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

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Komatsu D31EX-21, D31PX-21, D37EX-21, D37PX-21 Bulldozer Shop Manual SEBM025608 – PDF DOWNLOAD

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Komatsu D31EX-21, D31PX-21, D37EX-21, D37PX-21 Bulldozer Shop Manual SEBM025608 – PDF DOWNLOAD 

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

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TABLE OF CONTENTS:

Komatsu D31EX-21, D31PX-21, D37EX-21, D37PX-21 Bulldozer Shop Manual SEBM025608 – 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 VALVE 103
INCHING VALVE 108
FRAME ASSEMBLY 109
TRACK FRAME, RECOIL SPRING 110
IDLER 112
TRACK ROLLER 114
CARRIER ROLLER 116
SPROCKET 117
TRACK SHOE 119
ARRANGEMENT OF HYDRAULIC EQUIPMENT FOR WORK EQUIPMENT 123
WORK EQUIPMENT CONTROL 124
HYDRAULIC TANK, FILTER 126
HYDRAULIC PUMP 127
WORK EQUIPMENT CYLINDER 128
CONTROL VALVE 130
CLSS 138
WORK EQUIPMENT PPC VALVE 148
WORK EQUIPMENT 155
CUTTING EDGE, END BIT 158
CAB RELATED 159
SAFETY MECHANISM WHEN STARTING ENGINE 160
GEARSHIFT CONTROL SYSTEM 161
PARKING BRAKE CONTROL SYSTEM 162
COMPONENT EQUIPMENT OF SYSTEM 163
MONITOR SYSTEM 165
SENSORS 169
20 TESTING AND ADJUSTING 172
STANDARD VALUE TABLE FOR ENGINE 173
STANDARD VALUE TABLE FOR CHASSIS 175
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM 180
TESTING AND ADJUSTING 182
TOOLS LIST FOR TESTING AND ADJUSTING 183
MEASURING ENGINE SPEED 186
MEASURING EXHAUST COLOR 187
MEASURING BLOW-BY PRESSURE 188
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) 189
ADJUSTING VALVE CLEARANCE 190
TESTING ADJUSTING FUEL INJECTION TIMING 192
MEASURING COMPRESSION PRESSURE 193
ADJUSTING ENGINE STOP SOLENOIDE LINKAGE 194
MEASURING ENGINE OIL PRESSURE 195
BLEEDING AIR FROM FUEL CIRCUIT 196
REPLACEMENT OF FAN BELT 197
TESTING AND ADJUSTING TENSION OF AIR CONDITIONER COMPRESSOR BELT 199
MEASURING AND ADJUSTING HST OIL PRESSURE 200
MEASURING SOLENOID VALVE OUTPUT PRESSURE 206
MEASURING AND ADJUSTING WORK EQUIPMENT MAIN RELIEF PRESSURE 207
MEASURING PPC VALVE OUTPUT PRESSURE 209
MEASURING LEAKAGE INSIED CYLINDER 210
BLEEDING AIR FROM HYDRAULIC CYLINDERS 210
TESTING AND ADJUSTING TRACK SHOE TENSION 211
TESTING AND ADJUSTING TRAVEL DEVIATION 212
ADJUSTING FUEL CONTROL LINKAGE 215
ADJUSTING DECELERATOR PEDAL LINKAGE 217
ADJUSTING BRAKE PEDAL LINKAGE 218
ADJUSTING STEERING/DIRECTIONAL/GEAR SHIFT LEVER AND LOCK LEVER 219
ADJUSTING BLADE CONTROL LEVER AND LOCK LEVER 222
ADJUSTING WORK EQUIPMENT PPC VALVE 223
PROCEDURE FOR RELEASING PARKING BRAKE 224
PROCEDURE FOR INSPECTING DIODE 226
TROUBLESHOOTING 227
POINTS TO REMEMBER WHEN TROUBLESHOOTING 228
SEQUENCE OF EVENTS IN TROUBLESHOOTING 229
HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT 230
CHECKS BEFORE TROUBLESHOOTING 240
METHOD OF USING TROUBLESHOOTING CHARTS 241
TYPES AND LOCATIONS OF CONNECTORS 242
CONNECTOR ARRANGEMENT DIAGRAM 244
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 246
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 282
TROUBLESHOOTING FOR ELECTRICAL SYSTEM (E-MODE) 285
TABLE OF FAILURE MODES AND CAUSES (ELECTRICAL SYSTEM) 286
ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM 288
E-1 WHEN STARTING SWITCH IS TURNED ON, STARTING MOTOR DOES NOT ROTATE 290
E-2 ENGINE DOES NOT START (ENGINE STOP SOLENOID DOES NOT OPERATE NORMALLY) 292
E-3 HEADLAMP DOES NOT LIGHT UP 293
E-4 WHEN STARTING SWITCH IS TURNED TO HEAT POSITION, ENGINE IS NOT HEATED 295
E-5 WINDSHIELD WIPER DOES NOT OPERATE 296
E-6 WASHING WATER DOES NOT SPOUT 298
E-7 AIR CONDITIONER DOES NOT WORK 300
a) AIR DOES NOT BLOW OUT 300
b) AIR IS NOT COOLED 303
E-8 PARKING BRAKE CANNOT BE RELEASED (PARKING BRAKE SOLENOID DOES NOT OPERATE) 307
E-9 TRAVEL SPEED CONTROL IS ABNORMAL 308
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 TRAVEL 311
E-11 HORN DOES NOT SOUND 313
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 SUDDENLY 317
H-2 MACHINE DOES NOT TRAVEL IN ONE DIRECTION 318
H-3 MACHINE TRAVELS WHILE TRAVEL LEVER IS IN NEUTRAL 318
H-5 MACHINE DEVIATES WHILE TRAVEL LEVER IS IN PARTIAL POSITION 318
H-7 MACHINE SWHINGS MOMENTARILY WHEN IT STARTS ON FLAT GROUND 318
H-11 TURNING TIME LAG IS LARGE 318
H-12 WHEN OPERATOR INTENDS TO TURN GARDUALLY, MACHINE TURNS SHARPLY 318
H-13 MACHINE DOES NOT RETURN QUICKLY TO STRAIGHT TRAVEL POSITION 318
H-14 MACHINE IS NOT DECELERATED SMOOTHLY OR TRAVEL SPEED CANNOT BE CONTROLLED ON DOWNHILL GROUND 318
H-15 MACHINE DEVIATES WHEN IT IS DECELERATED 318
H-4 MACHINE DEVIATES WHEN TRAVEL LEVER IS MOVED TO STROKE END 319
H-6 MACHINE MOVES BACK WHEN OPERATOR STARTS ON UPHILL GROUND 319
H-8 MACHINE STARTS SHARPLY 319
H-9 MACHINE SWINGS MOMENTARLLY WHEN IT STARTS 320
H-10 STARTING TIME LAG IS LARGE 321
H-16 MAXIMUM TRAVEL SPEED IS LOW OR OUTPUT POWER IS INSUFFICIENT OR ACCELERATION IS LOW 322
H-17 ENGINE STALLS 323
H-18 HST NOISE IS LARGE 324
H-19 HST OIL TEMPERATURE RISES TOO HIGH 325
H-20 GEAR SPEED DOES NOT CHANGE 325
H-21 ABNORMAL SOUND IS HEARD FROM AROUND WORK EQUIPMENT PUMP OR HST PUMP 326
H-22 ANY WORK EQUIPMENT DOES NOT MOVE 326
H-23 SPEED OR POWER OF EACH WORK EQUIPMENT IS LOW 327
H-24 SPEED OR POWER OF BLADE LIFT OF BLADE TILT CYLINDER IS LOW 327
H-25 SPEED OR POWER OF BLADE ANGLE CYLINDER IS LOW 328
H-26 HYDRAULIC DRIFT OF BLADE LIFT CYLINDER IS LARGE 329
H-27 HYDRAULIC DRIFT OF BLADE TILT CYLINDER IS LARGE 329
H-28 HYDRAULIC DRIFT OF BLADE ANGLE CYLINDER IS LARGE 330
TROUBLESHOOTING FOR MACHINE MONITOR SYSTEM (M-MODE) 331
TABLE OF FAILURE MODES AND CAUSES (MACHINE MONITOR SYSTEM) 332
ELECTRIC CIRCUIT DIAGRAM FOR EACH SYSTEM 333
M-1 WHEN STARTING SWITCH IS TURNED ON , MONITOR PANEL IS NOT TURNED ON 335
M-2 TROUBLE IN PREHEATING CAUTION LAMP 336
a) PREHEATING MONITOR DOES NOT LIGHT UP 336
b) PREHEATING MONITOR KEEPS LIGHTING UP 336
M-3 CAUTION ITEM LIGHTS UP 337
a) CHARGE CAUTION LAMP LIGHTS UP WHILE ENGINE IS RUNNING 337
b) OIL PRESSURE CAUTION LAMP LIGHTS UP WHILE ENGINE IS RUNNING 338
c) HST FILTER CLOGGING CAUTION LAMP LIGHTS UP (WHILE FILTER IS NOT CLOGGED) 338
M-4 TROUBLE IN HST OIL TEMPERATURE GAUGE 339
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 TEMPERATURE 340
M-5 TROUBLE IN ENGINE WATER TEMPERATURE GAUGE 341
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 TEMPERATURE 342
M-6 TROUBLE IN FUEL LEVEL GAUGE 343
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 LEVEL 344
M-7 SERVICE METER DOES NOT OPERATE AFTER ENGINE IS STARTED 345
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 DISPLAYED 347
b) DISPLAYED SPEED IS DIFFERENT FROM ACTUAL TRAVEL SPEED 347
TROUBLESHOOTING FOR ENGINE SYSTEM (S-MODE) 349
METHOD OF USING TROUBLESHOOTING CHARTS 350
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 354
S-2 ENGINE DOES NOT START 355
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 358
S-4 ENGINE STOPS DURING OPERATIONS 359
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 QUICKLY 364
S-10 FUEL CONSUMPTION IS EXCESSIVE 365
S-11 OIL IS IN COOLANT, OR COOLANT SPURTS BACK, OR COOLANT LEVEL GOES DOWN 366
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 MADE 370
S-16 VIBRATION IS EXCESSIVE 371
30 DISASSEMBLY AND ASSEMBLY 373
HOW TO READ THIS MANUAL 374
COATING MATERIALS LIST 376
SPECIAL TOOL LIST 379
SKETCHES OF SPECIAL TOOLS 381
REMOVAL OF FUEL INJECTION PUMP ASSEMBLY 382
INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY 384
REMOVAL OF CYLINDER HEAD ASSEMBLY 386
INSTALLATION OF CYLINDER HEAD ASSEMBLY 391
REMOVAL OF ENGINE FRONT SEAL 393
INSTALLATION OF ENGINE FRONT SEAL 394
REMOVAL OF ENGINE REAR SEAL 395
INSTALLATION OF ENGINE REAR SEAL 396
REMOVAL OF RADIATOR GUARD ASSEMBLY 397
INSTALLATION OF RADIATOR GUARD ASSEMBLY 399
DISASSEMBLY OF RADIATOR, OIL COOLER, AND CHARGE AIR COOLER ASSEMBLIES 400
ASSEMBLY OF RADIATOR, OIL COOLER, AND CHARGE AIR COOLER ASSEMBLIES 402
REMOVAL OF ENGINE ASSEMBLY 404
INSTALLATION OF ENGINE ASSEMBLY 406
REMOVAL OF DAMPER 407
INSTALLATION OF DAMPER 407
REMOVAL OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 408
INSTALLATION OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 409
DISASSEMBLY OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 410
ASSEMBLY OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 414
REMOVAL OF IDLER AND RECOIL SPRING ASSEMBLY 419
INSTALLATION OF IDLER AND RECOIL SPRING ASSEMBLY 419
DISASSEMBLY OF RECOIL SPRING ASSEMBLY 420
ASSEMBLY OF RECOIL SPRING ASSEMBLY 421
DISASSEMBLY OF IDLER ASSEMBLY 423
ASSEMBLY OF IDLER ASSEMBLY 424
DISASSEMBLY OF TRACK ROLLER ASSEMBLY 426
ASSEMBLY OF TRACK ROLLER ASSEMBLY 427
DISASSEMBLY OF CARRIER ROLLER ASSEMBLY 430
ASSEMBLY OF CARRIER ROLLER ASSEMBLY 431
SPREADING TRACK SHOE ASSEMBLY 432
INSTALLATION OF TRACK SHOE ASSEMBLY 433
REMOVAL OF HST PUMP ASSEMBLY 434
INSTALLATION OF HST PUMP ASSEMBLY 435
REMOVAL OF MAIN CONTROL VALVE ASSEMBLY 436
INSTALLATION OF MAIN CONTROL VALVE ASSEMBLY 437
DISASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY 438
ASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY 442
DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLIES 446
ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLIES 447
REMOVAL OF BLADE ASSEMBLY 449
INSTALLATION OF BLADE ASSEMBLY 450
REMOVAL OF OPERATOR’S SEAT TRAME ASSEMBLY 451
INSTALLATION OF OPERATOR’S SEAT FRAME ASSEMBLY 454
REMOVAL OF FUEL TANK ASSEMBLY 455
INSTALLATION OF FUEL TANK ASSEMBLY 455
REMOVAL OF HYDRAULIC TANK ASSEMBLY 456
INSTALLATION OF HYDRAULIC TANK ASSEMBLY 457
90 OTHERS 458
HYDRAULIC CIRCUIT DIAGRAM (1/2)(D31EX-21 SERIAL NO 50001-50097 D31PX-21 SERIAL NO 50001-50181 D37EX-21 SERIAL NO 5001-5104 D37PX-21 SERIAL NO 5001-5090) 459
HYDRAULIC CIRCUIT DIAGRAM (1/2)(D31EX-21 SERIAL NO 50098 AND UP D31PX-21 SERIAL NO 50182 AND UP D37EX-21 SERIAL NO 5105 AND UP D37PX-21 SERIAL NO 5091 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 CONDITIONER 465

DESCRIPTION:

Komatsu D31EX-21, D31PX-21, D37EX-21, D37PX-21 Bulldozer Shop Manual SEBM025608 – 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

HOW TO READ THE SHOP MANUAL:

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

S.V 26/12/24