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Komatsu D39PX-21 User Manual

Komatsu D39PX-21
256 pages
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D31EX, PX-21
D37EX, PX-21
D39EX, PX-21
SERIAL NUMBER
D31EX-21 - 50501 and up
D31PX-21 - 50501 and up
D37EX-21 - 5501 and up
D37PX-21 - 5501 and up
D39EX-21 -1501 and up
D39PX-21 -1501 and up
BULLDOZER
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
this manual before operating or maintaining this
machine. This manual should be kept inside the cab for
reference and periodically reviewed by all personnel who
will come into contact with the machine.
Operation &
Maintenance Manual
EEAM023900
WARNING

Table of Contents

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Komatsu D39PX-21 Specifications

General IconGeneral
Engine ModelKomatsu S4D102E-1
Net Power77 kW
Operating Weight10770 kg
Blade Width2735 mm
Blade Capacity2.1 m³
Net Horsepower103 hp
Track Gauge1, 880 mm
Shoe Width450 mm

Summary

SAFETY INFORMATION

OPERATION

Pre-Start Engine Checks and Adjustments

Crucial checks and procedures before starting the engine.

Component Explanation

Explains various components of the machine and their functions.

Monitor System Check Procedure

Emergency Caution Items

Caution Items for Operator Observation

METER GROUP OVERVIEW

MACHINE INDICATOR LAMPS

Warning Lamp (Red)

Explains the function of the red warning lamp.

MAINTENANCE MODE USAGE

SELECTING MAINTENANCE MODES

OIL AND FILTER MAINTENANCE MODE

PM CLINIC AUXILIARY MODE USAGE

FAULT CODE DISPLAY MODE USAGE

USER ADJUST MODE FUNCTIONS

Display Panel B Adjustment

MACHINE SWITCHES

Switch Controls

Operator Switches

Starting Switch Operation

Details the operation of the starting switch for engine control.

Cab Interior Switches

Cab Accessory Controls

CONTROL LEVERS AND PEDALS

Fuel Control Lever Usage

Explains how to control engine speed and output using the fuel lever.

Joystick Operation (Steering, Directional, Gear Shift)

Brake Pedal Usage

Decelerator Pedal Usage

BLADE CONTROL LEVER

SAFETY LOCK LEVER

PARKING LEVER OPERATION

FUSE SYSTEM

CAB FEATURES

Locking Mechanisms

CAB CONVENIENCES

STORAGE COMPARTMENTS

STEREO CONTROLS

STEREO CONTROLS (cont.)

STEREO OPERATION METHODS (cont.)

STEREO USAGE PRECAUTIONS

AIR CONDITIONER HANDLING

AIR CONDITIONER CONTROLS

Air Conditioner Handling (cont.)

Air Conditioner Maintenance

ACCUMULATOR HANDLING

Releasing Pressure in Accumulator Circuit

Details how to release pressure from the accumulator circuit.

Coolant Level Check and Addition

Monitor System Check

Fuel Level Check and Addition

Engine Oil Level Check and Addition

Water Separator Check and Cleaning

Dust Indicator Check

Hydraulic Tank Oil Level Check and Addition

Electrical Wiring Inspection

Horn and Backup Alarm Checks

PRE-START ENGINE CHECKS AND ADJUSTMENTS

Walk-Around Check Procedure

Outlines the daily walk-around inspection procedure.

STARTING ENGINE

Normal Starting Procedure

Step-by-step guide for starting the engine normally.

STARTING IN COLD WEATHER

Engine Starting in Low Temperatures

Instructions for starting the engine in low temperatures.

OPERATIONS AND CHECKS AFTER STARTING ENGINE

New Machine Break-In Period

Precautions for breaking in a new machine.

Warming Up Operations

Details the necessary warm-up procedures before operation.

STOPPING ENGINE

MACHINE OPERATION

Moving the Machine

Step-by-step guide on how to move the machine.

STOPPING MACHINE

SHIFTING GEARS

SHIFTING BETWEEN FORWARD AND REVERSE

STEERING MACHINE

Normal Turning Procedures

Instructions for performing normal turns.

Pivot Turn and Slope Turning

Turning While Descending a Slope

Precautions for turning the machine on slopes.

Forward Driving and Turning

PRECAUTIONS FOR OPERATION

Traveling Up or Down Hills

PRECAUTIONS ON SLOPES

Cab Door and Glass Precautions

WORK POSSIBLE USING BULLDOZER

Bulldozer Work Applications

PARKING MACHINE

CHECK AFTER FINISHING WORK

LOCKING MECHANISMS

TIPS FOR LONGER UNDERCARRIAGE LIFE

Undercarriage Operation Methods

Provides tips on operation methods to extend undercarriage life.

Undercarriage Inspection and Adjustment

Details inspection and adjustment procedures for the undercarriage.

INSPECTION AND REPAIR

Undercarriage Wear Measurement

TRANSPORTATION

LOADING AND UNLOADING WORK

SECURING MACHINE FOR TRANSPORT

UNLOADING WORK PROCEDURE

LIFTING MACHINE OPERATION

COLD WEATHER OPERATION

Low Temperature Precautions

Safety and operational precautions for low temperatures.

Cold Weather Coolant

Details on coolant and antifreeze for cold weather.

BATTERY CARE IN COLD WEATHER

AFTER COMPLETION OF WORK

Post-Work Procedures (Cold Conditions)

Procedures to follow after completing work, especially in cold conditions.

LONG-TERM STORAGE PROCEDURES

TROUBLESHOOTING

Troubleshooting After Running Out of Fuel

Steps to take after the machine runs out of fuel.

Machine Towing Method

Detailed instructions for towing a disabled machine.

Engine Start Troubleshooting

Starting Engine When Previously Unable

Guidance for starting the engine when it was previously unable to start.

WHEN ENGINE DOES NOT START

WHEN ENGINE DOES NOT STOP

OTHER TROUBLE CATEGORIES

MONITOR PANEL ERROR CODES

CHASSIS TROUBLESHOOTING

ENGINE TROUBLESHOOTING

MAINTENANCE

General Maintenance Guidelines

General principles for performing maintenance.

General Maintenance Practices

Welding Safety Guidelines

Safety guidelines for welding on the machine.

Hydraulic System Air Bleeding Procedure

POST-MAINTENANCE CHECKS

Checks After Operation (Engine Stopped)

Checks to perform after operation with the engine stopped.

Checks When Engine is Running

Checks to perform with the engine running after maintenance.

OUTLINE OF SERVICE

Fluid Overview and Oil Clinic

Overview of fluids and oil analysis services.

COOLANT AND GREASE

Coolant and Antifreeze Information

Details on coolant, antifreeze, and system cleaning.

Komatsu Oil Wear Analysis Service

Explanation of the Komatsu Oil Wear Analysis service.

OIL SAMPLING AND STORAGE

Oil Sampling Guidelines

Guidelines for oil sampling.

Filter Importance and Replacement

Importance and replacement of filters.

ELECTRICAL SYSTEM MAINTENANCE

WEAR PARTS LIST

FLUID SELECTION BY AMBIENT TEMPERATURE

Proper Fuel, Coolant, Lubricant Selection

Guidance on selecting appropriate fluids based on temperature.

STANDARD BOLT AND NUT TORQUE SPECIFICATIONS

Torque List for Fasteners

Provides torque specifications for various bolts and nuts.

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

Safety Critical Parts List and Intervals

Lists safety-critical parts and their replacement intervals.

MAINTENANCE SCHEDULE CHART

When Required Maintenance Tasks

Maintenance tasks to be performed as needed.

Pre-Starting Checks

Daily checks before operating the machine.

Maintenance Schedule by Hours

Every 50 Hours Service

Maintenance tasks required every 50 hours.

Every 250 Hours Service

Maintenance tasks required every 250 hours.

Every 500 Hours Service

Maintenance tasks required every 500 hours.

Every 1000 Hours Service

Maintenance tasks required every 1000 hours.

Maintenance Schedule by Hours (cont.)

Every 2000 Hours Service

Maintenance tasks required every 2000 hours.

Every 4000 Hours Service

Maintenance tasks required every 4000 hours.

SERVICE PROCEDURE

Air Cleaner Element Check, Clean, Replace

Steps to check, clean, and replace the air cleaner element.

Air Cleaner Outer Element Cleaning/Replacement

Outer Element Cleaning or Replacement

Detailed steps for cleaning or replacing the outer air cleaner element.

Air Cleaner Element Replacement

Replacing Air Cleaner Elements

Instructions for replacing air cleaner elements.

CLEAN INSIDE OF COOLING SYSTEM

Cooling System Cleaning Procedure

How to clean the inside of the cooling system.

Coolant and Antifreeze Mixing Ratios

TRACK SHOE TENSION CHECK AND ADJUSTMENT

Track Shoe Tension Inspection

How to inspect track shoe tension.

Track Shoe Tension Adjustment

Procedures for adjusting track shoe tension.

Idler and Hinge Adjustments

CAB COMPONENT CHECKS AND ADJUSTMENTS

Air Conditioner Check and Adjustment

How to check and adjust the air conditioner.

Washer Fluid and Wiper Blade Maintenance

PROCEDURE FOR BLEEDING AIR IN HYDRAULIC SYSTEM

PROCEDURE FOR RELEASING INTERNAL PRESSURE OF HYDRAULIC SYSTEM

PRE-OPERATION CHECKS

Comprehensive Pre-Start Checklist

A comprehensive list of checks before starting the machine.

EVERY 50 HOURS SERVICE

Fuel Tank Water and Sediment Drain

Procedure to drain water and sediment from the fuel tank.

EVERY 250 HOURS SERVICE

Lubrication Points and Procedures

Details lubrication points and procedures.

Lubrication (cont.)

FINAL DRIVE CASE OIL CHECK AND ADDITION

BATTERY ELECTROLYTE LEVEL CHECK

CHECK BRAKE PERFORMANCE

AIR CONDITIONER FILTER CLEANING

Air Conditioner Filter Cleaning Steps

Steps for cleaning the air conditioner filters.

EVERY 500 HOURS SERVICE

Fuel Filter Cartridge Replacement

Instructions for replacing the fuel filter cartridge.

AUTOMATIC AIR BLEED MECHANISM USAGE

Automatic Air Bleeding Procedure

How to use the automatic air bleed mechanism after filter replacement.

Manual Air Bleeding Procedure

Manual Fuel System Air Bleeding

Manual procedure for bleeding air from the fuel system.

ENGINE OIL CHANGE AND FILTER REPLACEMENT

RADIATOR AND OIL COOLER FIN CLEANING

EVERY 1000 HOURS SERVICE

Final Drive Case Oil Change

Procedure for changing oil in the final drive case.

Turbocharger Rotor Play Check

EVERY 2000 HOURS SERVICE

Hydraulic Oil Change, Filter Replacement, Strainer Cleaning

Procedure for changing hydraulic oil, filter, and cleaning strainer.

Component Checks and Adjustments

EVERY 4000 HOURS SERVICE

SPECIFICATIONS

ATTACHMENTS AND OPTIONS

General Precautions for Attachments

General safety precautions for attachments and options.

Safety Precautions for Attachment Installation

Specific safety advice for installing attachments.

HANDLING HYDRAULIC RIPPER

RIPPER CONTROL LEVER OPERATION

RIPPER OPERATION

Ripper Pre-Operation Checks

Pre-operation checks for the ripper attachment.

Ripper Operating Precautions

Safety precautions during ripper operation.

HYDRAULIC RIPPER TROUBLESHOOTING

RIPPER MAINTENANCE

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