Komatsu Crawler Bulldozer D31EX-21, D31PX-21, D37EX-21, D37PX Shop Manual PDF

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Komatsu Crawler Bulldozer D31EX-21, D31PX-21, D37EX-21, D37PX Shop Manual-PDF DOWNLOAD 

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Komatsu Crawler Bulldozer D31EX-21, D31PX-21, D37EX-21, D37PX Shop Manual-PDF DOWNLOAD 

Language : English
Pages :465
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu Crawler Bulldozer D31EX-21, D31PX-21, D37EX-21, D37PX Shop Manual-PDF DOWNLOAD 

MACHINE MODEL                SERIAL No.
D31EX-21                                50001 and up
D31PX-21                                 50001 and up
D37EX-21                                  5001 and up
D37PX-21                                5001 and up

General

precautions k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine.

TABLE OF CONTENTS:

Komatsu Crawler Bulldozer D31EX-21, D31PX-21, D37EX-21, D37PX Shop Manual-PDF DOWNLOAD 

MACHINE MODEL                SERIAL No.
D31EX-21                                50001 and up
D31PX-21                                 50001 and up
D37EX-21                                  5001 and up
D37PX-21                                5001 and up

COVER 1
CONTENTS 2
01 GENERAL 35
SPECIFICATION DRAWING 36
SPECIFICATIONS 38
WEIGHT TABLE 46
TABLE OF FUEL, COOLANT AND LUBRICANTS 48
10 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD 49
COOLING SYSTEM 50
ENGINE CONTROL 51
POWER TRAIN 52
POWER TRAIN SYSTEM 53
HST HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAM 54
STEERING, BRAKE CONTROL 55
DAMPER 59
SOLENOID VALVE 60
FINAL DRIVE 62
HST PUMP 65
SAFETY-SUCTION VALVE 70
CUT-OFF VALVE 73
CHARGE SAFETY VALVE 74
CHARGE PUMP 76
HST BRAKE QUICK RETURN CIRCUIT 77
TOWING VALVE 78
PARKING BRAKE VALVE 79
AS VALVE 81
HST MOTOR 83
STEERING, DIRECTIONAL PPC VALVE 94
AUTOMATIC GEARSHIFTING VALVE103
INCHING VALVE108
FRAME ASSEMBLY109
TRACK FRAME, RECOIL SPRING110
IDLER112
TRACK ROLLER114
CARRIER ROLLER116
SPROCKET117
TRACK SHOE119
ARRANGEMENT OF HYDRAULIC EQUIPMENT FOR WORK EQUIPMENT123
WORK EQUIPMENT CONTROL124
HYDRAULIC TANK, FILTER126
HYDRAULIC PUMP127
WORK EQUIPMENT CYLINDER128
CONTROL VALVE130
CLSS138
WORK EQUIPMENT PPC VALVE148
WORK EQUIPMENT 155
CUTTING EDGE, END BIT158
CAB RELATED159
SAFETY MECHANISM WHEN STARTING ENGINE160
GEARSHIFT CONTROL SYSTEM161
PARKING BRAKE CONTROL SYSTEM162
COMPONENT EQUIPMENT OF SYSTEM163
MONITOR SYSTEM165
SENSORS169
20 TESTING AND ADJUSTING172
STANDARD VALUE TABLE FOR ENGINE173
STANDARD VALUE TABLE FOR CHASSIS175
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM180
TESTING AND ADJUSTING182
TOOLS LIST FOR TESTING AND ADJUSTING183
MEASURING ENGINE SPEED186
MEASURING EXHAUST COLOR187
MEASURING BLOW-BY PRESSURE188
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)189
ADJUSTING VALVE CLEARANCE190
TESTING ADJUSTING FUEL INJECTION TIMING192
MEASURING COMPRESSION PRESSURE193
ADJUSTING ENGINE STOP SOLENOIDE LINKAGE194
MEASURING ENGINE OIL PRESSURE195
BLEEDING AIR FROM FUEL CIRCUIT196
REPLACEMENT OF FAN BELT197
TESTING AND ADJUSTING TENSION OF AIR CONDITIONER COMPRESSOR BELT199
MEASURING AND ADJUSTING HST OIL PRESSURE200
MEASURING SOLENOID VALVE OUTPUT PRESSURE206
MEASURING AND ADJUSTING WORK EQUIPMENT MAIN RELIEF PRESSURE207
MEASURING PPC VALVE OUTPUT PRESSURE209
MEASURING LEAKAGE INSIED CYLINDER210
BLEEDING AIR FROM HYDRAULIC CYLINDERS210
TESTING AND ADJUSTING TRACK SHOE TENSION211
TESTING AND ADJUSTING TRAVEL DEVIATION212
ADJUSTING FUEL CONTROL LINKAGE215
ADJUSTING DECELERATOR PEDAL LINKAGE217
ADJUSTING BRAKE PEDAL LINKAGE218
ADJUSTING STEERING/DIRECTIONAL/GEAR SHIFT LEVER AND LOCK LEVER219
ADJUSTING BLADE CONTROL LEVER AND LOCK LEVER222
ADJUSTING WORK EQUIPMENT PPC VALVE223
PROCEDURE FOR RELEASING PARKING BRAKE224
PROCEDURE FOR INSPECTING DIODE226
TROUBLESHOOTING227
POINTS TO REMEMBER WHEN TROUBLESHOOTING228
SEQUENCE OF EVENTS IN TROUBLESHOOTING229
HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT230
CHECKS BEFORE TROUBLESHOOTING240
METHOD OF USING TROUBLESHOOTING CHARTS241
TYPES AND LOCATIONS OF CONNECTORS242
CONNECTOR ARRANGEMENT DIAGRAM244
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS246
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE282
TROUBLESHOOTING FOR ELECTRICAL SYSTEM (E-MODE)285
TABLE OF FAILURE MODES AND CAUSES (ELECTRICAL SYSTEM)286
ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM288
E-1 WHEN STARTING SWITCH IS TURNED ON, STARTING MOTOR DOES NOT ROTATE290
E-2 ENGINE DOES NOT START (ENGINE STOP SOLENOID DOES NOT OPERATE NORMALLY)292
E-3 HEADLAMP DOES NOT LIGHT UP293
E-4 WHEN STARTING SWITCH IS TURNED TO HEAT POSITION, ENGINE IS NOT HEATED295
E-5 WINDSHIELD WIPER DOES NOT OPERATE296
E-6 WASHING WATER DOES NOT SPOUT298
E-7 AIR CONDITIONER DOES NOT WORK300
a) AIR DOES NOT BLOW OUT300
b) AIR IS NOT COOLED303
E-8 PARKING BRAKE CANNOT BE RELEASED (PARKING BRAKE SOLENOID DOES NOT OPERATE)307
E-9 TRAVEL SPEED CONTROL IS ABNORMAL308
a) WHEN GEAR SHIFT SWITCH IS PRESSED,GEAR SPEED DOES NOT CHANGE OR GEAR SPEED CHANGES BY ITSELF (GEAR SHIFT SWITCH OR CONTROLLER IS ABNORMAL)308
b) GEAR SPEED CANNOT BE SELECTED NORMALLY (TRAVEL SPEED CHANGEOVER SOLENOID IS ABNORMAL)309
E-10 BACKUP ALARM DOES NOT SOUND DURING REVERSE TRAVEL311
E-11 HORN DOES NOT SOUND313
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)314
TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC AND MECHANICAL SYSTEMS)315
H-1 MACHINE DOES NOT TRAVEL IN EITHER DIRECTION OR IT STOPS SUDDENLY317
H-2 MACHINE DOES NOT TRAVEL IN ONE DIRECTION318
H-3 MACHINE TRAVELS WHILE TRAVEL LEVER IS IN NEUTRAL318
H-5 MACHINE DEVIATES WHILE TRAVEL LEVER IS IN PARTIAL POSITION318
H-7 MACHINE SWHINGS MOMENTARILY WHEN IT STARTS ON FLAT GROUND318
H-11 TURNING TIME LAG IS LARGE318
H-12 WHEN OPERATOR INTENDS TO TURN GARDUALLY, MACHINE TURNS SHARPLY318
H-13 MACHINE DOES NOT RETURN QUICKLY TO STRAIGHT TRAVEL POSITION318
H-14 MACHINE IS NOT DECELERATED SMOOTHLY OR TRAVEL SPEED CANNOT BE CONTROLLED ON DOWNHILL GROUND318
H-15 MACHINE DEVIATES WHEN IT IS DECELERATED318
H-4 MACHINE DEVIATES WHEN TRAVEL LEVER IS MOVED TO STROKE END319
H-6 MACHINE MOVES BACK WHEN OPERATOR STARTS ON UPHILL GROUND319
H-8 MACHINE STARTS SHARPLY319
H-9 MACHINE SWINGS MOMENTARLLY WHEN IT STARTS320
H-10 STARTING TIME LAG IS LARGE321
H-16 MAXIMUM TRAVEL SPEED IS LOW OR OUTPUT POWER IS INSUFFICIENT OR ACCELERATION IS LOW322
H-17 ENGINE STALLS323
H-18 HST NOISE IS LARGE324
H-19 HST OIL TEMPERATURE RISES TOO HIGH325
H-20 GEAR SPEED DOES NOT CHANGE325
H-21 ABNORMAL SOUND IS HEARD FROM AROUND WORK EQUIPMENT PUMP OR HST PUMP326
H-22 ANY WORK EQUIPMENT DOES NOT MOVE326
H-23 SPEED OR POWER OF EACH WORK EQUIPMENT IS LOW327
H-24 SPEED OR POWER OF BLADE LIFT OF BLADE TILT CYLINDER IS LOW327
H-25 SPEED OR POWER OF BLADE ANGLE CYLINDER IS LOW328
H-26 HYDRAULIC DRIFT OF BLADE LIFT CYLINDER IS LARGE329
H-27 HYDRAULIC DRIFT OF BLADE TILT CYLINDER IS LARGE329
H-28 HYDRAULIC DRIFT OF BLADE ANGLE CYLINDER IS LARGE330
TROUBLESHOOTING FOR MACHINE MONITOR SYSTEM (M-MODE)331
TABLE OF FAILURE MODES AND CAUSES (MACHINE MONITOR SYSTEM)332
ELECTRIC CIRCUIT DIAGRAM FOR EACH SYSTEM333
M-1 WHEN STARTING SWITCH IS TURNED ON , MONITOR PANEL IS NOT TURNED ON335
M-2 TROUBLE IN PREHEATING CAUTION LAMP336
a) PREHEATING MONITOR DOES NOT LIGHT UP336
b) PREHEATING MONITOR KEEPS LIGHTING UP336
M-3 CAUTION ITEM LIGHTS UP337
a) CHARGE CAUTION LAMP LIGHTS UP WHILE ENGINE IS RUNNING337
b) OIL PRESSURE CAUTION LAMP LIGHTS UP WHILE ENGINE IS RUNNING338
c) HST FILTER CLOGGING CAUTION LAMP LIGHTS UP (WHILE FILTER IS NOT CLOGGED)338
M-4 TROUBLE IN HST OIL TEMPERATURE GAUGE339
a) GAUGE DOES NOT RISE ABOVE C (LOWEST POINT)339
b) GAUGE DOES NOT LOWER BELOW H (HIGHEST POINT)339
c) HST OIL TEMPERATURE INDICATED BY GAUGE IS DIFFERENT FROM ACTUAL TEMPERATURE340
M-5 TROUBLE IN ENGINE WATER TEMPERATURE GAUGE341
a) GAUGE DOES NOT RISE ABOVE C (LOWEST POINT)341
b) GAUGE DOES NOT LOWER BELOW H (HIGHEST POINT)341
c) ENGINE WATER TEMPERATURE INDICATED BY GAUGE IS DIFFERENT FROM ACTUAL TEMPERATURE342
M-6 TROUBLE IN FUEL LEVEL GAUGE343
a) GAUGE DOES NOT RISE ABOVE E (LOWEST POINT)343
b) GAUGE DOES NOT LOWER BELOW F (HIGHEST POINT)343
c) FUEL LEVEL INDICATED BY GAUGE IS DIFFERENT FROM ACTUAL LEVEL344
M-7 SERVICE METER DOES NOT OPERATE AFTER ENGINE IS STARTED345
M-8 MONITOR PANEL LAMP DOES NOT LIGHT UP (WHILE HEADLAMP IS NORMAL)346
M-9 TROUBLE IN DISPLAY OF TRAVEL SPEED (WHILE ACTUAL TRAVEL SPEED IS NORMAL)347
a) TRAVEL SPEED IS NOT DISPLAYED347
b) DISPLAYED SPEED IS DIFFERENT FROM ACTUAL TRAVEL SPEED347
TROUBLESHOOTING FOR ENGINE SYSTEM (S-MODE)349
METHOD OF USING TROUBLESHOOTING CHARTS350
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 354
S-2 ENGINE DOES NOT START355
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)358
S-4 ENGINE STOPS DURING OPERATIONS359
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)360
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)361
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)362
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)363
S-9 OIL BECOMES CONTAMINATED QUICKLY364
S-10 FUEL CONSUMPTION IS EXCESSIVE365
S-11 OIL IS IN COOLANT, OR COOLANT SPURTS BACK, OR COOLANT LEVEL GOES DOWN366
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)367
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)368
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)369
S-15 ABNORMAL NOISE IS MADE370
S-16 VIBRATION IS EXCESSIVE371
30 DISASSEMBLY AND ASSEMBLY373
HOW TO READ THIS MANUAL374
COATING MATERIALS LIST376
SPECIAL TOOL LIST379
SKETCHES OF SPECIAL TOOLS381
REMOVAL OF FUEL INJECTION PUMP ASSEMBLY382
INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY384
REMOVAL OF CYLINDER HEAD ASSEMBLY386
INSTALLATION OF CYLINDER HEAD ASSEMBLY391
REMOVAL OF ENGINE FRONT SEAL393
INSTALLATION OF ENGINE FRONT SEAL394
REMOVAL OF ENGINE REAR SEAL395
INSTALLATION OF ENGINE REAR SEAL396
REMOVAL OF RADIATOR GUARD ASSEMBLY397
INSTALLATION OF RADIATOR GUARD ASSEMBLY399
DISASSEMBLY OF RADIATOR, OIL COOLER, AND CHARGE AIR COOLER ASSEMBLIES400
ASSEMBLY OF RADIATOR, OIL COOLER, AND CHARGE AIR COOLER ASSEMBLIES402
REMOVAL OF ENGINE ASSEMBLY404
INSTALLATION OF ENGINE ASSEMBLY406
REMOVAL OF DAMPER407
INSTALLATION OF DAMPER407
REMOVAL OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY408
INSTALLATION OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY409
DISASSEMBLY OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY410
ASSEMBLY OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY414
REMOVAL OF IDLER AND RECOIL SPRING ASSEMBLY419
INSTALLATION OF IDLER AND RECOIL SPRING ASSEMBLY419
DISASSEMBLY OF RECOIL SPRING ASSEMBLY420
ASSEMBLY OF RECOIL SPRING ASSEMBLY421
DISASSEMBLY OF IDLER ASSEMBLY423
ASSEMBLY OF IDLER ASSEMBLY424
DISASSEMBLY OF TRACK ROLLER ASSEMBLY426
ASSEMBLY OF TRACK ROLLER ASSEMBLY427
DISASSEMBLY OF CARRIER ROLLER ASSEMBLY430
ASSEMBLY OF CARRIER ROLLER ASSEMBLY431
SPREADING TRACK SHOE ASSEMBLY432
INSTALLATION OF TRACK SHOE ASSEMBLY433
REMOVAL OF HST PUMP ASSEMBLY434
INSTALLATION OF HST PUMP ASSEMBLY435
REMOVAL OF MAIN CONTROL VALVE ASSEMBLY436
INSTALLATION OF MAIN CONTROL VALVE ASSEMBLY437
DISASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY438
ASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY442
DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLIES446
ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLIES447
REMOVAL OF BLADE ASSEMBLY449
INSTALLATION OF BLADE ASSEMBLY450
REMOVAL OF OPERATOR’S SEAT TRAME ASSEMBLY451
INSTALLATION OF OPERATOR’S SEAT FRAME ASSEMBLY454
REMOVAL OF FUEL TANK ASSEMBLY455
INSTALLATION OF FUEL TANK ASSEMBLY455
REMOVAL OF HYDRAULIC TANK ASSEMBLY456
INSTALLATION OF HYDRAULIC TANK ASSEMBLY457
90 OTHERS458
HYDRAULIC CIRCUIT DIAGRAM (1/2)(D31EX-21 SERIAL NO50001-50097 D31PX-21 SERIAL NO50001-50181 D37EX-21 SERIAL NO 5001-5104 D37PX-21 SERIAL NO 5001-5090)459
HYDRAULIC CIRCUIT DIAGRAM (1/2)(D31EX-21 SERIAL NO50098 AND UP D31PX-21 SERIAL NO50182 AND UP D37EX-21 SERIAL NO5105 AND UP D37PX-21 SERIAL NO5091 AND UP)460
HYDRAULIC CIRCUIT DIAGRAM (2/2)461
HYDRAULIC CIRCUIT DIAGRAM (2/2) (FOR D37EX, PX-21 EU SPEC)462
ELECTRICAL CIRCUIT DIAGRAM (1/2)463
ELECTRICAL CIRCUIT DIAGRAM (2/2)464
ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER465

IMAGES PREVIEW OF THE MANUAL:

S.M 15/12/24