. 20-17
30 Testing and adjusting ....................................................................................................................30-1
Table of contents ........................................................................................................................30-2
Related information on testing and adjusting ................................................................................. 30-4
Tools for testing and adjusting ...............................................................................................30-4
Sketch of tools for testing and adjusting ................................................................................. 30-7
Engine and cooling system..........................................................................................................30-8
Testing engine speed ...........................................................................................................30-8
Testing exhaust gas color ...................................................................................................30-10
Testing and adjusting valve clearance.................................................................................. 30-12
Testing compression pressure............................................................................................. 30-14
Testing blowby pressure ..................................................................................................... 30-17
Testing engine oil pressure ................................................................................................. 30-18
Testing fuel pressure .......................................................................................................... 30-19
Testing fuel return rate and leakage .....................................................................................30-20
Bleeding air from fuel system .............................................................................................. 30-23
Testing fuel circuit for leakage .............................................................................................30-24
Handling cylinder cutout mode operation.............................................................................. 30-25
Handling no-injection cranking operation .............................................................................. 30-26
Testing of installed condition of cylinder heads and manifolds ................................................ 30-27
Testing engine piping for damage and looseness .................................................................. 30-28
Replacing belt for alternator and air conditioner compressor .................................................. 30-29
Writing compensation values at replacement of injector and engine controller ......................... 30-30
Power train............................................................................................................................... 30-34
Testing and adjusting HST oil pressure................................................................................. 30-34
Testing outlet pressure of solenoid valve .............................................................................. 30-39
Testing if machine travels straight ........................................................................................ 30-43
Simple test procedure for brake performance ....................................................................... 30-44
Adjusting deceleration/brake pedal ...................................................................................... 30-45
Adjusting parking brake lever .............................................................................................. 30-48
Move disabled machine urgently ......................................................................................... 30-50
Undercarriage and frame........................................................................................................... 30-53
Adjusting idler clearance..................................................................................................... 30-53
Checking sprocket wear ..................................................................................................... 30-54
Testing and adjusting track tension ...................................................................................... 30-55
Hydraulic system ...................................................................................................................... 30-56
D37, 39-23 00-3
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00 Index and foreword
Index
Releasing remaining pressure in work equipment cylinder ..................................................... 30-56
Testing and adjusting work equipment oil pressure................................................................ 30-57
Testing source pressure of control circuit.............................................................................. 30-59
Testing outlet pressure of work equipment EPC valve and fan EPC valve ............................... 30-60
Isolating the parts causing hydraulic drift in blade and ripper .................................................. 30-62
Testing internal oil leakage of work equipment cylinder .......................................................... 30-63
Testing fan speed............................................................................................................... 30-65
Testing fan circuit oil pressure .............................................................................................30-66
Bleeding air from hydraulic circuit ........................................................................................ 30-67
Work equipment ....................................................................................................................... 30-68
Adjusting work equipment lock lever .................................................................................... 30-68
Adjusting play of blade center ball........................................................................................30-70
Electrical system ...................................................................................................................... 30-71
Special functions of machine monitor................................................................................... 30-71
Adjustment method when HST controller has been replaced ................................................ 30-143
Adjustment method when electric or hydraulic device has been replaced .............................. 30-146
Adjusting rearview camera angle....................................................................................... 30-147
Testing windshield wiper operation .................................................................................... 30-148
Replacing windshield wiper blade...................................................................................... 30-149
Handling voltage circuit of engine controller........................................................................ 30-150
Handling battery disconnect switch .................................................................................... 30-151
Testing diodes ................................................................................................................. 30-152
Pm clinic ................................................................................................................................ 30-153
Pm Clinic service ............................................................................................................. 30-153
Pm Clinic service (D39EX-23,D39PX-23) ........................................................................... 30-155
Pm Clinic check sheet ...................................................................................................... 30-157
Pm Clinic check sheet (D39EX-23,D39PX-23).................................................................... 30-166
40 Troubleshooting............................................................................................................................40-1
Table of contents ........................................................................................................................40-2
Related information on troubleshooting......................................................................................... 40-9
Troubleshooting points .........................................................................................................40-9
Sequence of events in troubleshooting................................................................................. 40-11
Checks before troubleshooting............................................................................................ 40-13
Inspection procedure before troubleshooting ........................................................................ 40-15
Preparation for troubleshooting of electrical system............................................................... 40-33
Classification and procedures for troubleshooting ................................................................. 40-36
Symptom and troubleshooting numbers ............................................................................... 40-38
Information in troubleshooting table ..................................................................................... 40-40
Troubleshooting method for open circuit in wiring harness of pressure sensor system.............. 40-42
Connector list and layout .................................................................................................... 40-44
Connector contact identification........................................................................................... 40-55
T-branch box and T-branch adapter table ............................................................................. 40-93
Fuse location table ............................................................................................................. 40-98
Failure codes table........................................................................................................... 40-103
Troubleshooting by failure code (Display of code) ...................................................................... 40-112
Failure code [6091NX] HST Oil Filter Clogging ................................................................... 40-112
Failure code [989L00] Engine Controller Lock Caution 1...................................................... 40-114
Failure code [989M00] Engine Controller Lock Caution 2..................................................... 40-115
Failure code [989N00] Engine Controller Lock Caution 3 ..................................................... 40-116
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40-117
Failure code [AB00KE] Charge Voltage Low....................................................................... 40-119
Failure code [B@BAZG] Eng Oil Press Low ....................................................................... 40-121
Failure code [B@BCNS] Eng Water Overheat .................................................................... 40-122
Failure code [B@CRNS] HST Oil Overheat ........................................................................ 40-123
Failure code [B@CRZG] HST Charge Press Low ............................................................... 40-124
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................. 40-125
Failure code [CA122] Chg Air Press Sensor High Error ....................................................... 40-126
Failure code [CA123] Chg Air Press Sensor Low Error ........................................................ 40-128
Failure code [CA131] Throttle Sensor High Error................................................................. 40-130
00-4 D37, 39-23
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00 Index and foreword
Index
Failure code [CA132] Throttle Sensor Low Error ................................................................. 40-132
Failure code [CA144] Coolant Temp Sens High Error .......................................................... 40-134
Failure code [CA145] Coolant Temp Sens Low Error ........................................................... 40-136
Failure code [CA153] Chg Air Temp Sensor High Error........................................................ 40-138
Failure code [CA154] Chg Air Temp Sensor Low Error......................................................... 40-140
Failure code [CA187] Sensor 2 Supply Volt Low Error ......................................................... 40-142
Failure code [CA221] Ambient Press Sensor High Error ...................................................... 40-144
Failure code [CA222] Ambient Press Sensor Low Error ....................................................... 40-146
Failure code [CA227] Sensor 2 Supply Volt High Error......................................................... 40-148
Failure code [CA234] Eng Overspeed ................................................................................ 40-149
Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................... 40-150
Failure code [CA239] Ne Speed Sens Supply Volt High Error............................................... 40-151
Failure code [CA271] IMV/PCV1 Short Error ...................................................................... 40-152
Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40-153
Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................. 40-154
Failure code [CA324] Inj #3(L#3) Open/Short Error ............................................................. 40-156
Failure code [CA331] Inj #2(L#2) Open/Short Error ............................................................. 40-158
Failure code [CA332] Inj #4(L#4) Open/Short Error ............................................................. 40-160
Failure code [CA343] ECM Critical Internal Failure.............................................................. 40-162
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40-163
Failure code [CA352] Sensor 1 Supply Volt Low Error ......................................................... 40-164
Failure code [CA356] Mass Air Flow Sensor High Error ....................................................... 40-166
Failure code [CA357] Mass Air Flow Sensor Low Error........................................................ 40-168
Failure code [CA386] Sensor 1 Supply Volt High Error......................................................... 40-170
Failure code [CA435] Eng Oil Press Sw Error ..................................................................... 40-171
Failure code [CA441] Battery Voltage Low Error ................................................................. 40-172
Failure code [CA442] Battery Voltage High Error................................................................. 40-174
Failure code [CA449] Rail Press Very High Error................................................................. 40-175
Failure code [CA451] Rail Press Sensor High Error............................................................. 40-176
Failure code [CA452] Rail Press Sensor Low Error ............................................................. 40-178
Failure code [CA466] KVGT Motor Driver Position Error ...................................................... 40-180
Failure code [CA515] Rail Press Sens Sup Volt High Error .................................................. 40-182
Failure code [CA516] Rail Press Sens Sup Volt Low Error ................................................... 40-184
Failure code [CA553] Rail Press High Error ........................................................................ 40-186
Failure code [CA555] Crankcase Press High Error 1 ........................................................... 40-187
Failure code [CA556] Crankcase Press High Error 2 ........................................................... 40-188
Failure code [CA559] Rail Press Low Error......................................................................... 40-189
Failure code [CA689] Eng Ne Speed Sensor Error .............................................................. 40-192
Failure code [CA691] Intake Air Temp Sens High Error........................................................ 40-194
Failure code [CA692] Intake Air Temp Sens Low Error......................................................... 40-196
Failure code [CA697] ECM Internal Temp Sensor High Error................................................ 40-198
Failure code [CA698] ECM Int Temp Sensor Low Error........................................................ 40-199
Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................... 40-200
Failure code [CA778] Eng Bkup Speed Sensor Error........................................................... 40-203
Failure code [CA1117] Persistent Data Lost Error................................................................ 40-207
Failure code [CA1695] Sensor 5 Supply Volt High Error....................................................... 40-208
Failure code [CA1696] Sensor 5 Supply Volt Low Error ....................................................... 40-209
Failure code [CA1843] Crankcase Press Sens High Error.................................................... 40-210
Failure code [CA1844] Crankcase Press Sens Low Error .................................................... 40-212
Failure code [CA1896] EGR Valve Stuck Error.................................................................... 40-214
Failure code [CA1942] Crankcase Press Sens In Range Error ............................................. 40-215
Failure code [CA1961] EGR_Motor Driver IC Over Temp Error............................................. 40-216
Failure code [CA2185] Throt Sensor Sup Volt High Error ..................................................... 40-217
Failure code [CA2186] Throt Sensor Sup Volt Low Error...................................................... 40-218
Failure code [CA2249] Rail Press Very Low Error ............................................................... 40-219
Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................... 40-220
Failure code [CA2311] IMV Solenoid Error ......................................................................... 40-222
Failure code [CA2349] EGR Valve Solenoid Open Error ...................................................... 40-223
Failure code [CA2353] EGR Valve Solenoid Short Error ...................................................... 40-225
D37, 39-23 00-5
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00 Index and foreword
Index
Failure code [CA2357] EGR Valve Servo Error ................................................................... 40-227
Failure code [CA2555] Grid Htr Relay Volt Low Error ........................................................... 40-228
Failure code [CA2556] Grid Htr Relay Volt High Error .......................................................... 40-230
Failure code [CA2765] Inj Trim Data Error .......................................................................... 40-232
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ........................................ 40-233
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ......................................... 40-235
Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error........................................ 40-237
Failure code [CA3918] KVGT Stuck Error........................................................................... 40-239
Failure code [CA3919] KVGT Motor Driver IC Over Temp Error ............................................ 40-240
Failure code [CA3921] KVGT Servo Error 2........................................................................ 40-241
Failure code [CA3922] KVGT Motor Driver Open Error ........................................................ 40-242
Failure code [CA3923] KVGT Motor Driver Short Error ........................................................ 40-244
Failure code [D130KA] Neutral relay Open ......................................................................... 40-246
Failure code [D130KB] Neutral relay Short circuit................................................................ 40-248
Failure code [D130KY] Neutral relay: Hot Short .................................................................. 40-250
Failure code [D19JKZ] Personal Code Relay Abnormality.................................................... 40-252
Failure code [D811MC] KOMTRAX Error............................................................................ 40-255
Failure code [D862KA] GPS Antenna Open Circuit ............................................................. 40-256
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ...................................... 40-257
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ...................................... 40-259
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ............................................................ 40-260
Failure code [DAF0MB] Monitor ROM Abnormality.............................................................. 40-262
Failure code [DAF0MC] Monitor Error ................................................................................ 40-263
Failure code [DAF8KB] Camera Power Supply Short Circuit ................................................ 40-264
Failure code [DAF9KQ] Model Selection Abnormality .......................................................... 40-265
Failure code [DAFGMC] GPS Module Error........................................................................ 40-266
Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) ........................................... 40-267
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor)............................................ 40-269
Failure code [DAFQKR] CAN2 Discon (Monitor) ................................................................. 40-270
Failure code [DAJ000] HST controller: Abnormality in controller ........................................... 40-271
Failure code [DAJ0KQ] HST controller: Type select signal ................................................... 40-272
Failure code [DAJ0KT] HST controller: Abnormality in controller ........................................... 40-273
Failure code [DAJ0MC] HST Con Error .............................................................................. 40-274
Failure code [DAJ1KK] HST controller: Source voltage low .................................................. 40-275
Failure code [DAJ2KK] HST controller: Output voltage low................................................... 40-277
Failure code [DAJ5KK] HST: Sensor volt 5V (0) Out of normal range .................................... 40-279
Failure code [DAJ6KK] HST: Sensor volt 5V (1) Out of normal range .................................... 40-281
Failure code [DAJLKA] Operating Lamp Open Circuit (HST Con) ......................................... 40-283
Failure code [DAJLKB] Operating Lamp Short Circuit (HST Con) ......................................... 40-285
Failure code [DAJPMA] Inconsistency of Option Selection (HST) ......................................... 40-286
Failure code [DAJQKR] CAN2 Discon (HST Con) ............................................................... 40-287
Failure code [DAJRKR] CAN1 Discon (HST Con) ............................................................... 40-288
Failure code [DB2QKR] CAN2 Discon (Engine Con) ........................................................... 40-289
Failure code [DB2RKR] CAN1 Discon (Engine Con) ........................................................... 40-293
Failure code [DD12KA] Shift up SW: Open ......................................................................... 40-297
Failure code [DD12KB] Shift up SW: Short Circuit ............................................................... 40-299
Failure code [DD13KA] Shift down SW: Open..................................................................... 40-301
Failure code [DD13KB] Shift down SW: Short Circuit........................................................... 40-303
Failure code [DD14KA] Parking lever SW: Open ................................................................. 40-305
Failure code [DD14KB] Parking lever SW: Short circuit........................................................ 40-307
Failure code [DDKAKA] Blade float Sw: Open .................................................................... 40-309
Failure code [DDKAKB] Blade float Sw: Short circuit ........................................................... 40-311
Failure code [DDKFL4] Left Angle Sw: Signal mismatch ...................................................... 40-313
Failure code [DDKGL4] Right Angle Sw: Signal mismatch ................................................... 40-315
Failure code [DDKHKA] iB Sw: Open ................................................................................. 40-317
Failure code [DDKHKB] iB Sw: Short circuit........................................................................ 40-319
Failure code [DDNLKA] Weq lock Sw: Open....................................................................... 40-321
Failure code [DDNLKB] Weq lock Sw: Short circuit ............................................................. 40-323
Failure code [DDP6KA] Brake Pressure Sensor: Open........................................................ 40-325
00-6 D37, 39-23
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00 Index and foreword
Index
Failure code [DDP6KB] Brake Pressure Sensor: Hot Short .................................................. 40-327
Failure code [DDP6MA] Brake pressure sensor: Malfunction ............................................... 40-329
Failure code [DDU1FS] Parking lever Switch 2: Signal mismatch ......................................... 40-331
Failure code [DDU1KA] Parking lever Sw2:Open ................................................................ 40-333
Failure code [DDU1KY] Parking lever Sw2:Hot Short .......................................................... 40-335
Failure code [DFA4KX] Blade lift lever: Main and Sub Error ................................................. 40-337
Failure code [DFA4KZ] Blade lift lever: Main and Sub Error.................................................. 40-338
Failure code [DFA4L8] Blade lift lever: Signal mismatch ...................................................... 40-339
Failure code [DFA5KA] Blade lift lever1: Open .................................................................... 40-340
Failure code [DFA5KB] Blade lift lever1: Hot Short .............................................................. 40-343
Failure code [DFA6KA] Blade lift lever2: Open .................................................................... 40-345
Failure code [DFA6KB] Blade lift lever2: Hot Short .............................................................. 40-347
Failure code [DFA7KX] Blade tilt lever: Main and Sub Error ................................................. 40-349
Failure code [DFA7KZ] Blade tilt lever: Main and Sub Error.................................................. 40-350
Failure code [DFA7L8] Blade tilt lever: Signal mismatch ...................................................... 40-351
Failure code [DFA8KA] Blade tilt lever1: Open .................................................................... 40-352
Failure code [DFA8KB] Blade tilt lever1: Hot Short .............................................................. 40-355
Failure code [DFA9KA] Blade tilt lever2: Open .................................................................... 40-357
Failure code [DFA9KB] Blade tilt lever2: Hot Short .............................................................. 40-360
Failure code [DGS1KA] HST oil temp sensor: Open ............................................................ 40-362
Failure code [DGS1KX] HST oil temp sensor:Out of normal range ........................................ 40-364
Failure code [DH21KA] Weq pressure sensor: Open ........................................................... 40-365
Failure code [DH21KB] Weq pressure sensor: Hot Short ..................................................... 40-367
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit ............................................. 40-369
Failure code [DHH7KA] LF HST Pressure Sensor: Open ..................................................... 40-371
Failure code [DHH7KB] LF HST Pressure Sensor: Hot Short ............................................... 40-373
Failure code [DHH8KA] RF HST Pressure Sensor: Open .................................................... 40-375
Failure code [DHH8KB] RF HST Pressure Sensor: Hot Short............................................... 40-377
Failure code [DHH9KA] LR HST Pressure Sensor: Open..................................................... 40-379
Failure code [DHH9KB] LR HST Pressure Sensor: Hot Short............................................... 40-381
Failure code [DHHAKA] RR HST Pressure Sensor: Open.................................................... 40-383
Failure code [DHHAKB] RR HST Pressure Sensor: Hot Short.............................................. 40-385
Failure code [DK30KA] ST lever1: Open ............................................................................ 40-387
Failure code [DK30KB] ST lever1: Hot Short....................................................................... 40-389
Failure code [DK30KX] ST lever: Main and Sub Error.......................................................... 40-391
Failure code [DK30KZ] ST lever: Main and Sub Error .......................................................... 40-392
Failure code [DK30L8] ST lever: Signal mismatch............................................................... 40-393
Failure code [DK31KA] ST lever2: Open ............................................................................ 40-394
Failure code [DK31KB] ST lever2: Hot Short....................................................................... 40-396
Failure code [DK40KA] Decel/Brake potentiometer: Open ................................................... 40-398
Failure code [DK40KB] Decel/Brake potentiometer: Hot Short.............................................. 40-401
Failure code [DK55KX] FR lever: Main and Sub Error.......................................................... 40-403
Failure code [DK55KZ] FR lever: Main and Sub Error.......................................................... 40-404
Failure code [DK55L8] FR lever: Signal mismatch............................................................... 40-405
Failure code [DK56KA] FR lever1: Open ............................................................................ 40-406
Failure code [DK56KB] FR lever1: Hot Short ...................................................................... 40-408
Failure code [DK57KA] FR lever2: Open ............................................................................ 40-410
Failure code [DK57KB] FR lever2: Hot Short ...................................................................... 40-412
Failure code [DLM0KX] HST Motor Speed Sensor: Left/Right Error ...................................... 40-414
Failure code [DLM1KA] Left HST motor speed sensor: Open ............................................... 40-415
Failure code [DLM1KB] Left HST motor speed sensor: Short circuit...................................... 40-417
Failure code [DLM1MA] Left HST motor speed sensor: Malfunction...................................... 40-419
Failure code [DLM2KA] Right HST motor speed sensor: Open............................................. 40-420
Failure code [DLM2KB] Right HST motor speed sensor: Short circuit ................................... 40-422
Failure code [DLM2MA] Right HST motor speed sensor: Malfunction ................................... 40-424
Failure code [DLM3KA] Fan Speed Sensor Open Circuit ..................................................... 40-425
Failure code [DLM3KB] Fan Speed Sensor Short Circuit ..................................................... 40-427
Failure code [DLM3MB] Fan control: Mismatch ................................................................... 40-429
Failure code [DN21FS] Decel/Brake pedal SW: Signal mismatch ......................................... 40-430
D37, 39-23 00-7
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Index
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality ........................................ 40-432
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality ........................................ 40-433
Failure code [DV20KB] Back-up alarm : Short circuit ........................................................... 40-434
Failure code [DW4BKA] Parking brake solenoid: Open........................................................ 40-436
Failure code [DW4BKB] Parking brake solenoid: Short circuit .............................................. 40-438
Failure code [DW4BKY] Parking brake solenoid: Hot Short.................................................. 40-440
Failure code [DW7BKA] Fan reverse solenoid: Open .......................................................... 40-442
Failure code [DW7BKB] Fan reverse solenoid: Short circuit ................................................. 40-444
Failure code [DW7EKA] Slow brake solenoid: Open............................................................ 40-445
Failure code [DW7EKB] Slow brake solenoid: Short circuit .................................................. 40-447
Failure code [DW7EKY] Slow brake solenoid: Hot Short...................................................... 40-449
Failure code [DWN5KA] Fan EPC: Open............................................................................ 40-451
Failure code [DWN5KB] Fan EPC: Short circuit .................................................................. 40-453
Failure code [DWN5KY] Fan EPC: Hot Short...................................................................... 40-454
Failure code [DXA4KA] LF HST pump EPC: Open.............................................................. 40-456
Failure code [DXA4KB] LF HST pump EPC: Short circuit..................................................... 40-458
Failure code [DXA4KY] LF HST pump EPC: Hot Short ........................................................ 40-459
Failure code [DXA5KA] LR HST pump EPC:Open .............................................................. 40-461
Failure code [DXA5KB] LR HST pump EPC:Short circuit ..................................................... 40-463
Failure code [DXA5KY] LR HST pump EPC: Hot Short........................................................ 40-465
Failure code [DXA6KA] RF HST pump EPC: Open ............................................................. 40-467
Failure code [DXA6KB] RF HST pump EPC: Short circuit .................................................... 40-469
Failure code [DXA6KY] RF HST pump EPC: Hot Short........................................................ 40-470
Failure code [DXA7KA] RR HST pump EPC: Open ............................................................. 40-472
Failure code [DXA7KB] RR HST pump EPC: Short circuit.................................................... 40-474
Failure code [DXA7KY] RR HST pump EPC: Hot Short ....................................................... 40-475
Failure code [DXHRKA] Blade lift up EPC: Open ................................................................ 40-477
Failure code [DXHRKB] Blade lift up EPC: Short circuit ....................................................... 40-479
Failure code [DXHRKY] Blade lift up EPC: Hot short ........................................................... 40-480
Failure code [DXHSKA] Blade lift down EPC: Open ............................................................ 40-482
Failure code [DXHSKB] Blade lift down EPC: Short circuit ................................................... 40-484
Failure code [DXHSKY] Blade lift down EPC: Hot short ....................................................... 40-485
Failure code [DXHTKA] Blade tilt left EPC: Open ................................................................ 40-487
Failure code [DXHTKB] Blade tilt left EPC: Short circuit ....................................................... 40-489
Failure code [DXHTKY] Blade tilt left EPC: Hot short ........................................................... 40-490
Failure code [DXHUKA] Blade tilt right EPC: Open.............................................................. 40-492
Failure code [DXHUKB] Blade tilt right EPC: Short circuit..................................................... 40-494
Failure code [DXHUKY] Blade tilt right EPC: Hot short......................................................... 40-495
Failure code [DXJ4KA] Weq lock Sol.: Open ...................................................................... 40-497
Failure code [DXJ4KB] Weq lock Sol.: Short circuit ............................................................. 40-499
Failure code [DXJCKA] Blade angle left EPC: Open............................................................ 40-501
Failure code [DXJCKB] Blade angle left EPC: Short circuit .................................................. 40-502
Failure code [DXJCKY] Blade angle left EPC: Hot short ...................................................... 40-503
Failure code [DXJDKA] Blade angle right EPC: Open.......................................................... 40-505
Failure code [DXJDKB] Blade angle right EPC: Short circuit ................................................ 40-506
Failure code [DXJDKY] Blade angle right EPC: Hot short .................................................... 40-507
Failure code [DXK1KA] Left HST motor EPC: Open ............................................................ 40-509
Failure code [DXK1KB] Left HST motor EPC: Short circuit................................................... 40-511
Failure code [DXK1KY] Left HST motor EPC: Hot Short ...................................................... 40-512
Failure code [DXK2KA] Right HST motor EPC: Open.......................................................... 40-514
Failure code [DXK2KB] Right HST motor EPC: Short circuit................................................. 40-516
Failure code [DXK2KY] Right HST motor EPC: Hot Short .................................................... 40-517
Troubleshooting of electrical system (E-mode) .......................................................................... 40-519
E-1 Engine does not start (Engine does not crank) .............................................................. 40-519
E-2 Manual preheating system does not work..................................................................... 40-525
E-3 Automatic preheating system does not work................................................................. 40-528
E-4 While preheating is working, preheating monitor does not light up .................................. 40-530
E-5 When starting switch is turned to ON position, machine monitor displays nothing............. 40-532
00-8 D37, 39-23
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00 Index and foreword
Index
E-6 When starting switch is turned to ON position (with engine stopped), basic check monitor
lights up ............................................................................................................. 40-535
E-7 Air cleaner clogging monitor lights up in yellow while engine is running ........................... 40-536
E-8 Charge level monitor lights up in red while engine is running .......................................... 40-537
E-9 Engine coolant temperature monitor lights up in red while engine is running .................... 40-538
E-10 Engine oil pressure monitor lights up in red while engine is running .............................. 40-539
E-11 HST charge pressure monitor lights up in red while engine is running............................ 40-540
E-12 Hydraulic oil temperature monitor lights up in red while engine is running ...................... 40-541
E-13 HST oil filter clogging monitor lights up in red while engine is running ............................ 40-542
E-14 Fuel level gauge does not indicate correct level .......................................................... 40-543
E-15 Engine coolant temperature gauge does not indicate correct temperature ..................... 40-546
E-16 Hydraulic oil temperature gauge does not indicate correct temperature ......................... 40-547
E-17 Operation mode does not change .............................................................................. 40-548
E-18 Service mode cannot be selected .............................................................................. 40-549
E-19 Operating customize switch does not display customize screen ................................... 40-550
E-20 Modifying setting on customize screen does not change setting of machine .................. 40-551
E-21 Service meter is not displayed, while starting switch is in OFF position.......................... 40-552
E-22 Work equipment does not operate ............................................................................. 40-553
E-23 Foot heater does not operate .................................................................................... 40-555
E-24 Horn does not sound ................................................................................................ 40-560
E-25 Horn does not stop sounding..................................................................................... 40-562
E-26 Backup alarm does not sound ................................................................................... 40-563
E-27 Backup alarm does not stop sounding........................................................................ 40-564
E-28 Headlamp does not light up....................................................................................... 40-565
E-29 Rear lamp does not light up....................................................................................... 40-568
E-30 No wiper operates continuously or intermittently.......................................................... 40-571
E-31 Front wiper does not operate..................................................................................... 40-573
E-32 Rear wiper does not operate ..................................................................................... 40-575
E-33 Left door wiper does not operate (failed in both continuous and intermittent
operations)......................................................................................................... 40-577
E-34 Right door wiper does not operate (failed in both continuous and intermittent
operations)......................................................................................................... 40-581
E-35 Front washer does not operate .................................................................................. 40-585
E-36 Rear washer does not operate................................................................................... 40-587
E-37 Left door washer does not operate ............................................................................. 40-589
E-38 Right door washer does not operate........................................................................... 40-591
E-39 KOMTRAX system does not operate normally ............................................................ 40-593
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................. 40-595
Information described in troubleshooting table (H-mode) ..................................................... 40-595
System chart of hydraulic and mechanical systems............................................................. 40-596
Failure mode and cause table ........................................................................................... 40-598
H-1 Neither RH nor LH of tracks does not travel forward nor reverse (None of the travel system
operates) ........................................................................................................... 40-602
H-2 Either RH or LH of track does not travel forward nor reverse (Only RH or LH of travel
system operates) ................................................................................................ 40-604
H-3 Either RH or LH of track travel only forward or reverse (Only forward or reverse of RH or
LH of travel system does not operate)................................................................... 40-605
H-4 Travel speed or power is low....................................................................................... 40-607
H-5 Travel speed range does not change ........................................................................... 40-608
H-6 Shock is large when machine starts or stops ................................................................ 40-609
H-7 Machine deviates largely ............................................................................................ 40-610
H-8 Machine drift on a slope is large .................................................................................. 40-612
H-9 Engine stalls during travel or engine speed drops significantly ....................................... 40-613
H-10 Unusual noise is heard from around HST pump or motor ............................................. 40-614
H-11 All work equipment do not operate ............................................................................. 40-615
H-12 All work equipment operates slowly or lacks power ..................................................... 40-617
H-13 Blade lift speed or power is low ................................................................................. 40-619
H-14 Blade tilt speed or power is low ................................................................................. 40-620
H-15 Blade angle speed or power is low............................................................................. 40-621
D37, 39-23 00-9
00 Index and foreword
Index
H-16 Time lag of blade lift is large ...................................................................................... 40-622
H-17 Hydraulic drift of lifted blade is large........................................................................... 40-623
H-18 Hydraulic drift of tilted blade is large........................................................................... 40-624
H-19 Unusual noise is heard from around work equipment pump or control valve .................. 40-625
H-20 HST oil temperature (hydraulic oil temperature) rises too high ...................................... 40-626
H-21 Fan speed is abnormal (too high or low, or fan doe not rotate) ...................................... 40-628
H-22 Unusual noise is heard from around fan ..................................................................... 40-630
Troubleshooting of engine (S-mode)......................................................................................... 40-631
Information described in troubleshooting table (S mode)...................................................... 40-631
S-1 Engine does not crank when starting switch is turned to START position......................... 40-632
S-2 Engine cranks but no exhaust smoke comes out........................................................... 40-633
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not
start).................................................................................................................. 40-634
S-4 Engine startability is poor............................................................................................ 40-635
S-5 Engine does not pick up smoothly ............................................................................... 40-637
S-6 Engine stops during operation ..................................................................................... 40-639
S-7 Engine runs rough or is unstable ................................................................................. 40-641
S-8 Engine lacks power .................................................................................................... 40-642
S-9 Exhaust smoke is black .............................................................................................. 40-644
S-10 Engine oil consumption is excessive .......................................................................... 40-646
S-11 Oil becomes contaminated quickly ............................................................................. 40-647
S-12 Fuel consumption is excessive .................................................................................. 40-648
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)...................................... 40-649
S-14 Oil pressure drops.................................................................................................... 40-650
S-15 Fuel mixes into engine oil.......................................................................................... 40-651
S-16 Water mixes into engine oil (milky) ............................................................................. 40-652
S-17 Coolant temperature rises too high (overheating) ........................................................ 40-653
S-18 Unusual noise is heard ............................................................................................. 40-654
S-19 Vibration is excessive ............................................................................................... 40-655
S-20 Air cannot be bled from fuel circuit ............................................................................. 40-656
50 Disassembly and assembly ...........................................................................................................50-1
Table of contents ........................................................................................................................50-2
Related information on disassembly and assembly ........................................................................ 50-4
How to read this manual .......................................................................................................50-4
Coating materials list ............................................................................................................50-6
Special tools list ................................................................................................................. 50-10
Sketches of special tools .................................................................................................... 50-18
Engine and cooling system........................................................................................................ 50-32
Removal and installation of supply pump assembly............................................................... 50-32
Removal and installation of fuel injector assembly................................................................. 50-35
Removal and installation of cylinder head assembly.............................................................. 50-40
Removal and installation of radiator assembly ...................................................................... 50-50
Removal and installation of aftercooler assembly .................................................................. 50-53
Removal and installation of hydraulic oil cooler assembly ...................................................... 50-56
Removal and installation of cooling fan drive assembly ......................................................... 50-58
Removal and installation of cooling fan motor assembly ........................................................ 50-60
Removal and installation of engine and HST pump assembly................................................. 50-62
Disassembly and assembly of damper assembly .................................................................. 50-66
Removal and installation of engine front oil seal .................................................................... 50-67
Removal and installation of engine rear oil seal..................................................................... 50-69
Removal and installation of engine hood assembly ............................................................... 50-71
Removal and installation of fuel tank assembly ..................................................................... 50-74
Removal and installation of KCCV assembly ........................................................................ 50-76
Removal and installation of VFT assembly............................................................................ 50-77
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly....................... 50-78
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly........................ 50-80
Removal and installation of starting motor assembly ............................................................. 50-81
Removal and installation of belt for alternator and air conditioner compressor.......................... 50-82
Removal and installation of air cleaner assembly .................................................................. 50-84
00-10 D37, 39-23
00 Index and foreword
Index
Power train............................................................................................................................... 50-86
Removal and installation of HST motor and final drive assembly ............................................ 50-86
Disassembly and assembly of final drive .............................................................................. 50-88
Undercarriage and frame........................................................................................................... 50-96
Removal and installation of idler and recoil spring assembly .................................................. 50-96
Disassembly and assembly of idler ...................................................................................... 50-97
Disassembly and assembly of recoil spring ........................................................................ 50-100
Disassembly and assembly of track roller assembly ............................................................ 50-104
Disassembly and assembly of carrier roller assembly.......................................................... 50-108
Separation and connection of track shoe assembly (Standard type track shoe) ..................... 50-110
Separation and connection of track shoe assembly (PLUS type track shoe) .......................... 50-112
Overall disassembly and assembly of track shoe assembly (Standard type track
shoe) ................................................................................................................. 50-113
Overall disassembly and assembly of track shoe assembly (PLUS type track shoe)............... 50-126
Disassembly and assembly of one track link assembly in field (Standard type track
shoe) ................................................................................................................. 50-139
Disassembly and assembly of one track link assembly in field (PLUS type track
shoe) ................................................................................................................. 50-146
Hydraulic system .................................................................................................................... 50-151
Removal and installation of hydraulic tank assembly ........................................................... 50-151
Removal and installation of control valve assembly ............................................................. 50-153
Removal and installation of HST pump assembly................................................................ 50-155
Disassembly and assembly of hydraulic cylinder assembly.................................................. 50-157
Work equipment ..................................................................................................................... 50-161
Removal and installation of work equipment assembly ........................................................ 50-161
Removal and installation of blade assembly ....................................................................... 50-163
Removal and installation of U-frame assembly.................................................................... 50-165
Cab and its attachments.......................................................................................................... 50-167
Removal and installation of ROPS cab assembly................................................................ 50-167
Removal and installation of wiper arm ................................................................................ 50-171
Removal and installation of operator's cab glass (adhesion glass) ........................................ 50-173
Removal and installation of operator's seat......................................................................... 50-179
Removal and installation of seat belt .................................................................................. 50-180
Removal and installation of foot heater assembly................................................................ 50-181
Disassembly and assembly of foot heater assembly............................................................ 50-183
Removal and installation of air conditioner unit assembly..................................................... 50-184
Removal and installation of air conditioner compressor assembly......................................... 50-189
Electrical system .................................................................................................................... 50-191
Removal and installation of machine monitor assembly ....................................................... 50-191
Removal and installation of engine controller assembly ....................................................... 50-192
Removal and installation of HST controller assembly........................................................... 50-193
Removal and installation of mass air flow and temperature sensor ....................................... 50-194
Removal and installation of KOMTRAX terminal ................................................................. 50-195
60 Maintenance standard...................................................................................................................60-1
Table of contents ........................................................................................................................60-2
Engine and cooling system..........................................................................................................60-3
Engine mount ......................................................................................................................60-3
Cooling fan motor.................................................................................................................60-4
Oil cooler bypass and HST charge safety valve....................................................................... 60-6
Power train.................................................................................................................................60-7
Damper...............................................................................................................................60-7
HST pump...........................................................................................................................60-8
HST motor......................................................................................................................... 60-10
Charge pump..................................................................................................................... 60-11
Solenoid valve ................................................................................................................... 60-12
Final drive ......................................................................................................................... 60-13
Sprocket............................................................................................................................ 60-14
Full-scale drawing of sprocket tooth profile ........................................................................... 60-20
Undercarriage and frame........................................................................................................... 60-25
D37, 39-23 00-11
00 Index and foreword
Index
Track frame and idler cushion ............................................................................................. 60-25
Idler .................................................................................................................................. 60-28
Track roller ........................................................................................................................ 60-36
Carrier roller ...................................................................................................................... 60-44
Track shoe ........................................................................................................................ 60-48
Hydraulic system ...................................................................................................................... 60-60
Hydraulic tank.................................................................................................................... 60-60
Work equipment and cooling fan pump ................................................................................ 60-61
Control valve ..................................................................................................................... 60-64
Ripper PPC valve............................................................................................................... 60-71
Work equipment ....................................................................................................................... 60-73
Blade ................................................................................................................................ 60-73
Cutting edge and end bit..................................................................................................... 60-76
Ripper............................................................................................................................... 60-77
Lift cylinder........................................................................................................................ 60-79
Tilt cylinder ........................................................................................................................ 60-80
Angle cylinder.................................................................................................................... 60-81
Ripper cylinder................................................................................................................... 60-82
Cab and its attachments............................................................................................................ 60-83
Cab mount ........................................................................................................................ 60-83
Electrical system ...................................................................................................................... 60-84
System component parts .................................................................................................... 60-84
80 Appendix......................................................................................................................................80-1
Table of contents ........................................................................................................................80-2
Air conditioner components .........................................................................................................80-3
Precautions for refrigerant.....................................................................................................80-3
Air conditioner component ....................................................................................................80-4
Configuration and function of refrigeration cycle......................................................................80-7
Outline of refrigeration cycle..................................................................................................80-8
Air conditioner unit ............................................................................................................. 80-10
Dual pressure switch .......................................................................................................... 80-14
Pressure switch ................................................................................................................. 80-15
Compressor....................................................................................................................... 80-16
Condenser ........................................................................................................................ 80-17
Receiver drier .................................................................................................................... 80-19
Procedure for testing and troubleshooting ............................................................................ 80-20
Electrical circuit diagram ..................................................................................................... 80-23
System diagram................................................................................................................. 80-24
Parts and connectors layout................................................................................................80-26
Testing relays .................................................................................................................... 80-31
Troubleshooting chart 1 ...................................................................................................... 80-33
Troubleshooting chart 2 ...................................................................................................... 80-34
Information described in troubleshooting table ...................................................................... 80-36
A-1 Troubleshooting for condenser fan................................................................................. 80-37
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ........................ 80-40
A-3 Troubleshooting for blower motor system (No air comes out or air flow is
abnormal) ............................................................................................................ 80-44
A-4 Troubleshooting for temperature control ......................................................................... 80-46
Troubleshooting with gauge pressure................................................................................... 80-49
Connection of service tool................................................................................................... 80-52
Precautions for disconnecting and connecting hoses and tubes in air conditioner
circuit................................................................................................................... 80-54
Handling of compressor oil.................................................................................................. 80-56
90 Diagrams and drawings.................................................................................................................90-1
Table of contents ........................................................................................................................90-2
Hydraulic circuit diagram .............................................................................................................90-3
Symbols in hydraulic circuit diagram ...................................................................................... 90-3
Hydraulic circuit diagram.......................................................................................................90-7
Electric circuit diagram ................................................................................................................90-9
00-12 D37, 39-23
00 Index and foreword
Index
Symbols in electric circuit diagram.........................................................................................90-9
Electrical circuit diagram ..................................................................................................... 90-13
Index.................................................................................................................................................................... 1
D37, 39-23 00-13
00 Index and foreword
Foreword, safety and general information
Foreword, safety and general information
(ALL-0370-001-A-00-A)
Important safety notice
(ALL-1120-012-A-01-A)
(Rev. 2012/10)
•Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The
shop manual describes the effective and safe servicing and repair methods recommended by Komatsu.
Some of these methods require the use of the special tools designed by Komatsu for the specific purpose.
•The symbol mark kis used for such matters that require special cautions during the work. The work
indicated by the caution mark should be performed according to the instructions with special attention to
the cautions. Should hazardous situation occur or be anticipated during such work, be sure to keep safe
first and take every necessary measure.
General precautions
kk Inappropriate handling causes an extreme
danger. Read and understand what is
described in the operation and maintenance
manual before operating the machine. Read
and understand what is described in this
manual before starting the work.
•Before performing any greasing or repairs, read
all the safety labels stuck to the machine. For
the locations of the safety labels and detailed
explanation of precautions, see the operation
and maintenance manual.
•Locate a place in the repair workshop to keep
the tools and removed parts. Always keep the
tools and parts in their correct places. Always
keep the work area clean and make sure that
there is no dirt, water or oil on the floor. Smoke
only in the areas provided for smoking. Never
smoke while working.
•When performing any work, always wear the
safety shoes and helmet. Do not wear loose
work cloths, or clothes with buttons missing.
1. Always wear the protective eyeglasses when
hitting parts with a hammer.
2. Always wear the protective eyeglasses when
grinding parts with a grinder, etc.
•When performing any work with two or more
workers, always agree on the working procedure
before starting. While working, always keep
conversations of the work between your fellow
workers and your self on any step of the work.
During the work, hang the warning tag of
"UNDER WORKING" in the operator's
compartment.
•Only qualified workers must perform the work
and operation which require license or
qualification.
•Keep the tools in good condition. And learn the
correct way to use the tools, and use the proper
ones among them. Before starting the work,
thoroughly check the tools, lift truck, service
vehicle, etc.
•If welding repairs is required, always have a
trained and experienced welder with good
knowledge of welding perform the work. When
performing welding work, always wear welding
gloves, apron, shielding goggles, cap, etc.
•Before starting work, warm up your body
thoroughly to start work under good condition.
•Avoid continuing work for long hours and take
rests with proper intervals to keep your body in
good condition. Take a rest in a specified safe
place.
Safety points
1Good arrangement
2Correct work clothes
3Observance of work standard
4Practice of making and checking signals
5Prohibition of operation and handling by
unlicensed workers
6Safety check before starting work
7Wearing protective goggles (for cleaning or
grinding work)
8Wearing shielding goggles and protectors (for
welding work)
9Good physical condition and preparation
10 Precautions against work which you are not
used to or you are used to too much
Preparation
•Before adding oil or making any repairs, place
the machine on a firm and level ground, and
apply the parking brake and chock the wheels or
tracks to prevent the machine from moving.
•Before starting work, lower the work equipment
(blade, ripper, bucket, etc.) to the ground. If it is
not possible to lower the equipment to the
ground, insert the lock pin or use blocks to
prevent the work equipment from falling. And be
sure to lock all the work equipment control levers
and hang a warning tag on them.
•When performing the disassembling or
assembling work, support the machine securely
with blocks, jacks, or stands before starting the
work.
•Remove all of mud and oil from the steps or
other places used to get on and off the machine
completely. Always use the handrails, ladders of
00-14 D37, 39-23
00 Index and foreword
Foreword, safety and general information
steps when getting on or off the machine. Never
jump on or off the machine. When the scaffold is
not provided, use steps or stepladder to secure
your footing.
Precautions during work
•For the machine equipped with the battery
disconnect switch, check that the system
operating lamp is turned off before starting the
work. Then, turn the battery disconnect switch to
OFF (Q) position and remove the switch key. For
the machine not equipped with the battery
disconnect switch, remove the cable from the
battery before starting the work. Be sure to
remove the negative end (-) of the battery cable
first.
•Release the remaining pressure in the circuits
completely before the work when the parts in the
circuits of oil, fuel, coolant and air are
disconnected or removed. When the cap of the
oil filter, drain plug or oil pressure pickup plug is
removed, loose them slowly to prevent the oil
from spurting out.
•When removing or installing the checking plug or
the piping in the fuel circuit, wait 30 seconds or
longer after the engine is shut down and start
the work after the remaining pressure is
released from the fuel circuit.
•Immediately after the engine is shut down, the
coolant and oil in the circuits are hot. Be careful
not to get scalded by the hot coolant and oil.
Start the work after checking that the coolant
and oil are cooled down sufficiently.
•Start the work after the engine is shut down. Be
sure to shut down the engine when working on
or around the rotating parts in particular. When
checking the machine without shutting down the
engine (measuring oil pressure, rotational speed,
oil or coolant temperature), take extreme care
not to get caught in the rotating parts or the
working equipment.
•The hoist or crane must be used to sling the
components weighing 25 kg or heavier. Check
the slings (wire rope, nylon sling, chain and
hook) for damage before the work. Use the
slings with ample capacity and install them to
the proper places. Operate the hoist or crane
slowly to prevent the component from hitting any
other part. Do not work with any part still raised
by the hoist or crane.
•When removing the part which is under internal
pressure or reaction force of the spring, always
leave 2 bolts in diagonal positions. Loosen those
2 bolts gradually and alternately and release the
pressure, then, remove the part.
•When removing the part, be careful not to break
or damage the electrical wiring. The damaged
wiring may cause electrical fires.
•When removing piping, prevent the fuel or oil
from spilling out. If any fuel or oil drips onto the
floor, wipe it off immediately. Fuel or oil on the
floor can cause you to slip and can even cause
fires.
•As a general rule, do not use gasoline to wash
parts. Do not use gasoline to clean the electrical
parts, in particular.
•Reinstall the parts removed to their original
places. Replace the damaged parts and the
parts which must not be used with new ones.
When installing the hoses and wiring harnesses,
be careful that they are not damaged by
contacting with other parts when the machine is
operated.
•When connecting the high pressure hoses and
tubes, make sure that they are not twisted. The
damaged high pressure hoses and tubes are
very dangerous when they are installed. So, be
extremely careful when connecting the high
pressure pipings. In addition, check that their
connections are correct.
•When assembling or installing the parts, be sure
to tighten the bolts to the specified torque. When
installing the protective parts such as guards, or
the parts which vibrate violently or rotate at high
speeds, be sure to check that they are installed
correctly.
•When aligning 2 holes, never insert your fingers
or hand into the holes. Align the holes with care
so that your fingers are not caught in the hole.
•When measuring hydraulic pressure, check that
the measuring tools are correctly installed.
•Pay attention to safety when removing and
installing the tracks of the track type machines.
When removing the track, it separates suddenly.
The workers should not stand at either end of
the track.
•If the engine is operated for a long time in a
closed place which is not ventilated well, you
may suffer from gas poisoning. Accordingly,
open the windows and doors to ventilate the
place well.
Precautions for slinging work and making
signals
•Only one appointed worker must make signals
and co-worker must communicate with each
other frequently. The appointed signaler must
make specified signals clearly at the place
where the signaler is well seen from the
operator's seat and where the signaler can see
the working condition easily. The signaler must
always stand in front of the load and guide the
operator safely.
1. Do not stand under the load.
2. Do not step on the load.
•Check the slings before starting sling work.
D37, 39-23 00-15
00 Index and foreword
Foreword, safety and general information
•Keep putting on the gloves during sling work.
(Put on the leather gloves, if available.)
•Measure the weight of the load by the eye and
check its center of gravity.
•Use the proper sling according to the weight of
the load and method of slinging. If too thick wire
ropes are used to sling a light load, the load may
slip and fall.
•Do not sling a load with 1 wire rope only. If do so,
the load may rotate or the sling gets loose and
the sling may slip off. Install 2 or more wire ropes
symmetrically.
kSlinging with one rope may cause turning
of the load during hoisting, untwisting of
the rope, or slipping of the rope from its
original slinging position on the load,
which can result in a dangerous accident.
•Hanging angle must be 60 degrees or smaller as
a rule.
•When hanging a heavy load (25kg or heavier),
the hanging angle of the rope must be narrower
than that of the hook.
aWhen slinging a load with 2 ropes or more,
the larger the hanging angle is, the larger the
tension of each rope. The figure bellow
shows the variation of allowable load in kN
{kg} when hoisting is made with 2 ropes,
each of which is allowed to sling up to 9.8 kN
{1000kg} a load vertically, at various hanging
angles. When the 2 ropes sling a load
vertically, up to19.6 kN {2000 kg} of total
weight can be suspended. This weight is
reduced to 9.8 kN {1000 kg} when the 2
ropes make a hanging angle of 120 degrees.
If the two ropes sling a 19.6 kN {2000 kg}
load at a hanging angle of 150 degrees, each
rope is subjected to a force as large as 39.2
kN {4000 kg}.
•When installing wire ropes to an angular load,
apply pads to protect the wire ropes. If the load
is slippery, apply proper material to prevent the
wire rope from slipping.
•Use the specified eye bolts and fix wire ropes,
chains, etc. to them with shackles, etc.
•Apply wire ropes to the middle part of the hook.
aSlinging near the tip of the hook may cause
the rope to slip off the hook during hoisting.
The strength of the hook is maximum at its
central part.
•Do not use twisted or kinked wire ropes.
•When slinging up a load, observe the following.
1. Wind up the rope slowly until the wire rope
tensions. When putting your hands on the
wire ropes, do not grasp them but press them
down from above. If you grasp them, your
fingers may be caught.
2. After the wire ropes are stretched, stop the
crane and check the condition of the slung
load, wire ropes, and pads.
3. If the load is unstable or the wire rope or
chains are twisted, lower the load and lift it
up again.
4. Do not lift up the load at an angle.
•When lowering a load, pay attention to the
following.
1. When lifting down a load, stop it temporarily
at 30 cm above the floor, and then lower it
slowly.
2. Check that the load is stable, and then
remove the sling.
3. Remove kinks and dirt from the wire ropes
and chains used for the sling work, and put
them in the specified place.
Precautions for using mobile crane
aRead the Operation and Maintenance Manual of
the crane carefully in advance and operate the
crane safely.
Precautions for using overhead traveling crane
kk The hoist or crane must be used to sling the
components weighing 25 kg or heavier. A
part weighing 25 kg or heavier in
"disassembly and assembly" section is
indicated with the symbol of 44.
00-16 D37, 39-23
00 Index and foreword
Foreword, safety and general information
•Before starting work, check the wire ropes,
brake, clutch, controller, rails, over winding
prevention device, ground fault circuit interrupter
for electric shock prevention, crane collision
prevention device, and energizing warning lamp,
and check the following safety items.
•Observe the signals for sling work.
•Operate the hoist at a safe place.
•Be sure to check the directions of the direction
indication plate (north, south, east and west) and
the operating button.
•Do not sling a load at an angle. Do not move the
crane while the slung load is swinging.
•Do not raise or lower a load while the crane is
moving longitudinally or laterally.
•Do not drag a sling.
•When lifting up a load, stop it just after it leaves
the ground and check safety, and then lift it up.
•Consider the travel route in advance and lift up a
load to a safe height.
•Place the control switch in a position where it will
not be an obstacle to work and passage.
•After operating the hoist, do not swing the
control switch.
•Remember the position of the main switch so
that you can turn off the power immediately in an
emergency.
•Shut down the main switch when the hoist stops
because of a blackout. When turning on a switch
which is turned OFF by the ground fault circuit
interrupter for electric shock prevention, check
that the devices related to that switch are not in
operating condition.
•If you find an obstacle around the hoist, stop the
operation.
•After finishing the work, stop the hoist at the
specified position and raise the hook to at least 2
meters above the floor. Do not leave the sling
attached to the hook.
Selecting wire ropes
•Select adequate ropes depending on the weight
of the parts to be hoisted, referring to the table
below
Wire rope (JIS G3525, 6 x 37 - Type A)
(Standard Z twist wire ropes without galvanizing)
Nominal
diameter of rope Allowable load
mm kN ton
10 8.8 0.9
12 12.7 1.3
14 17.3 1.7
16 22.6 2.3
18 28.6 2.9
20 35.3 3.6
25 55.3 5.6
30 79.6 8.1
40 141.6 14.4
Nominal
diameter of rope Allowable load
mm kN ton
50 221.6 22.6
60 318.3 32.4
aThe allowable load is calculated as one sixth of
the breaking load of the rope to be used (safety
coefficient: 6).
Precautions for disconnecting and connecting
hoses and tubes in air conditioner circuit
Disconnection
kk When replacing the air conditioner unit, air
conditioner compressor, condenser or
receiver drier, etc., collect the refrigerant (air
conditioner gas: R134a) from the air
conditioner circuit before disconnecting the
air conditioner hoses.
aAsk a qualified person for collecting, adding and
filling operations of the refrigerant (air
conditioner gas: R134a). (Only registered
persons can work.)
aNever release the refrigerant (air conditioner
gas: R134a) to the atmosphere.
kk If refrigerant gas (air conditioner gas: R134a)
gets in your eyes, you may lose your sight.
And if it touches your skin, you may suffer
from frostbite. Put on protective eyeglasses,
gloves and working clothes with long
sleeves while collecting the refrigerant or
filling the air conditioner circuit with the
refrigerant.
•When loosening the nuts fixing air conditioner
hoses and tubes, be sure to use 2 wrenches;
use one wrench to fix and use the other one to
loosen the nut.
Connection
•When installing the hose for the air conditioner
circuit, take care not to allow invasion of dirt,
dusts and water into the hose.
•Check that the O-rings are fitted to the joints
when connecting the air conditioner piping.
•Once an O-ring is used, it is deformed and
deteriorated. Accordingly, do not reuse it.
•When removing the O-rings, use a soft tool so
that the piping is not damaged.
•Check that the O-ring is not damaged or
deteriorated.
•Apply compressor oil for refrigerant (R134a) to
the O-ring.
aHowever, do not apply oil to the threaded
portion of a bolt, nut or union.
D37, 39-23 00-17
00 Index and foreword
Foreword, safety and general information
Manufacturer Part name
DENSO ND-OIL8
VALEO THERMAL
SYSTEMS
ZXL100PG (equivalent to
PAG46)
SANDEN SP-10
•When tightening nuts of the air conditioner
hoses and tubes, be sure to use 2 wrenches.
Use one wrench to fix and tighten the nut with
the other wrench to the specified torque (Use a
torque wrench for tightening).
aExample of fitting of O-ring
•An O-ring is fitted to every joint of the air
conditioner piping.
For tightening torques, see "Others",
"Precautions for disconnection and connection
of air conditioner piping".
00-18 D37, 39-23
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