COMPONENT CODE              00PARTS & SERVICE                                                     REF NO. AA07242         ...
Page 2 of 40Parts Item          Part Number                                                         Description           ...
Page 3 of 40 Item       Part Number                                                        Description                    ...
Page 4 of 40 Item          Part Number                                                        Description                 ...
Page 5 of 40General Considerations:       • Park machine and chock wheels before beginning work       • Clean all oil, gre...
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Switch and Filter Installation Procedure

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Procedure to install switch and filter on fire dozer heavy equipment - edited highlights

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Switch and Filter Installation Procedure

  1. 1. COMPONENT CODE 00PARTS & SERVICE REF NO. AA07242 DATE November14, 2007NEWS Page 1 of 40SUBJECT: PROVIDE THE PROCEDURE TO INSTALL HEPA CAB FILTER AND WINCH-MOUNTED HYDRAULIC ACTUATED REAR HITCH.PURPOSE: To inform field personnel.APPLICATION: D39PX-21A Fire Dozer Serial Number 1501 and up (1946 first unit installed) D39EX-21A Fire Dozer Serial Number 1501 and upFAILURE CODE: 0000Z9DESCRIPTION: The purpose of this Parts & Service News is to provide part numbers and installation instructions for the HEPA filter package and Hydraulic Actuated Rear Hitch on the D39PX-21 Fire Dozer.Remark Related Parts and Service News: • AA02051A D39 PTO Installation • BT04132 D39 Ripper InstallationMachine Preparation 1. Park the machine on a flat level surface and lower the work equipment to the ground. 2. Shut off the engine and cycle the controls to remove any residual hydraulic pressure from the work equipment circuits. 3. Engage the parking brake and block any tracks or wheels. 4. Remove the key from the ignition switch until the work is complete. 5. Place a tag on the steering controls advising “This machine is being repaired. Do Not Start or move this machine for any reason until this tag is removed by the repair person who placed it". WARNING! Observe all safety standards as dictated by the work conditions under which the equipment will be inspected, reworked and repaired. Consult the appropriate Shop Manual, Operation and Maintenance Manual, and your Komatsu District Service Manager with any and all questions regarding safety.Remark These instructions supplement the service data contained in the appropriate "Shop Manual". Refer to that manual for Removal, Installation, Disassembly and Reassembly instructions when not contained in this document. AA07242
  2. 2. Page 2 of 40Parts Item Part Number Description Qty X960002140 HEPA Filter G. - CollectorA1 11Y-979-A010 BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2 11Y-979-A020 SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A3 11Y-979-A030 GUARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A4 11Y-979-A040 FILTER A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 07289-00145 ●CLAMP ........................................................ 8 07289-00195 ●CLAMP ........................................................ 2 11Y-979-A070 ●FILTER, CARBON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 11Y-979-A090 ●GASKET ....................................................... 1 11Y-979-A100 ●PLATE, SPARK ARRESTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 11Y-979-A110 ●PLATE, OUTLET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 11Y-979-A120 ●ADAPTOR, FLANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 11Y-979-A130 ●PLATE, COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 11Y-979-A140 ●HARNESS ...................................................... 1 11Y-979-A150 ●FAN A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 11Y-979-A160 ●FAN A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 11Y-979-A170 ●HOSE .......................................................... 2 11Y-979-A180 ●HOSE .......................................................... 2 11Y-979-A190 ●HOSE .......................................................... 1A5 11Y-979-A050 LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A6 11Y-979-A060 FILTER, IN-CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A7 11Y-979-A080 HOSE, FLEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A8 07289-00105 CLAMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A9 08147-42402 LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A10 01010-81225 BOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A11 01010-81235 BOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A11 01643-31232 WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A12 01596-01211 NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A13 01580-11210 NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 X960001920 Hydraulic Hitch G. - CollectorB1 11Y-69-A0130 HITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B2 02010-81257 BOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B3 01643-32245 WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B4 11Y-69-A0140 DRAWBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B5 09242-35130 PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B6 09249-00009 LATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B7 04050-12012 COTTER PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B8 04205-10825 PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B9 11Y-69-A0150 LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1AA07242
  3. 3. Page 3 of 40 Item Part Number Description QtyB10 11Y-69-A0160 COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B11 01024-81025 BOLT, SEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B12 11Y-69-A0171 GUARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B13 01024-81025 BOLT, SEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B14 11Y-69-A0180 COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B15 01024-81025 BOLT, SEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B16 11Y-60-A0130 HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B17 11Y-60-A0140 HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B18 11Y-60-A0360 HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B19 07094-30315 CLAMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B20 07095-00317 CUSHION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B21 01024-81055 BOLT, SEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B22 11Y-69-A0190 PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B23 11Y-69-A0210 PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B24 01573-22206 SEAT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B25 01572-21216 SEAT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B26 01572-20816 SEAT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B27 11Y-60-A0111 VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 11Y-60-A0161 ●SOLENOID ..................................................... 1 11Y-60-A0151 ●CARTRIDGE .................................................... 1B28 11Y-60-A0180 ADAPTER, 90× SWIVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B29 418-43-37610 NIPPLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B30 418-879-3120 NIPPLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B31 01024-80875 BOLT, SEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B32 1268208H91 SWITCH (*DEG-10311) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B33 11Y-60-A0120 CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B33-1 11Y-60-A0340 ●PIN, ROD END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B33-2 11Y-60-A0350 ●PIN, HEAD END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B33-3 11Y-60-A0310 ●BUSHING, ROD END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B33-4 11Y-60-A0320 ●BUSHING, HEAD END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B33-5 11Y-60-A0330 ●CLIP, PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B34 11Y-60-A0180 ADAPTER, 90× SWIVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B35 418-43-37610 NIPPLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B36 23B-60-41220 UNION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B37 11Y-62-12350 NIPPLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B38 07002-11823 O-RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B39 09245-04824 CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B40 09245-50060 HOOK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B41 08034-20519 BAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B42 11Y-60-A0410 HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B43 11Y-60-A0420 HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 AA07242
  4. 4. Page 4 of 40 Item Part Number Description QtyB44 1252158H91 VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B45 01010-80835 BOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B46 01643-30823 WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B47 424-62-31170 ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B48 11Y-60-A0430 ELBOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B49 01010-81235 BOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B50 01643-31232 WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2AA07242
  5. 5. Page 5 of 40General Considerations: • Park machine and chock wheels before beginning work • Clean all oil, grease, and fuel from machine (i.e. by pressure wash) before performing welding. Petroleum products are flammable and may catch fire from welding sparks and over spray. • Cover hoses and cables in welding areas with fire suppression cloths before welding or grinding. • Torque M10 bolts to 66 Nm (6.7kgm) • Torque M12 bolts to 110 Nm (11 kgm) • Torque M16 bolts to 260 Nm (26.5 kgm) 1. Inlet Air Box Installation . Weld plenum box, A1, to the back right-hand side of the rear hydraulic tank guard such that it covers the air inlet slots as shown in Figure 1, and Figure 2 . Weld 6 mm fillet weld all around at the joint. AA07242
  6. 6. Page 6 of 40 2. Seal Installation Attach SEAL, A2, to the backside (inside) surface of the hydraulic tank guard, right-hand side hinged panel as shown in Figure 3 and Figure 4. Insure that the inside perimeter of the seal is lined up with the outer edges of the slotted vent holes.AA07242
  7. 7. Page 7 of 403. HEPA Filter Assembly Installation Attach the HEPA filter assembly, A4, to the water tank mounting brackets at the back of the rear hydraulic tank guard in Figure 5 and Figure 6. The inlet and outlet ports face to the right-hand side of the machine as shown in Figure 7. AA07242
  8. 8. Page 8 of 40 4. Attach one end of 4" dia. hose, A7, to the outlet port of the FILTER, A4, and the other end of the hose to inlet port of BOX, A1 as shown in Figure 7. Next, connect the wiring harness to the receptacle located on the side of the filter box as shown in Figure 7. Contact JRB Attachments, LLC, Chattanooga, TN, (423-825-5504) for details to the wire harness installation and connection details.AA07242
  9. 9. Page 9 of 40 AA07242
  10. 10. Page 10 of 40 5. Cab Filter Lamp Installation On the upper right-side of the roof headliner, remove the black switch panel from the roof. Drill a 21 mm diameter hole through the switch panel to the right of the wiper on/off switch and approximately 40 mm (1 ½") below the top edge as shown in Figure 10. Assemble LAMP, A9 and LABEL, A5, to the switch plate. Connect the lamp lead wires to the HEPA filter wire harness. Re-assemble the switch plate to roof headliner.AA07242
  11. 11. Page 11 of 406. Cab Filter Installation In the cab, replace the in-cab A/C filter, 14X-911-7741, with FILTER, A6. AA07242
  12. 12. Page 12 of 40Hydraulic Hitch Installation 1. Control Valve modification Replace standard main control valve (3 spool) with ripper control valve (4 spool) if necessary, and install ripper control lever and piping. See Parts and Service News document BT04132 for details. Hoses (Items 77, 78 in BT04132) to rear are not needed from the ripper installation. Attach fittings to ports A4, B4 on the control valve.AA07242
  13. 13. Page 13 of 40 AA07242
  14. 14. Page 14 of 40 2. Winch Mounting Bracket Rework Remove the winch if necessary to get to the mounting bracket. Cut a hole in the bracket as shown in Figure 14.AA07242
  15. 15. Page 15 of 40Weld seats B24, B25, B26 in the locations shown in Figure 15 below. The diverter valve B27 will mountto these seats. AA07242
  16. 16. Page 16 of 40 3. Hitch Mounting After installing the winch to the machine, raise the hitch B1 into place and attach to the underside of the winch using bolts and washer B2, B3 as shown in Figure 16.AA07242
  17. 17. Page 17 of 40Insert the Drawbar B4 into the hitch as shown below in Figure 17. Assemble pin retainer and hitch pin (B5,B6, B7, B8) as shown below in Figure 17. Attach chain (not shown) between pin and drawbar hooks(09245-50060). AA07242
  18. 18. Page 18 of 40 4. Cylinder Installation Install fittings B34 and B35 on the cylinder B33 as shown below in Figure 18 . Cover fittings with plastic caps to avoid contamination of the hydraulics with dust an debris.AA07242
  19. 19. Page 19 of 40Orient the cylinder as shown below in Figure 19. Insert the cylinder, rod end first, into the hitch from theRH side of the machine. After clearing the first section of slide plates, rotate the cylinder slightly. Thiswill allow the cylinder to pass completely through the slot to the other side. Make sure the cylinder hoseports are facing the front of the machine as shown below.Next, orient the sliding lock B9 as shown and insert into the same opening. The lock will straddle thecylinder, and cylinder pin hole will line up with the lock pin hole. AA07242
  20. 20. Page 20 of 40Secure both ends of the cylinder with pins as shown in Figure 20 and Figure 21. Secure Pins with springclips.AA07242
  21. 21. Page 21 of 405. Valve installation Install the fittings to the solenoid valve as shown below. Adjust the angle as shown below and torque fittings to 103 Nm (10.5 kgm). AA07242
  22. 22. Page 22 of 40Mount the valve to the bracket as shown below.AA07242
  23. 23. Page 23 of 406. Hose hookup. Attach hoses to the valve as shown below. AA07242
  24. 24. Page 24 of 40AA07242
  25. 25. Page 25 of 40With cylinder extended, connect Hose to Cylinder Head fitting. AA07242
  26. 26. Page 26 of 40Connect Hose to Cylinder Rod End Fitting and cover.AA07242
  27. 27. Page 27 of 40Route hoses to top through the hole in the winch mounting bracket. AA07242
  28. 28. Page 28 of 40Connect Hoses to ports A4, B4 on the main control valve (ripper spool).AA07242
  29. 29. Page 29 of 40 AA07242
  30. 30. Page 30 of 40 7. Cover Installation Attach cover B12 as shown below.AA07242
  31. 31. Page 31 of 40Cut a opening and two holes in the Cover provided by the winch vendor. AA07242
  32. 32. Page 32 of 40Bolt covers together.AA07242
  33. 33. Page 33 of 408. Operation instructions: WARNING! Bring dozer to a stop. Pulling on the hitch drawbar while operating the hitch may cause damage to hitch linkage. A. Activate power to the hitch by pulling the red knob up. AA07242
  34. 34. Page 34 of 40 B. Operate the ripper lever to disengage the hitch.Tip: Pull dozer forward and drawbar will fall from hitch if tow implement is still attached.Quick disconnects from implement will detach when hoses pull tight. C. Once drawbar is placed back into the hitch, pull the ripper lever left as shown above to lock the drawbar in place.AA07242
  35. 35. Page 35 of 409. Decals: Place decals in cab beside the ripper control lever and the hitch activation switch. AA07242
  36. 36. Page 36 of 40 10. Solenoid Valve Service PartsAA07242
  37. 37. Page 37 of 4011. Hydraulic Diagram AA07242
  38. 38. Page 38 of 40 12. Wiring DiagramAA07242
  39. 39. Page 39 of 4013. HEPA Filter Assembly Service Parts AA07242
  40. 40. Page 40 of 40 14. Cylinder StructureAA07242

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