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Komatsu D31E-18, D31P-18, D31PL-18, D31S-18, D31Q-18, D37E-2, D37P-2 Dozer Shop Manual – PDF DOWNLOAD
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Komatsu D31E-18, D31P-18, D31PL-18, D31S-18, D31Q-18, D37E-2, D37P-2 Dozer Shop Manual
Book Code: SEBM01141805
MACHINE MODEL SERIAL No.
D31E-18 40001 and up
D31P-18 40001 and up
D31 P-18A 40001 and up
D31 PL-1 8 40001 and up
D31PLL-18 40001 and up
D31S-18 40001 and up
D31Q-18 40001 and up
D37E-2 1501 and up
D37P-2 1501 and up
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Description
Komatsu D31E-18, D31P-18, D31PL-18, D31S-18, D31Q-18, D37E-2, D37P-2 Dozer Shop Manual
FILE DETAILS:
Komatsu D31E-18, D31P-18, D31PL-18, D31S-18, D31Q-18, D37E-2, D37P-2 Dozer Shop Manual
Brands: Komatsu
Equipment Type: Crawler Bulldozer
Manuals Type: Shop Manual
Machine Model: D31E-18, D31P-18, D31P-18A, D31PL-18, D31PLL-18, D31S-18, D31Q-18, D37E-2, D37P-2
Serial Number: 40001 and up, 1501 and up
Book Code: SEBM01141805
Language: English
Pages: 371
File Format: Portable Document Format (PDF)
KOMATSU D31E-18, D31P-18, D31PL-18, D31S-18, D31Q-18, D37E-2, D37P-2 DOZER SHOP MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu D31E-18, D31P-18, D31PL-18, D31S-18, D31Q-18, D37E-2, D37P-2 Dozer Shop Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION:
This 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.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in thissection.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD :
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu D31E-18, D31P-18, D31PL-18, D31S-18, D31Q-18, D37E-2, D37P-2 Dozer Shop Manual
COVER........................................................................................................................................... 1 CONTENTS........................................................................................................................................ 2 10 ENGINE....................................................................................................................................... 21 12 TESTING AND ADJUSTING.................................................................................................................... 21 TESTING AND ADJUSTING DATA.............................................................................................................. 22 TOOL LIST FOR TESTING AND ADJUSTING..................................................................................................... 24 ADJUSTING VALVE CLEARANCE............................................................................................................... 25 MEASURING EXHAUST GAS COLOR............................................................................................................. 26 MEASURING COMPRESSION PRESSURE.......................................................................................................... 27 MEASURING BLOW-BY PRESSURE.............................................................................................................. 28 ADJUSTING FUEL INJECTION TIMING......................................................................................................... 29 TESTING AND ADJUSTING FAN BELT TENSION.................................................................................................. 30 BLEEDING AIR FROM FUEL CIRCUIT.......................................................................................................... 30 ADJUSTING FUEL CONTROL LEVER............................................................................................................ 31 13 DISASSEMBLY AND ASSEMBLY................................................................................................................. 32 STARTING MOTOR.......................................................................................................................... 33 REMOVAL AND INSTALLATION............................................................................................................ 33 ALTERNATOR.............................................................................................................................. 33 REMOVAL AND INSTALLATION............................................................................................................ 33 WATER PUMP.............................................................................................................................. 33 REMOVAL AND INSTALLATION............................................................................................................ 33 FUEL INJECTION PUMP..................................................................................................................... 35 REMOVAL AND INSTALLATION............................................................................................................ 35 NOZZLE HOLDER........................................................................................................................... 35 REMOVAL AND INSTALLATION............................................................................................................ 35 CYLINDER HEAD........................................................................................................................... 37 REMOVAL............................................................................................................................. 37 INSTALLATION........................................................................................................................ 39 RADIATOR GUARD.......................................................................................................................... 43 REMOVAL AND INSTALLATION............................................................................................................ 43 RADIATOR................................................................................................................................ 45 REMOVAL AND INSTALLATION............................................................................................................ 45 THERMOSTAT.............................................................................................................................. 45 REMOVAL AND INSTALLATION............................................................................................................ 45 ENGINE.................................................................................................................................. 47 REMOVAL............................................................................................................................. 47 INSTALLATION........................................................................................................................ 49 20 POWER TRAIN.................................................................................................................................. 51 21 STRUCTURE AND FUNCTION................................................................................................................... 51 GENERAL................................................................................................................................. 52 POWER TRAIN HYDRAULIC SYSTEM (D31E, P, PL, PLL-18, D31P-18A, D37E, P-2)................................................................. 54 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM (D31E, P, PL, PLL-18, D31P-18A, D37E,P-2)......................................................... 55 POWER TRAIN HYDRAULIC SYSTEM (D31S, Q-18)............................................................................................... 57 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM (D31S, Q-18)...................................................................................... 58 DAMPER AND UNIVERSAL JOINT.............................................................................................................. 59 HYDROSHIFT TRANSMISSION................................................................................................................. 60 TRANSMISSION CONTROL.................................................................................................................... 67 HYDROSHIFT TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM....................................................................................... 68 TRANSMISSION CONTROL VALVE.............................................................................................................. 70 TRANSMISSION PUMP....................................................................................................................... 77 BEVEL GEAR SHAFT AND STEERING CLUTCH.................................................................................................... 78 STEERING CONTROL (D31E, P, PL, PLL-18, D31P-18A, D37E,P-2).............................................................................. 80 STEERING CONTROL (D31S, Q-18)........................................................................................................... 81 STEERING HYDRAULIC PIPING............................................................................................................... 82 STEERING HYDRAULIC SYSTEM (D31E, P, PL, PLL-18, D31P-18A, D37E,P-2)..................................................................... 85 STEERING HYDRAULIC CIRCUIT DIAGRAM (D31E, P, PL, PLL-18, D31P-18A, D37E,P-2)............................................................ 85 STEERING HYDRAULIC SYSTEM (D37E, P-2)................................................................................................... 86 STEERING HYDRAULIC CIRCUIT DIAGRAM (D37E, P-2).......................................................................................... 86 STEERING HYDRAULIC SYSTEM (D31S, Q-18).................................................................................................. 87 STEERING HYDRAULIC CIRCUIT DIAGRAM (D31S, Q-18)......................................................................................... 87 STEERING CONTROL VALVE (D31E, P, PL, PLL-18, D31P-18A, D37E, P-2)....................................................................... 88 STEERING CONTROL VALVE (D31S, Q-18)..................................................................................................... 89 STEERING BOOSTER CYLINDER............................................................................................................... 94 STEERING BRAKE.......................................................................................................................... 96 FINAL DRIVE............................................................................................................................. 98 22 TESTING AND ADJUSTING.................................................................................................................... 99 STANDARD FOR TESTING AND ADJUSTING......................................................................................................100 TESTING AND ADJUSTING TOOL LIST.........................................................................................................101 MEASURING OIL TEMPERATURE...............................................................................................................102 MEASURING OIL PRESSURE..................................................................................................................103 ADJUSTING LINKAGE.......................................................................................................................105 ADJUSTING GEAR SHIFT LEVER CONTROL LINKAGE..........................................................................................105 ADJUSTING INCHING CONTROL LINKAGE...................................................................................................106 ADJUSTING STEERING CONTROL LINKAGE..................................................................................................107 TROUBLESHOOTING.........................................................................................................................111 1. MACHINE DOES NOT MOVE OFF........................................................................................................112 2. DRAWBAR-PULL IS SMALL OR TRAVEL SPEED IS LOW.....................................................................................113 3. TIME LAG IS EXCESSIVE WHEN MOVING OFF OR GEARSHIFTING............................................................................114 4. WHEN ENGINE IS STARTED, MACHINE MOVES............................................................................................115 5. MACHINE SHOCK IS EXCESSIVE WHEN MOVING OFF OR GEARSHIFTING.......................................................................115 6. OIL QUANTITY IN TRANSMISSION AND BEVEL GEAR CASE FLUCTUATES......................................................................115 23 DISASSEMBLY AND ASSEBMLY.................................................................................................................116 DAMPER..................................................................................................................................117 REMOVAL AND INSTALLATION............................................................................................................117 HYDROSHIFT TRANSMISSION.................................................................................................................119 REMOVAL.............................................................................................................................119 INSTALLATION........................................................................................................................121 DISASSEMBLY.........................................................................................................................123 ASSEMBLY............................................................................................................................137 MODULATING VALVE........................................................................................................................151 REMOVAL AND INSTALLATION............................................................................................................151 DISASSEMBLY AND ASSEMBLY............................................................................................................153 SELECTOR AND INCHING VALVE..............................................................................................................151 REMOVAL AND INSTALLATION............................................................................................................151 DISASSEMBLY AND ASSEMBLY............................................................................................................155 STEERING VALVE..........................................................................................................................157 REMOVAL AND INSTALLATION............................................................................................................157 DISASSEMBLY AND ASSEMBLY............................................................................................................157 STEERING CLUTCH.........................................................................................................................159 REMOVAL.............................................................................................................................159 INSTALLATION........................................................................................................................161 DISASSEMBLY.........................................................................................................................165 ASSEMBLY............................................................................................................................167 BEVEL GEAR SHAFT AND BEVEL GEAR.........................................................................................................171 REMOVAL.............................................................................................................................171 INSTALLATION........................................................................................................................173 FINAL DRIVE FIRST PINION................................................................................................................177 REMOVAL AND INSTALLATION............................................................................................................177 FINAL DRIVE.............................................................................................................................179 DISASSEMBLY.........................................................................................................................179 ASSEMBLY............................................................................................................................183 SPROCKET................................................................................................................................187 REMOVAL AND INSTALLATION............................................................................................................187 24 MAINTENANCE STANDARD.....................................................................................................................189 DAMPER AND UNIVERSAL JOINT..............................................................................................................190 TRANSMISSION AND STEERING PUMP..........................................................................................................191 HYDROSHIFT TRANSMISSION.................................................................................................................192 TRANSMISSION CONTROL VALVE..............................................................................................................194 BEVEL GEAR SHAFT........................................................................................................................196 STEERING CLUTCH.........................................................................................................................197 STEERING CONTROL VALVE (D31E, P, PL, PLL-18, D31P-18A, D37E, P-2).......................................................................199 STEERING CONTROL VALVE (D31S, Q-18).....................................................................................................200 STEERING BOOSTER CYLINDER...............................................................................................................201 STEERING BRAKE..........................................................................................................................203 FINAL DRIVE.............................................................................................................................204 30 UNDERCARRIAGE................................................................................................................................206 31 STRUCTURE AND FUNCTION...................................................................................................................206 TRACK (DRY TYPE TRACK LINK) (D31E, P, PL, PLL-18, D31P-18A, D37E, P-2)..................................................................207 TRACK (LUBRICATED TRACK LINK) (D31E, P, PL, PLL-18, D31P-18A, D37E, P-2)................................................................208 TRACK (DRY TYPE TRACK LINK) (D31S, Q-18)................................................................................................209 TRACK (LUBRICATED TRACK LINK) (D31S, Q-18)..............................................................................................210 TRACK GROUP.............................................................................................................................211 IDLER...................................................................................................................................214 IDLER CUSHION...........................................................................................................................215 TRACK ROLLER............................................................................................................................217 CARRIER ROLLER..........................................................................................................................217 MAIN FRAME AND SUSPENSION...............................................................................................................218 33 DISASSEMBLY AND ASSEMBLY.................................................................................................................220 TRACK FRAME.............................................................................................................................221 REMOVAL AND INSTALLATION............................................................................................................221 RECOIL SPRING...........................................................................................................................221 REMOVAL AND INSTALLATION............................................................................................................221 DISASSEMBLY AND ASSEMBLY............................................................................................................223 IDLER...................................................................................................................................225 REMOVAL AND INSTALLATION............................................................................................................225 CARRIER ROLLER..........................................................................................................................225 REMOVAL AND INSTALLATION............................................................................................................225 TRACK ROLLER............................................................................................................................227 REMOVAL AND INSTALLATION............................................................................................................227 TRACK SHOE..............................................................................................................................227 REMOVAL AND INSTALLATION............................................................................................................227 34 MAINTENANCE STANDARD.....................................................................................................................229 TRACK (DRY TYPE TRACK LINK) (D31E, P, PL, PLL-18, D31P-18A, D37E, P-2)..................................................................230 TRACK (LUBRICATED TRACK LINK) (D31E, P, PL, PLL-18, D31P-18A, D37E, P-2)................................................................232 TRACK (DRY TYPE TRACK LINK) (D31S, Q-18)................................................................................................234 TRACK (LUBRICATED TRACK LINK) (D31S, Q-18)..............................................................................................236 TRACK FRAME.............................................................................................................................238 IDLER CUSHION...........................................................................................................................240 IDLER...................................................................................................................................242 TRACK ROLLER............................................................................................................................244 CARRIER ROLLER..........................................................................................................................245 60 HYDRAULIC SYSTEM.............................................................................................................................246 61 STRUCTURE AND FUNCTION...................................................................................................................246 HYDRAULIC PIPING (D31E-18, D31P-18A, D37E, P-2).........................................................................................247 HYDRAULIC CONTROL (D31E-18, D31P-18A, D37E, P-2)........................................................................................248 HYDRAULIC CIRCUIT SYSTEM (D31E-18, D31P-18A, D37E, P-2).................................................................................249 HYDRAULIC CIRCUIT DIAGRAM (D31E-18, D31P-18A, D37E, P-2)................................................................................250 HYDRAULIC PIPING (D31P, PL, PLL-18).....................................................................................................251 HYDRAULIC CONTROL (D31P, PL, PLL-18)....................................................................................................252 HYDRAULIC CIRCUIT SYSTEM (D31P, PL, PLL-18).............................................................................................253 HYDRAULIC CIRCUIT DIAGRAM (D31P, PL, PLL-18)............................................................................................254 HYDRAULIC PIPING (D31S, Q-18)...........................................................................................................255 HYDRAULIC CONTROL (D31S, Q-18)..........................................................................................................256 HYDRAULIC CIRCUIT SYSTEM (D31S, Q-18)...................................................................................................257 HYDRAULIC CIRCUIT DIAGRAM (D31S, Q-18)..................................................................................................258 HYDRAULIC TANK AND FILTER...............................................................................................................259 HYDRAULIC PUMP..........................................................................................................................260 HYDRAULIC CONTROL VALVE (D31E-18, D31P-18A, D37E, P-2)..................................................................................261 HYDRAULIC CONTROL VALVE (D31P, PL, PLL-18)..............................................................................................263 HYDRAULIC CONTROL VALVE (D31S, Q-18)....................................................................................................265 HYDRAULIC LEVER OPERATION (D31E, P, PL-18, D31P-18A, D37E, P-2).........................................................................270 HYDRAULIC LEVER OPERATION (D31S, Q-18)..................................................................................................276 HYDRAULIC CYLINDER (D31E-18, D31P-18A, D37E, P-2).......................................................................................280 HYDRAULIC CYLINDER (D31P, PL, PLL-18)...................................................................................................282 HYDRAULIC CYLINDER (D31S, Q-18).........................................................................................................284 62 TESTING AND ADJUSTING....................................................................................................................286 STANDARD FOR TESTING AND ADJUSTING......................................................................................................287 TESTING AND ADJUSTING TOOL LIST.........................................................................................................290 MEASURING AND ADJUSTING OIL PRESSURE....................................................................................................291 MEASURING OIL TEMPERATURE...............................................................................................................292 BLEEDING AIR FROM ANGLE CYLINDER CIRCUIT................................................................................................293 TROUBLESHOOTING.........................................................................................................................294 1. BLADE LACKS LIFTING POWER AND LIFTING SPEED IS SLOW..............................................................................295 2. BLADE DOES NOT RISE, THE FRONT OF MACHINE CANNOT BE RAISED OFF GROUND WHEN LOWERING THE BLADE....................................296 3. HYDRAULIC DRIFT OF BLADE LIFT CYLINDER IS EXCESSIVE..............................................................................297 4. BLADE MOVES UNSTEADILY WHEN LEVELING THE GROUND. (CONTROL LEVER AT HOLD).........................................................298 5. BLADE LOWERS UNDER THE FOLLOWING CONDITIONS......................................................................................298 6. BLADE LACKS TILTING POWER, BLADE TILTING SPEED IS SLOW. THE MACHINE CANNOT BE RAISED OFF GROUND BY BLADE TILTING POWER...........299 7. BLADE TILT CYLINDER DOES NOT MOVE (TILTING IS IMPOSSIBLE)........................................................................300 8. HYDRAULIC DRIFT OF BLADE TILT CYLINDER IS EXCESSIVE..............................................................................301 9. BLADE LACKS ANGLING POWER, BLADE ANGLING SPEED IS SLOW (FOR POWER ANGLE AND TILTDOZER)...........................................302 10. BLADE ANGLE CYLINDER DOES NOT MOVE (ANGLING IS IMPOSSIBLE) (FOR POWER ANGLE AND TILTDOZER)......................................303 11. BLADE RETURNS STRAIGHTLY OR MOVES UNSTEADILY WHEN LOADING BY ANGLING (CONTROL LEVER AT HOLD) (FOR POWER ANGLE AND TILTDOZER)....304 12. LIFT ARM LACKS LIFTING POWER AND LIFTING SPEED IS SLOW..........................................................................305 13. LIFT ARM DOES NOT RISE, THE FRONT OF MACHINE CANNOT BE RAISED OFF GROUND WHEN LOWERING THE BUCKET...............................306 14. HYDRAULIC DRIFT OF BUCKET LIFT CYLINDER IS EXCESSIVE............................................................................307 15. BUCKET LACKS TILT BACK POWER AND BUCKET TILT SPEED IS SLOW......................................................................308 16. BUCKET DUMP CYLINDER DOES NOT MOVE (BUCKET TILT BACK IS IMPOSSIBLE).............................................................309 17. BUCKET DUMP CYLINDER DOES NOT MOVE (DUMPING IS IMPOSSIBLE), MACHINE CANNOT BE RAISED OFF GROUND BY THE DUMP CYLINDER............310 18. BUCKET DUMP SPEED IS SLOW.......................................................................................................311 19. HYDRAULIC DRIFT OF BUCKET DUMP CYLINDER IS EXCESSIVE............................................................................312 20. BUCKET MOVES UP AND DOWN ALONG GROUND AND LIFT ARM MOVES UNSTEADILY WHEN LEVELING THE GROUND. (CONTROL LEVER AT HOLD)...........313 21. LIFT ARM LOWERS UNDER THE FOLLOWING CONDITIONS..................................................................................313 22. BUCKET MOVES UNSTEADILY WHEN LEVELING THE GROUND WITH MACHINE TRAVELING IN REVERSE.(CONTROL LEVER AT HOLD)......................313 23. BUCKET DUMPS....................................................................................................................313 24. LIFT ARM CANNOT BE RAISED WHEN BUCKET DUMPS FULLY...............................................................................313 25. OPERATING FORCE OF WORK EQUIPMENT CONTROL LEVER IS HEAVY........................................................................314 63 DISASSEMBLY AND ASSEMBLY.................................................................................................................315 HYDRAULIC PUMP..........................................................................................................................316 REMOVAL AND INSTALLATION............................................................................................................316 MAIN RELIEF VALVE.......................................................................................................................316 REMOVAL AND INSTALLATION............................................................................................................316 HYDRAULIC CONTROL VALVE.................................................................................................................316 REMOVAL AND INSTALLATION............................................................................................................316 DISASSEMBLY (D31E-18, D31P-18A, D37E, P-2)..........................................................................................318 ASSEMBLY (D31E-18, D31P-18A, D37E, P-2).............................................................................................320 DISASSEMBLY (D31P, PL, PLL-18)......................................................................................................322 ASSEMBLY (D31P, PL, PLL-18).........................................................................................................324 DISASSEMBLY (D31S, Q-18)............................................................................................................326 ASSEMBLY (D31S, Q-18)...............................................................................................................328 BLADE LIFT CYLINDER.....................................................................................................................330 REMOVAL AND INSTALLATION............................................................................................................330 BLADE TIFT CYLINDER.....................................................................................................................330 REMOVAL AND INSTALLATION............................................................................................................330 BLADE ANGLE CYLINDER....................................................................................................................332 REMOVAL AND INSTALLATION............................................................................................................332 BUCKET LIFT CYLINDER....................................................................................................................332 REMOVAL AND INSTALLATION............................................................................................................332 BUCKET DUMP CYLINDER....................................................................................................................332 REMOVAL AND INSTALLATION............................................................................................................332 HYDRAULIC CYLINDER......................................................................................................................334 DISASSEMBLY.........................................................................................................................334 ASSEMBLY............................................................................................................................334 64 MAINTENANCE STANDARD.....................................................................................................................336 HYDRAULIC CONTROL VALVE (3-SPOOL) (D31E-18, D31P-18A, D37E, P-2).......................................................................337 HYDRAULIC CONTROL VALVE (D31P, PL, PLL-18)..............................................................................................339 HYDRAULIC CONTROL VALVE (D31S, Q-18)....................................................................................................341 HYDRAULIC CYLINDER (D31P, PL, PLL-18)...................................................................................................343 HYDRAULIC CYLINDER (D31E-18, D31P-18A, D37E, P-2).......................................................................................345 HYDRAULIC CYLINDER (D31S, Q-18).........................................................................................................347 HYDRAULIC PUMP..........................................................................................................................348 70 WORK EQUIPMENT...............................................................................................................................349 71 STRUCTURE AND FUNCTION...................................................................................................................349 POWER ANGLE AND TILTDOZER (D31E-18, D31P-18A, D37E, P-2)................................................................................350 STRAIGHT TILTDOZER (D31P, PL, PLL-18)...................................................................................................352 BUCKET AND LINK (D31S, Q-18)............................................................................................................354 73 DISASSEMBLY AND ASSEMBLY.................................................................................................................356 WORK EQUIPMENT..........................................................................................................................357 REMOVAL AND INSTALLATION............................................................................................................357 BLADE...................................................................................................................................359 REMOVAL AND INSTALLATION............................................................................................................359 WORK EQUIPMENT..........................................................................................................................361 REMOVAL AND INSTALLATION............................................................................................................361 BUCKET..................................................................................................................................361 REMOVAL AND INSTALLATION............................................................................................................361 74 MAINTENANCE STANDARD.....................................................................................................................363 POWER ANGLE AND TILTDOZER (D31E-18, D31P-18A, D37E, P-2)................................................................................364 STRAIGHT TILTDOZER (D31P, PL, PLL-18)...................................................................................................366 BUCKET LINK (D31S, Q-18)................................................................................................................368 80 ELECTRICAL SYSTEM............................................................................................................................370 81 STRUCTURE AND FUNCTION...................................................................................................................370 WIRING DIAGRAM..........................................................................................................................371
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
