Komatsu Bulldozer D31PLL-21 Shop Manual SEN06775-01 PDF DOWNLOAD

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Komatsu Bulldozer D31PLL-21 Shop Manual SEN06775-01 PDF – DOWNLOAD

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Komatsu Bulldozer D31PLL-21 Shop Manual SEN06775-01 PDF – DOWNLOAD

Language : English
Pages : 742
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu Bulldozer D31PLL-21 Shop Manual SEN06775-01 PDF – DOWNLOAD

• SERIAL NUMBERS 55226 and up

Cover 1
00 INDEX AND FOREWORD 3
TABLE OF CONTENTS 4
ACRONYMS . 10
SAFETY NOTICE 15
HOW TO READ THE SHOP MANUAL 20
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 22
HOW TO READ ELECTRIC WIRE CODE . 24
PRECAUTIONS WHEN CARRYING OUT OPERATION 27
METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER 30
STANDARD TIGHTENING TORQUE TABLE . 33
CONVERSION TABLE . 37
01 GENERAL . 43
SPECIFICATION DRAWING 45
SPECIFICATIONS . 47
WEIGHT TABLE . 51
TABLE OF FUEL, COOLANT AND LUBRICANTS 53
10 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD 55
ENGINE AND COOLING SYSTEM 57
COOLING SYSTEM . 57
ENGINE CONTROL . 58
POWER TRAIN 59
POWER TRAIN 59
POWER TRAIN SYSTEM . 60
DAMPER . 61
HST HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAM 62
STEERING, BRAKE CONTROL 64
SOLENOID VALVE . 66
TOWING VALVE . 68
FINAL DRIVE 69
HST PUMP . 72
SAFETY-SUCTION VALVE . 80
CHARGE SAFETY VALVE 84
CHARGE PUMP 86
TOWING VALVE . 87
HST MOTOR 88
ELECTRIC LEVER (FOR STEERING) 100
UNDERCARRIAGE AND FRAME 103
FRAME ASSEMBLY .103
TRACK FRAME, RECOIL SPRING .104
IDLER 106
TRACK ROLLER .108
CARRIER ROLLER .110
SPROCKET .112
TRACK SHOE .114
HYDRAULIC SYSTEM .118
ARRANGEMENT OF HYDRAULIC EQUIPMENT FOR WORK EQUIPMENT 118
WORK EQUIPMENT CONTROL .120
HYDRAULIC TANK, FILTER .122
PPC LOCK VALVE .123
HYDRAULIC PUMP .124
HYDRAULIC CYLINDER .126
CONTROL VALVE 130
CLSS .138
PPC VALVE 148
WORK EQUIPMENT .160
WORK EQUIPMENT .160
CUTTING EDGE, END BIT 163
RPTO .164
CONTROL VALVE 168
3-POINT HITCH 170
CAB AND ITS ATTACHMENTS 172
AIR CONDITIONER PIPING .172
ELECTRICAL SYSTEM 174
ENGINE CONTROL .174
HST CONTROL SYSTEM .175
GEAR SHIFT CONTROL SYSTEM 176
PARKING BRAKE CONTROL SYSTEM .180
COMPONENT EQUIPMENT OF SYSTEM 182
MONITOR SYSTEM .186
MONITOR PANEL 188
SENSORS 192
20 STANDARD VALUE TABLE 197
STANDARD VALUE TABLE .199
STANDARD VALUE TABLE FOR ENGINE 199
STANDARD VALUE TABLE FOR CHASSIS .200
30 TESTING AND ADJUSTING .205
GENERAL INFORMATION ON TESTING AND ADJUSTING .207
LIST OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 207
SKETCH OF SPECIAL TOOL .210
ENGINE AND COOLING SYSTEM 211
MEASURING ENGINE SPEED .211
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) .212
MEASURING EXHAUST TEMPERATURE 214
MEASURING EXHAUST GAS COLOR 216
ADJUSTING VALVE CLEARANCE 217
MEASURING COMPRESSION PRESSURE .219
MEASURING BLOW-BY PRESSURE .220
MEASURING ENGINE OIL PRESSURE 221
TESTING AND ADJUSTING FUEL INJECTION TIMING 222
BLEEDING AIR FROM FUEL CIRCUIT .224
ADJUSTING ENGINE STOP SOLENOID LINKAGE .225
ADJUSTING ENGINE SPEED SENSOR 226
REPLACEMENT OF FAN BELT 226
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION (WITH CAB) .227
ADJUSTING FUEL CONTROL LEVER AND DECELERATOR PEDAL .228
POWER TRAIN 231
TESTING AND ADJUSTING HST OIL PRESSURE .231
MEASURING HST SOLENOID VALVE OUTLET PRESSURE .235
TESTING TRAVEL DEVIATION .237
ADJUSTING HST MOTOR SPEED SENSOR .238
ADJUSTING PARKING BRAKE LEVER 241
PROCEDURE OF SIMPLE TEST OF BRAKE PERFORMANCE 242
ADJUSTING BRAKE PEDAL LINKAGE 243
METHOD OF RELEASING PARKING BRAKE (PROCEDURE FOR EMERGENCY ESCAPE) .244
UNDERCARRIAGE AND FRAME 246
TESTING AND ADJUSTING IDLER CLEARANCE 246
TESTING AND ADJUSTING TRACK SHOE TENSION .247
HYDRAULIC SYSTEM .248
TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE 248
MEASURING WORK EQUIPMENT PPC VALVE OUTPUT PRESSURE .250
ADJUSTING PLAY OF WORK EQUIPMENT PPC VALVE .252
ADJUSTING WORK EQUIPMENT LOCK LEVER 253
MEASURING LEAKAGE IN WORK EQUIPMENT CYLINDER .254
RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT .255
BLEEDING AIR FROM HYDRAULIC CIRCUIT 256
ELECTRICAL SYSTEM 257
PROCEDURE FOR TESTING DIODES .257
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) 258
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM .299
PM-CLINIC 300
PM-CLINIC SERVICE 300
40 TROUBLESHOOTING .309
GENERAL INFORMATION ON TROUBLESHOOTING .314
POINTS TO REMEMBER WHEN TROUBLESHOOTING 314
SEQUENCE OF EVENTS IN TROUBLESHOOTING 315
HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT .316
CHECKS BEFORE TROUBLESHOOTING 325
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING .326
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM 329
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS .342
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 378
TROUBLESHOOTING WHEN ERROR CODE IS DISPLAYED .381
ERROR CODES TABLE 381
INFORMATION IN TROUBLESHOOTING TABLE .384
ERROR CODE [6091NX] (HST CHARGE FILTER ELEMENT: CLOGGING) 386
ERROR CODE [AB00MA] (ALTERNATOR: MALFUNCTION) 387
ERROR CODE [B@BAZG] (ENGINE OIL: LOWERING OF OIL PRESSURE) .388
ERROR CODE [B@BCNS] (COOLANT: OVERHEATING) .389
ERROR CODE [B@CRNS] (HST OIL: OVERHEATING) .390
ERROR CODE [B@CRZG] (HST OIL: LOWERING OF OIL PRESSURE) 391
ERROR CODE [D110KB] (BATTERY RELAY: SHORT CIRCUIT) .392
ERROR CODE [D130KA] (SAFETY RELAY: DISCONNECTION) 394
ERROR CODE [D130KB] (SAFETY RELAY: SHORT CIRCUIT) 396
ERROR CODE [DAFRKR] (MONITOR CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM)) 398
ERROR CODE [DAJ0KK] (HST CONTROLLER: LOWERING OF SOURCE VOLTAGE (INPUT)) .400
ERROR CODE [DAJ0KT] (HST CONTROLLER: INTERNAL DEFECT OF CONTROLLER) 402
ERROR CODE [DAJ5KK] (HST CONTROLLER SENSOR POWER SUPPLY OUTPUT: LOWERING OF SOURCE VOLTAGE (INPUT)) 404
ERROR CODE [DD12KA] (SHIFT-UP SWITCH: DISCONNECTION) .408
ERROR CODE [DD12KB] (SHIFT-UP SWITCH: SHORT CIRCUIT) .410
ERROR CODE [DD13KA] (SHIFT-DOWN SWITCH: DISCONNECTION) .412
ERROR CODE [DD13KB] (SHIFT-DOWN SWITCH: SHORT CIRCUIT) .414
ERROR CODE [DD14KB] (TRAVEL LOCK SW1: SHORT CIRCUIT) .416
ERROR CODE [DDDCKB] (REVERSE TRAVEL SPEED SWITCH: SHORT CIRCUIT) .418
ERROR CODE [DDP6KB] (BRAKE PRESSURE SWITCH: SHORT CIRCUIT) .420
ERROR CODE [DDQ2KA] (TRAVEL LOCK SW1: DISCONNECTION) .422
ERROR CODE [DDU1FS] (PARKING BRAKE ON-OFF SWITCH: STICK) .424
ERROR CODE [DDU1KA] (PARKING BRAKE ON-OFF SWITCH: DISCONNECTION) .426
ERROR CODE [DDU1KB] (PARKING BRAKE ON-OFF SWITCH: SHORT CIRCUIT) .428
ERROR CODE [DDU1KY] (PARKING BRAKE ON-OFF SWITCH: SHORT CIRCUIT WITH POWER SUPPLY LINE) 430
ERROR CODE [DDU1L4] (PARKING BRAKE ON-OFF SWITCH: DISAGREEMENT OF ON AND OFF SIGNALS) 432
ERROR CODE [DGS1KX] (HYDRAULIC TANK OIL TEMPERATURE SENSOR: OUT OF INPUT SIGNAL RANGE) .434
ERROR CODE [DHH5KA] (LH PUMP PRESSURE SENSOR: DISCONNECTION) .436
ERROR CODE [DHH5KB] (LH PUMP PRESSURE SENSOR: SHORT CIRCUIT) .438
ERROR CODE [DHH6KA] (RH PUMP PRESSURE SENSOR: DISCONNECTION) .440
ERROR CODE [DHH6KB] (RH PUMP PRESSURE SENSOR: SHORT CIRCUIT) .442
ERROR CODE [DK10KA] (THROTTLE ANGLE SENSOR: DISCONNECTION) .444
ERROR CODE [DK10KB] (THROTTLE ANGLE SENSOR: SHORT CIRCUIT) .446
ERROR CODE [DK12KA] (DECELERATION SENSOR: DISCONNECTION) .448
ERROR CODE [DK12KB] (DECELERATION SENSOR: SHORT CIRCUIT) .450
ERROR CODE [DK30KA] (STEERING ANGLE SENSOR: DISCONNECTION) .452
ERROR CODE [DK30KB] (STEERING ANGLE SENSOR: SHORT CIRCUIT) .454
ERROR CODE [DK30KX] (STEERING ANGLE SENSOR: OUT OF INPUT SIGNAL RANGE) .456
ERROR CODE [DK30KZ] (STEERING ANGLE SENSOR: DISCONNECTION OR SHORT CIRCUIT) 457
ERROR CODE [DK30L8] (STEERING ANGLE SENSOR: DISAGREEMENT OF ANALOG SIGNALS) 458
ERROR CODE [DK31KA] (STEERING ANGLE SENSOR 2: DISCONNECTION) .460
ERROR CODE [DK31KB] (STEERING ANGLE SENSOR 2: SHORT CIRCUIT) .462
ERROR CODE [DK40KA] (BRAKE ANGLE SENSOR: DISCONNECTION) 464
ERROR CODE [DK40KB] (BRAKE ANGLE SENSOR: SHORT CIRCUIT) 466
ERROR CODE [DK55KX] (DIRECTIONAL POTENTIOMETER: OUT OF INPUT SIGNAL RANGE) .468
ERROR CODE [DK55KZ] (DIRECTIONAL POTENTIOMETER: DISCONNECTION OR SHORT CIRCUIT) 469
ERROR CODE [DK55L8] (DIRECTIONAL POTENTIOMETER: DISAGREEMENT OF ANALOG SIGNALS) 470
ERROR CODE [DK56KA] (DIRECTIONAL POTENTIOMETER 1: DISCONNECTION) .472
ERROR CODE [DK56KB] (DIRECTIONAL POTENTIOMETER 1: SHORT CIRCUIT) .474
ERROR CODE [DK57KA] (DIRECTIONAL POTENTIOMETER 2: DISCONNECTION) .476
ERROR CODE [DK57KB] (DIRECTIONAL POTENTIOMETER 2: SHORT CIRCUIT) .478
ERROR CODE [DLE2KA] (ENGINE SPEED SENSOR: DISCONNECTION) .480
ERROR CODE [DLE2KB] (ENGINE SPEED SENSOR: SHORT CIRCUIT) .482
ERROR CODE [DLM0KX] (MOTOR SPEED SENSOR: OUT OF INPUT SIGNAL RANGE) 484
ERROR CODE [DLM1KA] (LEFT HST MOTOR SPEED SENSOR: DISCONNECTION) .486
ERROR CODE [DLM1KB] (LEFT HST MOTOR SPEED SENSOR: SHORT CIRCUIT) .488
ERROR CODE [DLM1MA] (LEFT HST MOTOR SPEED SENSOR: MALFUNCTION) .490
ERROR CODE [DLM2KA] (RIGHT HST MOTOR SPEED SENSOR: DISCONNECTION) 492
ERROR CODE [DLM2KB] (RIGHT HST MOTOR SPEED SENSOR: SHORT CIRCUIT) 494
ERROR CODE [DLM2MA] (RIGHT HST MOTOR SPEED SENSOR: MALFUNCTION) 496
ERROR CODE [DN21FS] (CENTER BRAKE LIMIT SWITCH: FIXING) 498
ERROR CODE [DV00KB] (BUZZER: SHORT CIRCUIT) 500
ERROR CODE [DV20KB] (BACKUP ALARM BUZZER: SHORT CIRCUIT) .502
ERROR CODE [DW28KA] (2ND GEAR SPEED SOLENOID VALVE: DISCONNECTION) .504
ERROR CODE [DW28KB] (2ND GEAR SPEED SOLENOID VALVE: SHORT CIRCUIT) .506
ERROR CODE [DW29KA] (3RD GEAR SPEED SOLENOID VALVE: DISCONNECTION) .508
ERROR CODE [DW29KB] (3RD GEAR SPEED SOLENOID VALVE: SHORT CIRCUIT) .510
ERROR CODE [DW4BKA] (PARKING BRAKE SOLENOID VALVE: DISCONNECTION) 512
ERROR CODE [DW4BKB] (PARKING BRAKE SOLENOID VALVE: SHORT CIRCUIT) 514
ERROR CODE [DW7EKA] (SLOW BRAKE SOLENOID VALVE: DISCONNECTION) .516
ERROR CODE [DW7EKB] (SLOW BRAKE SOLENOID VALVE: SHORT CIRCUIT) .518
ERROR CODE [DXA4KA] (LH PUMP F-EPC SOLENOID VALVE: DISCONNECTION) 520
ERROR CODE [DXA4KB] (LH PUMP F-EPC SOLENOID VALVE: SHORT CIRCUIT) 522
ERROR CODE [DXA5KA] (LH PUMP R-EPC SOLENOID VALVE: DISCONNECTION) 524
ERROR CODE [DXA5KB] (LH PUMP R-EPC SOLENOID VALVE: SHORT CIRCUIT) 526
ERROR CODE [DXA6KA] (RH PUMP F-EPC SOLENOID VALVE: DISCONNECTION) 528
ERROR CODE [DXA6KB] (RH PUMP F-EPC SOLENOID VALVE: SHORT CIRCUIT) 530
ERROR CODE [DXA7KA] (RH PUMP R-EPC SOLENOID VALVE: DISCONNECTION) 532
ERROR CODE [DXA7KB] (RH PUMP R-EPC SOLENOID VALVE: SHORT CIRCUIT) 534
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 536
BEFORE CARRYING OUT TROUBLESHOOTING FOR ELECTRICAL SYSTEM (E-MODE) .536
INFORMATION IN TROUBLESHOOTING TABLE .538
E-1 ENGINE DOES NOT START 539
E-2 ENGINE IS NOT PREHEATED 544
E-3 ENGINE DOES NOT STOP .546
E-4 WHEN STARTING SWITCH IS TURNED ON, ANY ITEM DOES NOT LIGHT UP 548
E-5 WHEN STARTING SWITCH IS TURNED ON, ALL ITEMS LIGHT UP AND NONE OF THEM GOES OFF 550
E-6 CHARGE LEVEL CAUTION FLASHES WHILE ENGINE IS RUNNING .550
E-7 EMERGENCY WARNING ITEMS FLASH WHILE ENGINE IS RUNNING 552
E-8 PREHEATING PILOT LAMP DOES NOT LIGHT UP DURING PREHEATING OPERATION 558
E-9 ENGINE COOLANT THERMOMETER IS ABNORMAL .560
E-10 HST OIL THERMOMETER IS ABNORMAL .562
E-11 FUEL LEVEL GAUGE IS ABNORMAL 564
E-12 REVERSE TRAVEL SPEED INDICATOR IS ABNORMAL 566
E-13 GEAR SPEED, SET TRAVEL SPEED, AND SHIFT MODE INDICATOR IS ABNORMAL 566
E-14 MULTI-INFORMATION SECTION IS ABNORMAL .566
E-15 CAUTION LAMP DOES NOT FLASH OR DOES NOT GO OFF 566
E-16 CAUTION BUZZER DOES NOT SOUND OR DOES NOT STOP 567
E-17 REVERSE TRAVEL SPEED SETTING SWITCH DOES NOT FUNCTION .568
E-18 SHIFT MODE SWITCH DOES NOT FUNCTION .570
E-19 BUZZER CANCEL SWITCH DOES NOT FUNCTION 572
E-20 INFORMATION SWITCH DOES NOT FUNCTION 574
E-21 SYSTEM IS NOT SET IN SERVICE MODE OR IS NOT SET OUT OF SERVICE MODE .576
E-22 BACKUP ALARM DOES NOT SOUND .578
E-23 HEADLAMP OR REAR LAMP DOES NOT LIGHT UP .580
E-24 CANOPY HEATER DOES NOT OPERATE [CANOPY SPECIFICATION] .582
E-25 AIR CONDITIONER DOES NOT OPERATE [CAB SPECIFICATION] 584
E-26 WINDSHIELD WIPER AND WINDSHIELD WASHER DO NOT OPERATE [CAB SPECIFICATION] .589
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) 595
INFORMATION IN TROUBLESHOOTING TABLE .595
H-1 RIGHT AND LEFT TRAVEL SYSTEMS DO NOT OPERATE FORWARD AND IN REVERSE (NO TRAVEL SYSTEMS OPERATE) 596
H-2 RIGHT OR LEFT TRAVEL SYSTEM DOES NOT OPERATE FORWARD AND IN REVERSE (ONLY RIGHT OR LEFT TRAVEL SYSTEM DOES NOT OPERATE) 597
H-3 RIGHT OR LEFT TRAVEL SYSTEM DOES NOT OPERATE FORWARD OR IN REVERSE (ONLY 1 SYSTEM DOES NOT OPERATE) 597
H-4 SPEED OR POWER OF TRAVEL IS LOW 598
H-5 GEAR IS NOT SHIFTED 599
H-6 LARGE SHOCK IS MADE WHEN MACHINE STOPS TRAVELING .600
H-7 MACHINE DEVIATES LARGELY DURING TRAVEL .600
H-8 HYDRAULIC DRIFT OF TRAVEL IS LARGER 601
H-9 ENGINE STALLS OR ENGINE SPEED LOWERS EXTREMELY DURING TRAVEL .601
H-10 ABNORMAL SOUND COMES OUT FROM AROUND HST PUMP AND MOTOR .602
H-11 WORK EQUIPMENT DOSE NOT OPERATE AT ALL 603
H-12 SPEED OR POWER OF WHOLE WORK EQUIPMENT IS LOW .604
H-13 SPEED OR POWER OF LIFTING BLADE IS LOW 605
H-14 SPEED OR POWER OF TILTING BLADE IS LOW 605
H-15 SPEED OR POWER OF ANGLING BLADE IS LOW 606
H-16 TIME LAG IN LIFTING BLADE IS LARGE 607
H-17 HYDRAULIC DRIFT OF LIFTING BLADE IS LARGE .607
H-18 HYDRAULIC DRIFT OF TILTING BLADE IS LARGE .607
H-19 ABNORMAL SOUND COMES OUT FROM AROUND WORK EQUIPMENT PUMP AND CONTROL VALVE 608
H-20 HST OIL TEMPERATURE (HYDRAULIC OIL TEMPERATURE) RISES TOO HIGH 609
TROUBLESHOOTING OF ENGINE (S MODE) .610
METHOD OF USING TROUBLESHOOTING CHARTS .610
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 614
S-2 ENGINE DOES NOT START 615
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) .618
S-4 ENGINE STOPS DURING OPERATIONS .619
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 620
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER) .621
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) .622
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) 623
S-9 OIL BECOMES CONTAMINATED QUICKLY .624
S-10 FUEL CONSUMPTION IS EXCESSIVE .625
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN .626
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) 627
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL) 628
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 629
S-15 ABNORMAL NOISE IS MADE 630
S-16 VIBRATION IS EXCESSIVE 631
50 DISASSEMBLY AND ASSEMBLY 633
GENERAL INFORMATION ON DISASSEMBLY AND ASSEMBLY 635
HOW TO READ THIS MANUAL 635
COATING MATERIALS LIST .637
SPECIAL TOOL LIST 640
SKETCHES OF SPECIAL TOOLS 642
ENGINE AND COOLING SYSTEM 643
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY .643
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY .647
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL 654
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL .657
REMOVAL AND INSTALLATION OF RADIATOR GUARD ASSEMBLY 659
DISASSEMBLY AND ASSEMBLY OF RADIATOR, OIL COOLER, AND CHARGE AIR COOLER ASSEMBLIES .662
POWER TRAIN 666
REMOVAL AND INSTALLATION OF ENGINE AND HST PUMP ASSEMBLY .666
REMOVAL AND INSTALLATION OF DAMPER .669
UNDERCARRIAGE AND FRAME 670
SPREADING AND INSTALLATION OF TRACK SHOE ASSEMBLY 670
REMOVAL AND INSTALLATION OF HST MOTOR AND FINAL DRIVE ASSEMBLY .672
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY .674
REMOVAL AND INSTALLATION OF IDLER AND RECOIL SPRING ASSEMBLY .683
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY .684
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY .687
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY 690
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY 694
HYDRAULIC SYSTEM .696
REMOVAL AND INSTALLATION OF HST PUMP ASSEMBLY 696
REMOVAL AND INSTALLATION OF MAIN CONTROL VALVE ASSEMBLY 698
DISASSEMBLY AND ASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY 700
REMOVAL AND INSTALLATION OF BLADE ASSEMBLY .708
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLIES 710
OTHERS .713
REMOVAL AND INSTALLATION OF OPERATOR’S SEAT FRAME ASSEMBLY .713
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY .717
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY 718
REMOVAL AND INSTALLATION OF HST CONTROLLER ASSEMBLY 720
90 CIRCUIT DIAGRAMS 721
HYDRAULIC CIRCUIT DIAGRAM 723
RPTO HYDRAULIC CIRCUIT DIAGRAM .723
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM .725
ELECTRICAL CIRCUIT DIAGRAM .729
ELECTRICAL CIRCUIT DIAGRAM .729
INDEX 737

DESCRIPTION:

Komatsu Bulldozer D31PLL-21 Shop Manual SEN06775-01 PDF – DOWNLOAD

• SERIAL NUMBERS 55226 and up

1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop. For
ease of understanding, the manual is divided into the following sections.
00. FOREWORD
This section explains the safety and basic information.
01. GENERAL
This section explains the specifications of the machine.
10. STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly
and service.
20. TESTING AND ADJUSTING
Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting,
and troubleshooting. This standard value table is used to check the standard values in testing and
adjusting and to judge parts in troubleshooting.
Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided
by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in
the Chassis volume and Engine volume. In this case, see the Chassis volume.
30. DISASSEMBLY AND ASSEMBLY
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and quantity
and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. OTHERS
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
2. Revision and distribution
Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most upto-
date information before you start any work.

G.B 25/12/24