PDF Shop Manual Komatsu D37EXi-24 D37PXi-24 D39EXi-24 Dozer - 3 MB
This is the official Komatsu shop manual for the advanced D37-24 and D39-24 series intelligent Machine Control (iMC) dozers.
It is a highly comprehensive resource for service technicians, providing detailed, step-by-step instructions for troubleshooting, servicing, and performing major repairs.
The manual gives special attention to the advanced iMC systems, in addition to covering the hydraulics, engine, and powertrain.
This guide is essential for ensuring your high-tech dozer is maintained to the highest possible standards.
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--- Page 1 ---
SEN06593-16
BULLDOZER D37EXi -24
D37PXi -24
D39EXi -24
D39PXi -24
D37EXi- 85001
D37PXi- 85001
SERIAL NUMBERS and up
D39EXi- 95001
D39PXi- 95001
--- Page 3 ---
Safety Notice for Operation 00 Index and Foreword
• Always wear the protective eyeglasses when hitting parts
with a hammer.
• Always wear the protective eyeglasses when grinding
parts with a grinder, etc.
• When performing any operation with multiple workers, al-
ways agree on the operating procedure before starting. Be
clear in verbal communication, and observe hand signals.
Hang “UNDER REPAIR” warning tag in the operator's
compartment Before starting work. ,&
• Only the approved personnel can do the work in a closed
environment or in a prohibited area.
• Work and operation which require license or qualification should be performed by qualified workers.
• Welding repairs should be performed by trained and experienced welders. When performing welding work,
always wear welding gloves, apron, welding goggles, cap and other clothes suited for welding work.
• Warm up before starting the work with exercise which increases alertness and the range of motion in order
to prevent injury.
• Avoid prolonged work, and take a rest at times to keep up a good condition. Take a rest at designated safe
area.
• When you work in high places, use a platform.
• Before you start the work, use the personal fall-arrest equipment to prevent falling. There is a danger of
personal accident that you fall by slipping.
• Always do the work correctly. If you find the unsafe behavior of co-worker, give him/her a notice and stop it.
• Because there is a danger that you are caught, be very careful when the work is done in dangerous areas
such as: when you go in the range where the lifted load possibly falls, or when you stand directly in front of
tire, or when you are near the sliding parts.
• When you handle chemical materials (such as nitrogen gas), see the MSDS (safety data sheet) and local
guidelines, and get the important information (such as a safe handling method). Also, put on applicable pro-
tective equipment (such as protective goggles, gloves, and masks).
• If necessary, cut out all the power sources (electricity, oil pressure, compressed air, etc.) before you start
the work. If the machine has a lock mechanism, set it to the LOCK position and install the warning tag in a
position where it is easy to see. Do not release the lock until the work is completed.
Precautions for Preparatory Work
• 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 adding oil or making any repairs.
• Lower the work equipment (blade, ripper, bucket, etc.) to the ground before starting work. If this is not pos-
sible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to
lock all the control levers and hang “UNDER REPAIR” 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 mud and oil from the steps or other places for
going up and down on the machine. Always use the hand-
rails, ladders or steps when for going up and down on the
machine. Never jump on or off the machine. When the
scaffold is not provided, use steps or stepladder to secure
your footing. Do not use handrails, ladders, or steps if they
are damaged or deformed. Repair it or replace it immedi-
ately.
,&
00-30 D37EXI-24, D37PXI-24, D39EXI-24, D39PXI-24
--- Page 4 ---
00 Index and Foreword Disconnect and Connect Push-Pull Type Coupler
Connection
Hold the tightening adapter part, and push body (2) straight un-
til sliding prevention ring (1) contacts contact surface (a) of the
hexagonal part at the male end.
How to Disconnect and Connect Type 3 Push-Pull Type Coupler
Disconnection
1. Hold the tightening adapter part and push body (2) straight
until sliding prevention ring (1) contacts contact surface (a)
of the hexagonal part at the male end.
2. While keeping the condition of step 1, push cover (3)
straight until it contacts contact surface (a) of the hexago-
nal portion on the male side.
3. While keeping the conditions of steps 1 and 2, pull out
whole body (2) to disconnect it.
REMARK
Provide an container to receive a quantity of hydraulic oil
which may flow out.
D37EXI-24, D37PXI-24, D39EXI-24, D39PXI-24 00-61
--- Page 5 ---
Conversion Table 00 Index and Foreword
1 °C = 33.8 °F
°C °F °C °F °C °F °C °F
-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8
-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8
-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0
-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0
-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0
-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-92 D37EXI-24, D37PXI-24, D39EXI-24, D39PXI-24
--- Page 6 ---
01 Specification Specifications
D39PXI-24
Serial No. :95001 to 95496
Item Unit
635 mm
Single shoe
Length of track on ground mm 2345
Shoe width (standard track shoe) mm 635
Minimum ground clearance mm 390
Engine
Model - SAA4D95LE-7
4-cycle, water-cooled, in-line, vertical, and direct in-
Type - jection type with turbocharger and air-cooled after-
cooler
No. of cylinders - bore x stroke mm 4-95 x 115
Total piston displacement ℓ {cc} 3.26 {3260}
Performance
Rated horsepower
• SAE J1995 (gross) (*1) 80 {107}/2200 {2200}
kW {HP}/
• ISO 14396 80 {107}/2200 {2200}
min-1 {rpm}
• ISO 9249/ SAE J1349 (net) (*2) 78.4 {105}/2200 {2200}
Nm {kgm}/
Maximum torque (net) (*2) 415 {42.3}/1600 {1600}
min-1 {rpm}
Maximum speed with no load min-1 {rpm} 2360 {2360}
Minimum speed with no load min-1 {rpm} 1075 {1075}
Fuel consumption ratio at rated horse-
g/kWh{g/HPh} 227 {169}
power
Starting motor - 24 V, 4.5 kW
Alternator - 24 V, 85 A
Battery (*3) - 12 V, 92 Ah x 2 pieces
Radiator core type - Corrugated aluminum
*1: Indicates the value of the bare engine (without cooling fan).
*2: Indicates the value at the minimum cooling fan speed.
*3: The battery capacity (Ah) is indicated in the 5-hour rate.
REMARK
• The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated horse-
power measured on the basic engine unit. Net denotes the value of an engine which is measured under the
condition almost the same as that of the time when it would be installed on a machine.
• The rated horsepower (net) at the maximum cooling fan speed is the following value.
72.9 kW/97.7 HP{2200 min-1/2200 rpm}
Power train
HST pump
Main pump
Type x quantity - Variable displacement swash plate piston type x 2
D37EXI-24, D37PXI-24, D39EXI-24, D39PXI-24 01-31
--- Page 7 ---
Layout Drawing of Urea SCR System 10 Structure and Function
Urea SCR System
SCR
Abbreviation for Selective Catalytic Reduction
Layout Drawing of Urea SCR System
1: Ambient temperature sensor 6: SCR temperature sensor
2: DEF tank coolant inlet hose 7: Ammonia sensor
3: DEF pressure hose (low-temperature side) 8: SCR outlet NOx sensor
4: DEF tank pressure hose (high-temperature side) 9: SCR outlet temperature sensor
5: Turbocharger outlet NOx sensor
10-12 D37EXI-24, D37PXI-24, D39EXI-24, D39PXI-24
--- Page 8 ---
10 Structure and Function System Operating Lamp System
REMARK
• The system operating lamp goes out in a maximum of 6 minutes after the starting switch is turned to “OFF”
position.
• The system operating lamp may sometimes lights up while the starting switch is in “OFF” position, because
KOMTRAX terminal may maintain its communication under this condition.
On and Off of System Operation Lamp
• Voltage of 24 V is constantly applied to one side of system operating lamp (light emitting diode).
• When any controller is in operation, the controller outputs Low (0 V), and a current flows through the diode
and the system operating lamp is lit.
• When no controllers are in operation, the controller outputs High (24 V), and no current flows through the
diode and the system operating lamp is not lit.
• KOMTRAX terminal starts and stops repeatedly to perform the communication periodically even when the
starting switch is in “OFF” position.
• The start and stop cycle (sleep cycle) of KOMTRAX terminal varies depending on the factors including the
communication state and the time when the machine is not in operation, and the lamp may be lit for approx-
imately one hour at the maximum.
• The system operating lamp may look slightly luminous in the dark even when it is not lit. It is due to the
minute leakage of current and this is not an abnormal phenomenon.
REMARK
• When you want to cut off the battery circuit for maintenance but the system operating lamp is lit, turn the
starting switch to “ON” position once, and then turn it to “OFF” position, and the lamp goes out in a maxi-
mum of six minutes.
After the system operating lamp goes out, turn the battery disconnect switch immediately to “OFF” position.
• After the engine is stopped, DEF in DEF injector or DEF pump is automatically sucked into DEF tank to pre-
vent malfunction caused by freezing of DEF or deposition of urea. Accordingly, the system operation lamp
keeps lit for a while after the starting switch is turned to “OFF” position, and this is not an abnormal phenom-
enon.
Function of System Operating Lamp System (Machine with Gateway Function
Controller)
The operation state of each controller is checked by being lit or not being lit of the system operating lamp.
This lamp is lit to inform the operator that any controller is in operation. With this function, an abnormal finishing
of the battery power circuit can be prevented from occurring.
k For shutting off the battery power supply circuit, turn the starting switch to “OFF” position, and
check that the system operating lamp is not lit, then turn the battery disconnect switch to “OFF”
position.
k If the battery disconnect switch is turned to “OFF” position (the battery power supply circuit is shut
off) while the system operating lamp is lit, data loss error of controller may occur. Never operate the
battery disconnect switch while the system operating lamp is lit.
REMARK
• The system operating lamp goes out in a maximum of 6 minutes after the starting switch is turned to “OFF”
position.
• The system operating lamp may sometimes lights up while the starting switch is in “OFF” position, because
Gateway Function Controller may maintain its communication under this condition.
On and Off of System Operation Lamp
• Voltage of 24 V is constantly applied to one side of system operating lamp (light emitting diode).
• When any controller is in operation, the controller outputs Low (0 V), and a current flows through the diode
and the system operating lamp is lit.
D37EXI-24, D37PXI-24, D39EXI-24, D39PXI-24 10-43
--- Page 9 ---
Component Parts of Engine System 10 Structure and Function
EGR Cooler
EGR
Abbreviation for Exhaust Gas Recirculation
Structure of EGR Cooler
REMARK
The shape is subject to machine models.
General View and Sectional View
A: EGR gas inlet D: EGR gas outlet
B: Air vent E: Coolant inlet
C: Coolant outlet
1: Tube 2: Shell
1: Flat tube 2: Inner fin
10-74 D37EXI-24, D37PXI-24, D39EXI-24, D39PXI-24
--- Page 10 ---
10 Structure and Function KOMTRAX System
2: Communication terminal
3: GNSS antenna
4: Communication antenna (Iridium communication version)
Function of KOMTRAX System
• KOMTRAX system transmits various types of information on the machine. KOMTRAX administrator sees
the information in the office and supplies various services to the customers.
• KOMTRAX system can transmits the following information.
• Positional information
• Working information
• Alarm and failure information
• Fuel consumption information
• Maintenance information
• Machine working condition information
REMARK
To provide the services, you need to establish radio station for KOMTRAX separately.
D37EXI-24, D37PXI-24, D39EXI-24, D39PXI-24 10-105
--- Page 11 ---
Component Parts of Control System 10 Structure and Function
Input and output
Pin No. Signal name
signals
19 (*1) -
20 (*1) -
21 Datalink4 (+) (sensor controller) Communication
22 Datalink1(+)(KOMNET/c) Communication
23 (*1) -
24 (*1) -
25 Power supply (+24 V continuous) Power supply
26 Power supply (+24 V continuous) Power supply
27 Power supply (+24 V continuous) Power supply
28 Power supply (+24 V continuous) Power supply
29 (*1) -
30 (*1) -
31 (*1) -
Ground/Shield/
32 GND
Return
Ground/Shield/
33 GND
Return
34 (*1) -
35 (*1) -
36 (*1) -
37 (*1) -
38 DEF line heater 2 Input
39 DEF line heater 1 Input
40 (*1) -
41 (*1) -
42 (*1) -
43 Idle validation switch 2:Machine with accelerator pedal Input
44 Idle validation switch 1:Machine with accelerator pedal Input
45 Datalink4 (-) (sensor controller) Communication
46 Datalink4(-)(KOMNET/c) Communication
47 (*1) -
48 System operating lamp Output
Ground/Shield/
49 Power GND
Return
Ground/Shield/
50 Power GND
Return
Ground/Shield/
51 Power GND
Return
Ground/Shield/
52 Power GND
Return
10-136 D37EXI-24, D37PXI-24, D39EXI-24, D39PXI-24
--- Page 12 ---
10 Structure and Function Component Parts of Hydraulic System
Angle valve
4: Pressure compensation valve F (angle) (*1)
5: Suction valve (angle RIGHT)
6: Spool (angle)
7: Suction valve (angle LEFT)
8: Pressure compensation valve R (angle) (*2)
Ripper valve
9: Pressure compensation valve F (ripper) (*1)
10: Suction valve (ripper LOWER)
11: Spool (ripper)
12: Suction valve (ripper RAISE)
13: Pressure compensation valve R (ripper) (*2)
14: Centralized safety valve
15: Pressure relief plug
*1: Flow control valve
*2: Pressure reducing valve
D37EXI-24, D37PXI-24, D39EXI-24, D39PXI-24 10-167
--- Page 13 ---
HST Control System 10 Structure and Function
Straight Travel Correction Control Function
• HST controller monitors the operating condition of each lever and each pedal, and constantly controls HST
pump swash plate angle, or the discharged volume, so that the output speeds of R.H. and L.H. HST motors
are the same.
• When the machine travels forward straight, if R.H. HST motor speed is higher than L.H. HST motor speed,
this reduces the control signal of R.H. forward HST pump EPC valve and controls it so that the machine
constantly travels straight.
Conditions to Cancel Straight Travel Correction Control
• When the joystick (steering, directional and gear shift lever) is operated to “turn LEFT” or “turn RIGHT”.
• When the travel direction operation of the joystick (steering, directional and gear shift lever) is in “NEU-
TRAL”.
• When each pedal or the fuel control dial is operated and the speed signal of HST motor speed sensor is
0.15 km/h or less.
• When HST motor speed sensor is judged failed because of an open circuit, etc.
Straight travel is secured in all conditions other than the above.
10-198 D37EXI-24, D37PXI-24, D39EXI-24, D39PXI-24
--- Page 14 ---
10 Structure and Function Component Parts of Power Train System
Structure of Charge Relief Valve of HST Motor
Sectional View
1: Valve 4: Poppet
2: Spring 5: Spring
3: Valve seat 6: Adjustment screw
Function of Charge Relief Valve of HST Motor
• The charge relief valve is installed inside the end cover. By this charge relief valve, the pressure (charge
pressure) on the low pressure side of HST main circuit selected by the low-pressure selector spool is pre-
vented from increasing above the set pressure. Also, the oil is relieved into the motor case at the set rate to
prevent overheating of the motor.
• In addition, this valve discharges the dirtiest oil in HST main circuit to outside and keep the inside of HST
main circuit clean.
Operation of Charge Relief Valve of HST Motor
1. Port (A) is connected to the pressure (charge circuit) on
the low pressure side of HST motor's main circuit selected
by the low-pressure selector spool.
2. Port (B) is connected to the tank drain circuit through HST
motor case.
3. The pressurized oil also fills chamber (C) through orifice
(g) of valve(1). Poppet (2) is in close contact with valve
seat (3).
D37EXI-24, D37PXI-24, D39EXI-24, D39PXI-24 10-229
--- Page 15 ---
Component Parts of Work Equipment System 10 Structure and Function
Piston Valve
Function of Piston Valve of Blade Angle Cylinder
The piston valve is installed on the piston in the blade angle cylinder. When the piston reaches its stroke end,
the valve releases the oil from the hydraulic pump to reduce the oil pressure being exerted on the piston.
Operation of Piston Valve of Blade Angle Cylinder
Operation When Piston Valve is Close (During Stroke)
1. The pressurized oil from the work equipment pump pushes
piston (2) against spring (4) and open it. Then it flows into
chamber (A).
2. Chamber (A) is filled with pressurized oil. Piston valve (5)
is pushed to the right, and contacts the tapered area of the
piston valve seat (a) to seal in oil.
3. The oil pressure in the cylinder increases and piston (3) is
pushed to the right.
Operation When Piston Valve is Open (At Stroke End)
1. Before piston rod (1) reaches its stroke end, slider (6) con-
tacts cylinder bottom (b) and stops movement.
2. Slider (6) touches the end of piston valve (5) and only pis-
ton (3) continues moving.
3. Pressurized oil in chamber (A) that has been sealed in by
piston valve (5) is released from the piston valve seat (a)
to the bottom end and the pressure in the cylinder decrea-
ses.
10-260 D37EXI-24, D37PXI-24, D39EXI-24, D39PXI-24
--- Page 16 ---
10 Structure and Function Component Parts of ICT System
Input and output
Pin No. Signal name
signals
17 (*1) -
18 (*1) -
19 (*1) -
20 (*1) -
21 GND (power supply) -
22 Power supply (24 V) Input
23 (*1) -
24 Starting switch ACC signal Input
25 (*1) -
26 (*1) -
27 (*1) -
28 (*1) -
29 (*1) -
30 (*1) -
31 GND (power supply) -
32 GND (power supply) -
33 GND (power supply) -
34 System operating lamp Output
35 (*1) -
36 (*1) -
37 (*1) -
38 (*1) -
39 (*1) -
40 (*1) -
*1: Never connect these pins, otherwise it may cause malfunction or failures.
D37EXI-24, D37PXI-24, D39EXI-24, D39PXI-24 10-291
--- Page 17 ---
CAB Mount 10 Structure and Function
Function of CAB Mount
Sealed and lubricated type damper absorbs vibration of machine in order to reduce the vibration transmitted to
an operator.
10-322 D37EXI-24, D37PXI-24, D39EXI-24, D39PXI-24
--- Page 18 ---
20 Standard Value Table Standard Value Table for Machine: D37EXI-24
Machine model D37EXI-24
Engine SAA4D95LE-7
Standard value for
Item Measurement condition Unit Repair limit
new machine
• Level road surface
• HST oil temperature (hydraulic oil tem-
perature)40 to 60 °C
• Operating Mode: P (Power mode)
• Fuel control dial: MAX (High idle) posi-
Travel deviation tion mm Max. 120 Max. 150
• Travel deviation (x): Run 20 m after
run up distance of more than 10 m
• For measurement posture, see “Ma-
chine Posture and Procedures to
Measure Performance”, Fig. 1.
• 20 ° slope
• Machine posture: Both front up and
front down
• Joystick (steering, directional, and
gear shift lever) (PCCS lever): NEU-
TRAL position
Machine drift on • Control brake: Release mode
m Max. 3.6 Max. 4.0
slope • Parking brake lock lever: FREE posi-
tion
• Hydraulic drift after the elapse of 1
min.
• For measurement posture, see “Ma-
chine Posture and Procedures to
Measure Performance”, Fig. 2.
Work Equipment Oil Pressure
Machine model D37EXI-24
Engine SAA4D95LE-7
Standard value for
Item Measurement condition Unit Repair limit
new machine
• HST oil temperature (hydraulic oil tem-
perature)40 to 60 °C
Work equipment • Operating Mode: P (Power mode) MPa 27.44±0.98 Min. 24.5
pump relief pres-
sure • Fuel control dial: MAX (High idle) posi- {kg/cm2} {280±10 } {Min. 250}
tion
• During work equipment relief
• HST oil temperature (hydraulic oil tem-
perature)40 to 60 °C
Control circuit oil MPa 3.23±0.29 3.23±0.29