Komatsu D37EX-23, D37PX-23, D39EX-23, D39PX-23 Bulldozer Service Repair Manual INSTANT (SN: 80001 and up , 90001 and u

BULLDOZER SEN06061-03 D37EX -23 D37PX -23 D39EX -23 D39PX -23 SERIAL NUMBERS D37EX-80001 D37PX-80001 D39EX-90001 D39PX-90001 and up

SHOP MANUAL BULLDOZER D37EX-23 D37PX-23 D39EX-23 D39PX-23 Model D37EX-23 D37PX-23 D39EX-23 D39PX-23 Serial Number 80001 and up 80001 and up 90001 and up 90001 and up 00 Index and foreword 1 00 Index and foreword D37, 39-23 00-1

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

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 HSToil 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

Komatsu D37EX-23, D37PX-23, D39EX-23, D39PX-23 Bulldozer Service Repair Manual INSTANT (SN: 80001 and up , 90001 and u

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