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KOMATSU D31E,P,PL,PLL-20 D31P-20A D31S,Q-20 D37E-5,D37P-5A BULLDOZER SERVICE REPAIR MANUAL – PDF Download
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- KOMATSU D31E,P,PL,PLL-20 D31P-20A D31S,Q-20 D37E-5,D37P-5A BULLDOZER SERVICE REPAIR MANUAL
- PUBLICATION NUMBER:SEBM001007
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Description
KOMATSU D31E,P,PL,PLL-20 D31P-20A D31S,Q-20 D37E-5,D37P-5A BULLDOZER SERVICE REPAIR MANUAL
KOMATSU D31E,P,PL,PLL-20 D31P-20A D31S,Q-20 D37E-5,D37P-5A BULLDOZER SERVICE REPAIR MANUAL – PDF DOWNLOAD:
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KOMATSU D31E,P,PL,PLL-20 D31P-20A D31S,Q-20 D37E-5,D37P-5A BULLDOZER SERVICE REPAIR MANUAL
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman 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 this section. - 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,P,PL,PLL-20 D31P-20A D31S,Q-20 D37E-5,D37P-5A BULLDOZER SERVICE REPAIR MANUAL
MAIN MENU....................................................................................................................................... 0 CONTENTS........................................................................................................................................ 2 01 GENERAL ..................................................................................................................................... 25 SPECIFICATION DRAWINGS...................................................................................................................... 26 SPECIFICATIONS.............................................................................................................................. 38 WEIGHT TABLE................................................................................................................................ 62 LIST OF LUBRICANT AND WATER................................................................................................................. 74 10 STRUCTURE AND FUNCTION ...................................................................................................................... 79 POWER TRAIN SYSTEM ......................................................................................................................... 80 POWER TRAIN SKELETON ....................................................................................................................... 81 POWER TRAIN HYDRAULIC PIPING ............................................................................................................... 84 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM ...................................................................................................... 86 POWER TRAIN HYDRAULIC SYSTEM ............................................................................................................... 87 DAMPER AND UNIVERSAL JOINT ................................................................................................................. 88 TRANSMISSION CONTROL........................................................................................................................ 89 TRANSMISSION PUMP .......................................................................................................................... 94 HYDROSHIFT TRANSMISSION..................................................................................................................... 96 TRANSMISSION CONTROL VALVE .................................................................................................................105 STEERING CONTROL............................................................................................................................113 STEERING CYLINDER ..........................................................................................................................117 BRAKE CYLINDER..............................................................................................................................118 PPC VALVE ..................................................................................................................................119 BEVEL GEAR SHAFT AND STEERING CLUTCH .......................................................................................................131 STEERING BRAKE..............................................................................................................................133 FINAL DRIVE ................................................................................................................................135 TRACK FRAME ................................................................................................................................136 MAIN FRAME AND SUSPENSION ..................................................................................................................138 HYDRAULIC PIPING ...........................................................................................................................140 HYDRAULIC CIRCUIT DIAGRAM ..................................................................................................................147 HYDRAULIC CIRCUIT SYSTEM ...................................................................................................................148 HYDRAULIC CONTROL ..........................................................................................................................155 HYDRAULIC TANK AND FILTER ..................................................................................................................157 HYDRAULIC CONTROL VALVE ....................................................................................................................159 ANGLE SELECTOR VALVE .......................................................................................................................165 SUCTION SAFETY VALVE .......................................................................................................................168 WORK EQUIPMENT .............................................................................................................................169 ELECTRICAL CIRCUIT DIAGRAM..................................................................................................................172 ENGINE CONTROL..............................................................................................................................175 MONITOR SYSTEM .............................................................................................................................176 SENSORS ....................................................................................................................................177 20 TESTING AND ADJUSTING .......................................................................................................................180 STANDARD VALUE TABLE FOR ENGINE ............................................................................................................181 STANDARD VALUE TABLE FOR CHASSIS ...........................................................................................................183 STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM .................................................................................................192 TABLE OF TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING ..................................................................................193 MEASURlNG ENGINE SPEED .....................................................................................................................195 MEASURING EXHAUST COLOR ....................................................................................................................197 ADJUSTING VALVE CLEARANCE ..................................................................................................................198 MEASURING COMPRESSION PRESSURE .............................................................................................................201 MEASURING BLOW-BY PRESSURE .................................................................................................................203 TESTING AND ADJUSTING FUEL INJECTION TIMING ...............................................................................................205 BLEEDING AIR FROM FUEL CIRCUIT .............................................................................................................209 MEASURING ENGINE OIL PRESSURE ..............................................................................................................210 TESTING AND ADJUSTING FAN BELT TENSION .....................................................................................................213 MEASURING POWER TRAIN OIL PRESSURE .........................................................................................................214 ADJUSTING PPC VALVE ........................................................................................................................215 BLEEDING AIR FROM STEERING CIRCUIT ........................................................................................................216 MEASURING AND ADJUSTING WORK EQUIPMENT MAIN RELIEF PRESSURE ..............................................................................217 BLEEDING AIR FROM HYDRAULIC CYLINDERS ......................................................................................................219 BLEEDING AIR FROM ANGLE CYLINDER CIRCUIT ...................................................................................................220 ADJUSTING FUEL CONTROL CABLE ...............................................................................................................221 ADJUSTING FUEL CONTROL LEVER ...............................................................................................................222 PROCEDURE FOR ADJUSTING ENGINE STOP MOTOR CABLE ............................................................................................223 ADJUSTING ENGINE STOP SOLENOID LINKAGE .....................................................................................................225 ADJUSTING TRANSMISSION CONTROL LINKAGE .....................................................................................................227 ADJUSTING TRAVEL OF INCHING PEDAL ..........................................................................................................233 ADJUSTING BRAKE PEDAL, STEERING BRAKE CYLINDER .............................................................................................234 ADJUSTING BRAKE LINING CLEARANCE ...........................................................................................................237 TROUBLESHOOTING.............................................................................................................................238 POINTS TO REMEMBER WHEN TROUBLESHOOTING ................................................................................................239 SEQUENCE OF EVENTS IN TROUBLESHOOTING ..................................................................................................240 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE .......................................................................................241 HANDLING CONNECTORS.....................................................................................................................248 CHECKS BEFORE TROUBLESHOOTING ..........................................................................................................249 TROUBLESHOOTING OF ENGINE (S MODE)......................................................................................................250 METHOD OF USING TROUBLESHOOTING CHARTS ............................................................................................251 D31E-20 Serial No.: 42001-42713, D31P-20A Serial No.: 45001-47616, D31P, PL-20 Serial No.: 45001-47616, D37E-5 Serial No.: 3........255 S-1 Starting performance is poor (Starting always takes time) ......................................................................255 S-2 Engine does not start .........................................................................................................256 S-3 Engine does not pick up smoothly (Follow-up is poor) ...........................................................................259 S-4 Engine stops during operations .................................................................................................260 S-5 Engine does not rotate smoothly ................................................................................................261 S-6 Engine lacks output (no power) .................................................................................................262 S-7 Exhaust gas is black (incomplete combustion) ...................................................................................263 S-8 Oil consumption is excessive (or exhaust gas is blue)...........................................................................264 S-9 Oil becomes contaminated quickly ...............................................................................................265 S-10 Fuel consumption is excessive .................................................................................................266 S-11 Oil is in cooling water, or water spurts back, or water level goes down .......................................................267 S-12 Oil pressure lamp lights up (drop in oil pressure) ............................................................................268 S-13 Oil level rises................................................................................................................269 S-14 Water temperature becomes too high (overheating) ..............................................................................270 S-15 Abnormal noise is made.........................................................................................................271 S-16 Vibration is excessive.........................................................................................................272 D31E-20 Serial No.: 42714 and up, D31P-20A Serial No.: 47617 and up, D31P, PL-20 Serial No.: 47617 and up, D37E-5 Serial No.: 37....273 S-1 Starting performance is poor (starting always takes time) ......................................................................273 S-2 Engine does not start ..........................................................................................................274 (1) Engine does not turn........................................................................................................274 (2) Engine turns but no exhaust smoke comes out (fuel is not being injected)....................................................275 (3) Exhaust smoke comes out but engine does not start (Fuel is being injected)..................................................276 S-3 Engine does not pick up smoothly (follow-up is poor) ...........................................................................277 S-4 Engine stops during operations .................................................................................................278 S-5 Engine does not rotate smoothly (hunting) ......................................................................................279 S-6 Engine lacks output (no power) .................................................................................................280 S-7 Exhaust smoke is black (incomplete combustion) ................................................................................281 S-8 Oil consumption is excessive (or exhaust smoke is blue) ........................................................................282 S-9 Oil becomes contaminated quickly ...............................................................................................283 S-10 Fuel consumption is excessive .................................................................................................284 S-11 Oil is in cooling water, or water spurts back, or water level goes down .......................................................285 S-12 Oil pressure caution lamp lights up (drop in oil pressure) ....................................................................286 S-13 Oil level rises (water, fuel in oil) ..........................................................................................287 S-14 Water temperature becomes too high (overheating) ..............................................................................288 S-15 Abnormal noise is made ........................................................................................................289 S-16 Vibration is excessive ........................................................................................................290 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)................................................................................292 METHOD OF USING TROUBLESHOOTING CHART...............................................................................................293 TABLE OF FAILURE MODES AND CAUSES...................................................................................................295 H-1. Machine does not start ........................................................................................................295 H-2. Drawbar pull is weak, travel speed is slow.....................................................................................296 H-3. Excessive time lag when starting or shifting gear checks before troubleshooting ...............................................297 H-4. Steering does not work properly ...............................................................................................298 H-5. Machine moves when engine is started ..........................................................................................299 H-6. Excessive shock when starting or shifting gear ................................................................................299 H-7. Level of oil in transmission case or bevel gear case changes ..................................................................299 H-8. Lack of blade lifting force, speed ............................................................................................300 H-9. Impossible to raise blade or push up chassis ..................................................................................301 H-10. Excessive hydraulic drift of blade ...........................................................................................302 H-11. Blade moves up and down during leveling operations (control lever at HOLD) ...................................................302 H-12. Blade goes down ..............................................................................................................302 H-13. Blade tilt lacks power, speed, impossible to push up chassis with tilt .......................................................303 H-14. Blade cannot be tilted .......................................................................................................304 H-15. Excessive hydraulic drift of blade tilt ......................................................................................305 H-16. Blade angle lacks power, speed (applicable to power angle, power tilt dozer) .................................................306 H-17. Blade cannot be angled (applicable to power angle tiltdozer) ................................................................307 H-18. When blade is angled, blade returns to straight position or shakes during operations (control lever at HOLD) ................308 H-19. Lift arm lacks lifting power, speed ..........................................................................................309 H-20. Impossible to raise lift arm, impossible to raise chassis ....................................................................310 H-21. Excessive hydraulic drift of lift arm ........................................................................................311 H-22. Bucket tilt back lacks power, speed ..........................................................................................312 H-23. Impossible to tilt back bucket ...............................................................................................313 H-24. Impossible to dump bucket, impossible to raise chassis with dump cylinder ....................................................314 H-25. Bucket dump speed is slow ....................................................................................................315 H-26. Excessive hydraulic drift of bucket dump circuit .............................................................................316 H-27. Bucket moves up and down along ground surface during leveling operations, but lift arm moves irregularly [control lever at....317 H-28. Lift arm goes down ...........................................................................................................317 H-29. Bucket moves irregularly during leveling operations (control lever at HOLD) ..................................................317 H-30. Bucket dumps .................................................................................................................317 H-31. When bucket is dumped to maximum, it is impossible to raise lift arm .........................................................317 H-32. Work equipment control levers are heavy ......................................................................................318 30 DISASSEMBLY AND ASSEMBLY ....................................................................................................................320 METHOD OF USING MANUAL......................................................................................................................322 PRECAUTIONS WHEN CARRYING OUT OPERATION.....................................................................................................323 SPECIAL TOOL LIST...........................................................................................................................325 STARTING MOTOR..............................................................................................................................329 REMOVAL AND INSTALLATION................................................................................................................329 ALTERNATOR..................................................................................................................................331 REMOVAL AND INTALLATION.................................................................................................................331 ENGINE OIL COOLER CORE......................................................................................................................333 REMOVAL AND INSTALLATION................................................................................................................333 FUEL INJECTION PUMP.........................................................................................................................335 REMOVAL ................................................................................................................................335 INSTALLATION ...........................................................................................................................336 WATER PUMP..................................................................................................................................343 REMOVAL AND INSTALLATION................................................................................................................343 THERMOSTAT..................................................................................................................................345 REMOVAL AND INSTALLATION................................................................................................................345 NOZZLE HOLDER...............................................................................................................................347 REMOVAL AND INSTALLATION................................................................................................................347 TURBOCHARGER................................................................................................................................350 REMOVAL ................................................................................................................................350 INSTALLATION............................................................................................................................352 CYLINDER HEAD...............................................................................................................................353 REMOVAL ................................................................................................................................353 INSTALLATION ...........................................................................................................................354 RADIATOR GUARD..............................................................................................................................365 REMOVAL ................................................................................................................................365 INSTALLATION ...........................................................................................................................366 RADIATOR....................................................................................................................................367 REMOVAL.................................................................................................................................367 INSTALLATION ...........................................................................................................................368 RADIATOR, RADIATOR GUARD....................................................................................................................369 REMOVAL.................................................................................................................................369 INSTALLATION............................................................................................................................372 ENGINE......................................................................................................................................373 REMOVAL ................................................................................................................................373 INSTALLATION............................................................................................................................374 DAMPER......................................................................................................................................379 REMOVAL.................................................................................................................................379 INSTALLATION............................................................................................................................380 HYDROSHIFT TRANSMISSION.....................................................................................................................385 REMOVAL.................................................................................................................................385 INSTALLATION............................................................................................................................387 DISASSEMBLY.............................................................................................................................388 ASSEMBLY ...............................................................................................................................400 MODULATING VALVE AND PUMP...................................................................................................................414 REMOVAL AND INSTALLATION................................................................................................................414 MODULATING VALVE............................................................................................................................415 DISASSEMBLY.............................................................................................................................415 ASSEMBLY ...............................................................................................................................416 SELECTOR AND INCHING VALVE..................................................................................................................417 REMOVAL AND INSTALLATION................................................................................................................417 DISASSEMBLY ............................................................................................................................418 ASSEMBLY ...............................................................................................................................419 MAIN RELIEF VALVE...........................................................................................................................420 REMOVAL AND INSTALLATION................................................................................................................420 STEERING PPC VALVE..........................................................................................................................421 REMOVAL AND INSTALLATION................................................................................................................421 DISASSEMBLY AND ASSEMBLY................................................................................................................424 STEERING CLUTCH.............................................................................................................................429 REMOVAL ................................................................................................................................429 INSTALLATION ...........................................................................................................................431 DISASSEMBLY ............................................................................................................................432 ASSEMBLY ...............................................................................................................................434 BEVEL GEAR SHAFT AND BEVEL GEAR.............................................................................................................437 REMOVAL ................................................................................................................................437 INSTALLATION ...........................................................................................................................440 FINAL DRIVE FIRST PINION....................................................................................................................444 REMOVAL AND INSTALLATION................................................................................................................444 FINAL DRIVE.................................................................................................................................446 DISASSEMBLY ............................................................................................................................446 ASSEMBLY ...............................................................................................................................449 TRACK FRAME.................................................................................................................................454 REMOVAL AND INSTALLATION................................................................................................................454 RECOIL SPRING...............................................................................................................................458 DISASSEMBLY ............................................................................................................................458 ASSEMBLY ...............................................................................................................................459 IDLER.......................................................................................................................................460 REMOVAL AND INSTALLATION................................................................................................................460 DISASSEMBLY ............................................................................................................................461 ASSEMBLY................................................................................................................................463 CARRIER ROLLER..............................................................................................................................465 REMOVAL AND INSTALLATION................................................................................................................465 DISASSEMBLY.............................................................................................................................466 ASSEMBLY ...............................................................................................................................467 TRACK ROLLER................................................................................................................................468 REMOVAL AND INSTALLATION................................................................................................................468 DISASSEMBLY ............................................................................................................................469 ASSEMBLY ...............................................................................................................................470 TRACK SHOE..................................................................................................................................478 REMOVAL AND INSTALLATION................................................................................................................478 HYDRAULIC PUMP..............................................................................................................................479 REMOVAL AND INSTALLATION................................................................................................................479 HYDRAULIC CONTROL VALVE.....................................................................................................................482 REMOVAL AND INSTALLATION................................................................................................................482 DISASSEMBLY AND ASSEMBLY................................................................................................................485 BLADE LIFT CYLINDER ........................................................................................................................499 REMOVAL AND INSTALLATION (D13E, P-20, D31P-20A, D37E-5, D37P-5A)........................................................................499 (D31PL, PLL-20).........................................................................................................................500 BLADE TILT CYLINDER ........................................................................................................................501 REMOVAL AND INSTALLATION (D31 E, P-20, D31 P-20A. D37E-5, D37P-5A)......................................................................501 (D31 PL, PLL-20)........................................................................................................................502 BLADE ANGLE CYLINDER .......................................................................................................................503 REMOVAL AND INSTALLATION (D31 E, P-20, D31 P-20A. D37E-5, D37P-5A)......................................................................503 BUCKET LIFT CYLINDER........................................................................................................................504 REMOVAL AND INSTALLATION (D31S, Q-20)...................................................................................................504 BUCKET DUMP CYLINDER........................................................................................................................505 (D31S, Q-20)............................................................................................................................505 HYDRAULIC CYLINDER..........................................................................................................................506 DISASSEMBLY.............................................................................................................................506 ASSEMBLY ...............................................................................................................................507 WORK EQUIPMENT..............................................................................................................................509 REMOVAL AND INSTALLATION (D31 E, P-20, D31 P-20A, D37E-5, D37P-5A)......................................................................509 (D31PL, PLL-20).........................................................................................................................510 BLADE.......................................................................................................................................511 REMOVAL AND INSTALLATION (D31 E, P-20, D31 P-20A, D37E-5, D37P-5A)......................................................................511 (D31PL, PLL-20).........................................................................................................................512 WORK EQUIPMENT..............................................................................................................................513 REMOVAL AND INSTALLATION (D31S. Q-20)...................................................................................................513 BUCKET......................................................................................................................................514 REMOVAL AND INSTALLATION (D31S, Q-20)...................................................................................................514 OPERATOR’S SEAT FRAME.......................................................................................................................515 REMOVAL ................................................................................................................................515 INSTALLATlON............................................................................................................................516 40 MAINTENANCE STANDARD ........................................................................................................................518 DAMPER AND UNIVERSAL JOINT .................................................................................................................519 HYDROSHIFT TRANSMISSION ....................................................................................................................521 TRANSMISSION CONTROL VALVE .................................................................................................................523 TRANSMISSION AND STEERING PUMP .............................................................................................................525 PPC VALVE ..................................................................................................................................526 STEERING CYLINDER ..........................................................................................................................529 BEVEL GEAR SHAFT ...........................................................................................................................530 STEERING CLUTCH ............................................................................................................................531 STEERING BRAKE .............................................................................................................................533 FINAL DRIVE ................................................................................................................................535 TRACK FRAME ................................................................................................................................537 IDLER CUSHION ..............................................................................................................................539 IDLER ......................................................................................................................................541 TRACK ROLLER ...............................................................................................................................543 CARRIER ROLLER .............................................................................................................................546 TRACK (LUBRICATED TRACK LINK) D31E, P, PL, PLL-20, D31P-20A, D37E-5, D37P-5A................................................................547 TRACK (DRY TYPE TRACK LINK) D31E, P, PL, PLL-20, D31P-20A, D37E-5, D37P-5A..................................................................549 TRACK (LUBRICATED TRACK LINK) D31S, Q-20....................................................................................................555 TRACK (DRY TYPE TRACK LINK) D31S, Q-20......................................................................................................557 HYDRAULIC PUMP..............................................................................................................................559 HYDRAULIC CONTROL VALVE ....................................................................................................................561 HYDRAULIC CYLINDER..........................................................................................................................567 WORK EQUIPMENT .............................................................................................................................573 90 OTHERS ......................................................................................................................................580 TRIMMING DOZER..............................................................................................................................582 CONTENTS ...............................................................................................................................583 GENERAL ................................................................................................................................584 SPECIFICATION DRAWING...............................................................................................................584 SPECIFICATIONS .....................................................................................................................587 WEIGHT TABLE .......................................................................................................................591 TABLE OF FUEL, COOLANT AND LUBRICANTS ..............................................................................................593 STRUCTURE AND FUNCTION .................................................................................................................595 POWER TRAIN HYDRAULIC PIPING .......................................................................................................595 TRANSMISSION CONTROL................................................................................................................597 STEERING CONTROL ...................................................................................................................601 PPC VALVE ..........................................................................................................................603 TRACK FRAME ........................................................................................................................615 HYDRAULIC PIPING ...................................................................................................................617 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM ...........................................................................................619 WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM ............................................................................................620 WORK EQUIPMENT CONTROL .............................................................................................................621 WORK EQUIPMENT CONTROL VALVE .......................................................................................................623 TRIMMING DOZER......................................................................................................................627 ELECTRICAL WIRING DIAGRAM...........................................................................................................630 ENGINE CONTROL......................................................................................................................631 MAINTENANCE STANDARD ...................................................................................................................633 PPC VALVE ..........................................................................................................................633 TRACK FRAME ........................................................................................................................635 IDLER CUSHION ......................................................................................................................637 IDLER ..............................................................................................................................639 TRACK ROLLER .......................................................................................................................643 CARRIER ROLLER .....................................................................................................................645 TRACK...............................................................................................................................647 WORK EQUIPMENT CONTROL VALVE .......................................................................................................659 HYDRAULIC CYLINDER .................................................................................................................663 TRIMMING DOZER......................................................................................................................665
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