Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
KOMATSU D31EX-22 D31PX-22 D37EX-22 D37PX-22 BULLDOZER SHOP MANUAL SEN04343-12 – PDF DOWNLOAD
$35.95
KOMATSU D31EX-22 D31PX-22 D37EX-22 D37PX-22 BULLDOZER SHOP MANUAL SEN04343-12 – PDF DOWNLOAD
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
KOMATSU D31EX-22 D31PX-22 D37EX-22 D37PX-22 BULLDOZER SHOP MANUAL SEN04343-12 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU D31EX-22 D31PX-22 D37EX-22 D37PX-22 BULLDOZER SHOP MANUAL SEN04343-12 – PDF DOWNLOAD
Language : English
Pages : 1070
Downloadable : Yes
File Type : PDF
SERIAL NUMBERS
D31EX-60001 and up
D31PX-60001 and up
D37EX-60001 and up
D37PX-60001 and up
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU D31EX-22 D31PX-22 D37EX-22 D37PX-22 BULLDOZER SHOP MANUAL SEN04343-12 – PDF DOWNLOAD
Cover........................................................................................................................................................ 1 00 Index and foreword........................................................................................................................................ 3 100 Index................................................................................................................................................ 3 Composition of shop manual........................................................................................................................... 4 Table of contents.................................................................................................................................... 6 200 Foreword and general information..................................................................................................................... 15 Safety notice........................................................................................................................................ 16 How to read the shop manual.......................................................................................................................... 21 Explanation of terms for maintenance standard........................................................................................................ 23 Handling of electric equipment and hydraulic component............................................................................................... 25 Handling of connectors newly used for engines........................................................................................................ 34 How to read electric wire code....................................................................................................................... 37 Precautions when carrying out operation.............................................................................................................. 40 Method of disassembling and connecting push-pull type coupler........................................................................................ 43 Standard tightening torque table..................................................................................................................... 46 Conversion table..................................................................................................................................... 50 01 General................................................................................................................................................... 57 100 Specification and technical data..................................................................................................................... 57 Specification dimensional drawing.................................................................................................................... 58 Specifications....................................................................................................................................... 60 Weight table......................................................................................................................................... 68 Table of fuel, coolant and lubricants................................................................................................................ 72 10 Structure, function and maintenance standard.............................................................................................................. 75 100 Engine and cooling system............................................................................................................................ 75 Engine system parts.................................................................................................................................. 76 Cooling system....................................................................................................................................... 77 Cooling fan pump..................................................................................................................................... 78 Cooling fan motor.................................................................................................................................... 79 Oil cooler bypass valve.............................................................................................................................. 84 200 Power train.......................................................................................................................................... 89 Power train.......................................................................................................................................... 90 Power train system................................................................................................................................... 91 Damper............................................................................................................................................... 92 HST hydraulic equipment arrangement diagram.......................................................................................................... 93 Steering and brake control........................................................................................................................... 94 Solenoid valve....................................................................................................................................... 96 Final drive.......................................................................................................................................... 103 HST pump............................................................................................................................................. 106 HST motor............................................................................................................................................ 118 Charge pump.......................................................................................................................................... 128 300 Undercarriage and frame.............................................................................................................................. 131 Main frame........................................................................................................................................... 132 Track frame and idler cushion........................................................................................................................ 134 Idler................................................................................................................................................ 136 Track roller......................................................................................................................................... 138 Carrier roller....................................................................................................................................... 140 Sprocket............................................................................................................................................. 142 Track shoe........................................................................................................................................... 144 410 Hydraulic system, Part 1............................................................................................................................. 149 Arrangement of hydraulic equipment for work equipment................................................................................................ 150 Work equipment control............................................................................................................................... 152 Hydraulic tank and filter............................................................................................................................ 154 Work equipment and fan pump.......................................................................................................................... 156 Control valve........................................................................................................................................ 164 CLSS................................................................................................................................................. 176 Functions and operation of each valve................................................................................................................ 179 420 Hydraulic system, Part 2............................................................................................................................. 189 Blade PPC valve...................................................................................................................................... 190 Accumulator.......................................................................................................................................... 199 500 Work equipment....................................................................................................................................... 201 Work equipment....................................................................................................................................... 202 Cutting edge and end bit............................................................................................................................. 206 Ripper............................................................................................................................................... 207 Work equipment cylinder.............................................................................................................................. 208 Piston valve......................................................................................................................................... 211 600 Cab and its attachments.............................................................................................................................. 213 ROPS cab............................................................................................................................................. 214 Cab mount............................................................................................................................................ 215 Canopy mount......................................................................................................................................... 216 Air conditioner...................................................................................................................................... 217 700 Electrical system.................................................................................................................................... 221 Monitor system....................................................................................................................................... 222 Engine control....................................................................................................................................... 224 Engine control system................................................................................................................................ 225 Cooling control system............................................................................................................................... 226 HST control system................................................................................................................................... 228 Parking brake control system......................................................................................................................... 234 KOMTRAX system....................................................................................................................................... 236 Component equipment of system........................................................................................................................ 240 PCCS lever (for steering)............................................................................................................................ 249 Sensor............................................................................................................................................... 252 20 Standard value table...................................................................................................................................... 265 100 Standard service value table......................................................................................................................... 265 Standard service value table for engine.............................................................................................................. 266 Standard service value table for chassis............................................................................................................. 268 30 Testing and adjusting..................................................................................................................................... 279 110 Testing and adjusting, Part 1........................................................................................................................ 279 Tools for testing, adjusting, and troubleshooting.................................................................................................... 281 Measuring engine speed............................................................................................................................... 285 Measuring intake air pressure (boost pressure)....................................................................................................... 286 Testing exhaust temperature.......................................................................................................................... 288 Measuring exhaust gas color (boost pressure)......................................................................................................... 289 Adjusting valve clearance............................................................................................................................ 290 Testing compression pressure......................................................................................................................... 292 Measuring blow-by pressure........................................................................................................................... 294 Testing oil pressure................................................................................................................................. 296 Handling fuel system equipment....................................................................................................................... 297 Releasing residual pressure in fuel system........................................................................................................... 297 Bleeding air from fuel circuit....................................................................................................................... 298 Testing fuel pressure................................................................................................................................ 301 Testing leakage from pressure limiter and return rate from injector.................................................................................. 302 Testing leakage in fuel system....................................................................................................................... 305 Measuring fan circuit pressure and fan speed......................................................................................................... 306 Adjustment of fan speed sensor....................................................................................................................... 307 Handling reduced cylinder mode operation............................................................................................................. 308 Handling no-injection cranking operation............................................................................................................. 308 Check of muffler and muffler stack for looseness and damage.......................................................................................... 309 Check of muffler function............................................................................................................................ 309 Check of installed condition of cylinder head and manifolds.......................................................................................... 310 Check of engine piping for damage and looseness...................................................................................................... 310 Testing and adjusting alternator belt tension........................................................................................................ 311 Testing and adjusting air conditioner compressor belt tension........................................................................................ 312 120 Testing and adjusting, Part 2........................................................................................................................ 315 Adjusting decelerator pedal.......................................................................................................................... 316 Testing and adjusting HST oil pressure............................................................................................................... 318 Measuring solenoid valve output oil pressure......................................................................................................... 323 Testing travel deviation............................................................................................................................. 326 Adjusting parking brake lever........................................................................................................................ 327 Simple brake performance test procedure.............................................................................................................. 329 Adjusting brake pedal................................................................................................................................ 330 Method of releasing parking brake (Procedure for emergency escape)................................................................................... 332 Testing and adjusting idler clearance................................................................................................................ 334 Testing and adjusting track shoe tension............................................................................................................. 335 Testing work equipment oil pressure.................................................................................................................. 336 Testing work equipment PPC valve output oil pressure................................................................................................. 338 Adjusting play of work equipment PPC valve........................................................................................................... 340 Adjusting work equipment lock lever.................................................................................................................. 341 Testing internal leakage of work equipment cylinder.................................................................................................. 342 Releasing residual pressure in hydraulic circuit..................................................................................................... 344 Bleeding air from hydraulic circuit.................................................................................................................. 345 Adjusting play of blade center ball.................................................................................................................. 346 Procedure for testing diodes......................................................................................................................... 347 Preparation work for troubleshooting for electrical system........................................................................................... 348 How to start operation of KOMTRAX terminal........................................................................................................... 352 Lamp display of KOMTRAX terminal..................................................................................................................... 355 130 Testing and adjusting, Part 3........................................................................................................................ 359 Special functions of monitor panel (EMMS)............................................................................................................ 360 Items to be adjusted when electric/hydraulic devices are adjusted/replaced........................................................................... 420 Adjustment procedure after replacement of HST controller............................................................................................. 421 Adjustment procedure after replacement of monitor panel.............................................................................................. 423 Pm-clinic service (D31EX-22, D31PX-22)............................................................................................................... 425 Pm-clinic service (D37EX-22, D37PX-22)............................................................................................................... 433 40 Troubleshooting........................................................................................................................................... 443 100 Failure code table and fuse locations................................................................................................................ 443 Failure code table................................................................................................................................... 444 Before carrying out troubleshooting for electrical system (E-mode)................................................................................... 450 200 General information on troubleshooting............................................................................................................... 455 Points to remember when troubleshooting.............................................................................................................. 456 Sequence of events in troubleshooting................................................................................................................ 457 Testing before troubleshooting....................................................................................................................... 458 Classification and procedures of troubleshooting..................................................................................................... 459 Information contained in troubleshooting table....................................................................................................... 462 Connection table for connector pin numbers........................................................................................................... 464 T- branch box and T- branch adapter table............................................................................................................ 500 310 Troubleshooting by failure code (Display of code), Part 1............................................................................................ 505 Failure code [6091NX] HST charge filter element: Clogging............................................................................................ 507 Failure code [AA10NX] Air cleaner: Clogging.......................................................................................................... 508 Failure code [AB00MA] Alternator: Malfunction........................................................................................................ 510 Failure code [B@BAZG] Engine oil: Lowering of oil pressure........................................................................................... 511 Failure code [B@BCNS] Coolant: Overheat.............................................................................................................. 512 Failure code [B@CRNS] HST oil: Overheating........................................................................................................... 513 Failure code [B@CRZG] HST oil: Lowering of oil pressure.............................................................................................. 514 Failure code [CA111] Engine controller: Abnormality in controller.................................................................................... 515 Failure code [CA115] Abnormal engine Ne and Bkup speed sensors: Abnormal speed sensor signal......................................................... 518 Failure code [CA122] Charge pressure sensor tool high: Excessively high voltage detected............................................................. 519 Failure code [CA123] Charge pressure sensor too low: Excessively low voltage detected................................................................ 521 Failure code [CA131] Decelerator pedal sensor tool high: Excessively high voltage detected........................................................... 522 Failure code [CA132] Decelerator pedal sensor too low: Excessively low voltage detected.............................................................. 524 Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected.......................................................... 526 Failure code [CA145] Coolant temperature sensor too low: Excessively low voltage detected............................................................ 528 Failure code [CA153] Charge air temperature sensor too high: Excessively high voltage detected....................................................... 530 Failure code [CA154] Charge temperature sensor too low: Excessively low voltage detected............................................................. 532 Failure code [CA187] Sensor power source 2 too low: Excessively low voltage detected................................................................. 533 Failure code [CA221] Atmospheric pressure sensor too high: Excessively high voltage detected......................................................... 534 Failure code [CA222] Atmospheric pressure sensor too low: Excessively low voltage detected........................................................... 536 Failure code [CA227] Sensor power source 2 too high: Excessively high voltage detected............................................................... 538 Failure code [CA234] Engine over speed: Excessively high speed....................................................................................... 540 Failure code [CA238] Abnormal power source for Ne speed sensor: Excessively low voltage detected..................................................... 542 Failure code [CA271] IMV/PCV1 short circuit: Short circuit........................................................................................... 544 Failure code [CA272] IMV/PCV1 disconnection: Disconnection........................................................................................... 546 320 Troubleshooting by failure code (Display of code), Part 2............................................................................................ 549 Failure code [CA322] Injector No. 1 system disconnection or short circuit: disconnection, short circuit.............................................. 552 Failure code [CA324] Injector No. 3 system disconnection or short circuit: disconnection, short circuit.............................................. 554 Failure code [CA331] Injector No. 2 system disconnection or short circuit: disconnection, short circuit.............................................. 556 Failure code [CA332] Injector No. 4 system disconnection or short circuit: disconnection, short circuit.............................................. 558 Failure code [CA351] Injector drive circuit abnormality: Abnormal circuit............................................................................ 560 Failure code [CA352] Sensor power source 1 too low: Excessively low voltage detected................................................................. 562 Failure code [CA386] Sensor power source 1 too high: Excessively high voltage detected............................................................... 564 Failure code [CA428] Water in fuel sensor too high: Excessively high voltage detected................................................................ 566 Failure code [CA429] Water in fuel sensor too low: Excessively low voltage detected.................................................................. 568 Failure code [CA435] Abnormal engine oil pressure switch: Abnormal signal circuit.................................................................... 570 Failure code [CA441] Power source voltage too low: Excessively low voltage detected.................................................................. 571 Failure code [CA442] Power source voltage too high: Excessively high voltage has occurred in the controller power source circuit..................... 572 Failure code [CA449] Common rail pressure too high (2): Excessively high pressure trouble occurred................................................... 573 Failure code [CA451] Common rail pressure sensor too high: Excessively high voltage detected......................................................... 574 Failure code [CA452] Common rail pressure sensor too low: Excessively low voltage detected........................................................... 576 Failure code [CA553] Common rail pressure too high (1): Excessively high pressure detected........................................................... 577 Failure code [CA559] Loss of pressure feed from supply pump (1): Loss of pressure feed detected...................................................... 578 Failure code [CA689] Abnormal engine Ne speed sensor: Abnormal signal................................................................................ 582 Failure code [CA731] Abnormal engine Bkup speed sensor phase: Abnormal phase......................................................................... 584 Failure code [CA757] Loss of all engine controller data: Loss of all data............................................................................ 585 Failure code [CA778] Abnormal engine Bkup speed sensor: Abnormal Bkup signal......................................................................... 586 Failure code [CA1633] Abnormal KOMNET: Abnormal communication........................................................................................ 588 Failure code [CA2185] Decelerator pedal sensor power source too high: Excessively high voltage detected.............................................. 590 Failure code [CA2186] Decelerator pedal sensor power source too low: Excessively low voltage detected................................................ 592 Failure code [CA2249] Loss of pressure feed from supply pump (2): Loss of pressure feed detected..................................................... 593 Failure code [CA2311] Abnormal IMV solenoid: Abnormal resistance..................................................................................... 594 Failure code [CA2555] Air intake heater relay disconnection: Disconnection........................................................................... 596 Failure code [CA2556] Air intake heater relay short circuit: Short circuit1.......................................................................... 598 330 Troubleshooting by failure code (Display of code), Part 3............................................................................................ 601 Failure code [D130KA] Neutral safety relay: Disconnection............................................................................................ 604 Failure code [D130KB] Neutral safety relay: Short circuit............................................................................................ 606 Failure code [DAFRKR] CAN communication (Monitor panel - HST controller): Defective communication (Abnormality in objective component system)........ 608 Failure code [DAFRMC] CAN communication (Monitor panel - ENGINE controller): Defective communication (Abnormality in objective component system)..... 611 Failure code [DAJ000] HST controller: Memory error................................................................................................... 614 Failure code [DAJ0KK] HST controller: Lowing of source voltage....................................................................................... 616 Failure code [DAJ0KQ] HST controller: Machine code error............................................................................................. 618 Failure code [DAJ0KT] HST controller: Memory error................................................................................................... 619 Failure code [DAJ5KK] HST controller sensor 5 V power supply No.1: Lowing of source voltage/Input.................................................... 620 Failure code [DAJ6KK] HST controller sensor 5 V power supply No.2: Lowing of source voltage/Input.................................................... 622 Failure code [DAJRKR] CAN communication (HST controller - Monitor panel): Defective communication (Abnormality in objective component system)........ 624 Failure code [DB2RKR] CAN communication (HST controller - Engine controller): Defective communication (Abnormality in objective component system).... 627 Failure code [DD12KA] Shift up switch: Disconnection................................................................................................. 630 Failure code [DD12KB] Shift up switch: Short circuit................................................................................................. 632 Failure code [DD13KA] Shift down switch: Disconnection............................................................................................... 634 Failure code [DD13KB] Shift down switch: Short circuit............................................................................................... 636 Failure code [DD14KB] Travel lock limit switch 1: Short circuit...................................................................................... 638 Failure code [DD1NL4] Fan rotation selector switch: Disagreement of ON, OFF Signals.................................................................. 640 Failure code [DDDCKB] Reverse travel speed switch: Short circuit..................................................................................... 642 Failure code [DDP6KA] Brake oil pressure sensor: Disconnection....................................................................................... 644 Failure code [DDP6KB] Brake oil pressure sensor: Short circuit....................................................................................... 646 Failure code [DDP6MA] Brake oil pressure sensor: Malfunction......................................................................................... 648 Failure code [DDQ2KA] Travel lock limit switch 1: Disconnection...................................................................................... 650 Failure code [DDT0L4] Shift mode switch: Disagreement of ON/ OFF Signals............................................................................. 652 Failure code [DDU1FS] Travel lock limit switches 1 and 2: Fixing..................................................................................... 654 Failure code [DDU1KA] Travel lock limit switch 2: Disconnection...................................................................................... 656 Failure code [DDU1KY] Travel lock limit switch 2: Short circuit with power supply line............................................................... 658 Failure code [DGS1KA] HST oil temperature sensor: Disconnection...................................................................................... 660 Failure code [DGS1KX] HST oil temperature sensor: Out of Input signal range.......................................................................... 662 340 Troubleshooting by failure code (Display of code), Part 4............................................................................................ 665 Failure code [DHH5KA] Left HST pump pressure sensor: Disconnection................................................................................... 668 Failure code [DHH5KB] Left HST pump pressure sensor: Short circuit................................................................................... 670 Failure code [DHH6KA] Right HST pump pressure sensor: Disconnection.................................................................................. 672 Failure code [DHH6KB] Right HST pump pressure sensor: Short circuit.................................................................................. 674 Failure code [DK10KA] Fuel dial sensor: Disconnection................................................................................................ 676 Failure code [DK10KB] Fuel dial sensor: Short circuit................................................................................................ 678 Failure code [DK30KA] Steering angle sensor 1: Disconnection......................................................................................... 680 Failure code [DK30KB] Steering angle sensor 1: Short circuit......................................................................................... 682 Failure code [DK30KX] Steering angle sensor: Out of input signal range............................................................................... 684 Failure code [DK30KZ] Steering angle sensor: Disconnection or short circuit.......................................................................... 685 Failure code [DK30L8] Steering angle sensor: Disagreement of analog signals.......................................................................... 686 Failure code [DK31KA] Steering angle sensor 2: Disconnection......................................................................................... 688 Failure code [DK31KB] Steering angle sensor 2: Short circuit......................................................................................... 690 Failure code [DK40KA] Brake pedal sensor: Disconnection.............................................................................................. 692 Failure code [DK40KB] Brake pedal sensor: Short circuit.............................................................................................. 694 Failure code [DK55KX] Directional potentiometer: Out of input signal range........................................................................... 696 Failure code [DK55KZ] Directional potentiometer: Disconnection or short circuit...................................................................... 697 Failure code [DK55L8] Directional potentiometer: Disagreement of analog signals...................................................................... 698 Failure code [DK56KA] Directional potentiometer 1: Disconnection..................................................................................... 700 Failure code [DK56KB] Directional potentiometer 1: Short circuit..................................................................................... 702 Failure code [DK57KA] Directional potentiometer 2: Disconnection..................................................................................... 704 Failure code [DK57KB] Directional potentiometer 2: Short circuit..................................................................................... 706 Failure code [DLM0KX] HST motor speed sensors: Out of input signal range............................................................................. 708 Failure code [DLM1KA] Left HST motor speed sensor: Disconnection..................................................................................... 710 Failure code [DLM1KB] Left HST motor speed sensor: Short circuit..................................................................................... 712 Failure code [DLM1MA] Left HST motor speed sensor: Malfunction....................................................................................... 714 Failure code [DLM2KA] Right HST motor speed sensor: Disconnection.................................................................................... 716 Failure code [DLM2KB] Right HST motor speed sensor: Short circuit.................................................................................... 718 Failure code [DLM2MA] Right HST motor speed sensor: Malfunction...................................................................................... 720 Failure code [DLM3KA] Fan speed sensor: Disconnection................................................................................................ 722 Failure code [DLM3KB] Fan speed sensor: Short circuit................................................................................................ 724 350 Troubleshooting by failure code (Display of code), Part 5............................................................................................ 727 Failure code [DN21FS] Brake pedal and proximity switch: Fixing....................................................................................... 730 Failure code [DV00KB] Caution buzzer: Short circuit.................................................................................................. 732 Failure code [DV20KB] Back alarm buzzer: Short circuit............................................................................................... 733 Failure code [DW4BKA] Parking brake solenoid valve: Disconnection.................................................................................... 734 Failure code [DW4BKB] Parking brake solenoid valve: Short circuit.................................................................................... 736 Failure code [DW4BKY] Parking brake solenoid valve: Short circuit with power supply line............................................................. 738 Failure code [DW7BKA] Fan reverse solenoid valve: Disconnection...................................................................................... 740 Failure code [DW7BKB] Fan reverse solenoid valve: Short circuit...................................................................................... 742 Failure code [DW7BKY] Fan reverse solenoid valve: Short circuit with power supply line............................................................... 743 Failure code [DW7EKA] Slow brake solenoid valve: Disconnection....................................................................................... 744 Failure code [DW7EKB] Slow brake solenoid valve: Short circuit....................................................................................... 748 Failure code [DW7EKY] Slow brake solenoid valve: Short circuit with power supply line................................................................ 750 Failure code [DWN5KA] Fan EPC solenoid valve: Disconnection.......................................................................................... 752 Failure code [DWN5KB] Fan EPC solenoid valve: Short circuit.......................................................................................... 754 Failure code [DWN5KY] Fan EPC solenoid valve: Short circuit with power supply line................................................................... 756 Failure code [DXA4KA] LF HST pump EPC solenoid valve: Disconnection.................................................................................. 758 Failure code [DXA4KB] LF HST pump EPC solenoid valve: Short circuit.................................................................................. 760 Failure code [DXA4KY] LF HST pump EPC solenoid valve: Short circuit with power supply line........................................................... 762 Failure code [DXA5KA] LR HST pump EPC solenoid valve: Disconnection.................................................................................. 764 Failure code [DXA5KB] LR HST pump EPC solenoid valve: Short circuit.................................................................................. 766 Failure code [DXA5KY] LR HST pump EPC solenoid valve: Short circuit with power supply line........................................................... 768 Failure code [DXA6KA] RF HST pump EPC solenoid valve: Disconnection.................................................................................. 770 Failure code [DXA6KB] RF HST pump EPC solenoid valve: Short circuit.................................................................................. 772 Failure code [DXA6KY] RF HST pump EPC solenoid valve: Short circuit with power supply line........................................................... 773 Failure code [DXA7KA] RR HST pump EPC solenoid valve: Disconnection.................................................................................. 774 Failure code [DXA7KB] RR HST pump EPC solenoid valve: Short circuit.................................................................................. 776 Failure code [DXA7KY] RR HST pump EPC solenoid valve: Short circuit with power supply line........................................................... 778 Failure code [DXK1KA] Left HST motor EPC solenoid valve: Disconnection............................................................................... 779 Failure code [DXK1KB] Left HST motor EPC solenoid valve: Short circuit............................................................................... 780 Failure code [DXK1KY] Left HST motor EPC solenoid valve: Short circuit with power supply line........................................................ 781 Failure code [DXK2KA] Right HST motor EPC solenoid valve: Disconnection.............................................................................. 782 Failure code [DXK2KB] Right HST motor EPC solenoid valve: Short circuit.............................................................................. 783 Failure code [DXK2KY] Right HST motor EPC solenoid valve: Short circuit with power supply line....................................................... 784 400 Troubleshooting of electrical system (E-mode)........................................................................................................ 787 E-1 Engine does not start (Starting motor does not rotate) .......................................................................................... 790 E-2 Engine is not preheated.......................................................................................................................... 793 E-3 When starting switch is turned ON, any item does not light up.................................................................................... 796 E-4 Charge level caution flashes while engine is running............................................................................................. 798 E-5 Emergency warning items flash while engine is running............................................................................................ 800 E-6 Preheating pilot lamp does not light up during preheating operation.............................................................................. 806 E-7 The coolant temperature gauge does not indicate correctly........................................................................................ 808 E-8 The HST oil temperature gauge does not indicate correctly........................................................................................ 809 E-9 Fuel level gauge does not indicate properly...................................................................................................... 810 E-10 Gear speed, set travel speed, and shift mode indicator does not display normally................................................................ 812 E-12 Caution lamp does not flash or does not go off.................................................................................................. 813 E-13 Caution buzzer does not sound or does not stop.................................................................................................. 814 E-14 Reverse travel speed setting switch does not function........................................................................................... 816 E-15 Shift mode switch does not function............................................................................................................. 818 E-16 Buzzer cancel switch does not function.......................................................................................................... 820 E-17 Information switch does not function............................................................................................................ 822 E-18 The fan cleaning does not operate or cannot be reset............................................................................................ 824 E-19 Backup alarm does not sound..................................................................................................................... 826 E-20 The horn does not sound or does not stop........................................................................................................ 827 E-21 Work equipment does not move.................................................................................................................... 828 E-22 Headlamp or rear lamp does not light up......................................................................................................... 830 E-23 Foot heater does not operate.................................................................................................................... 833 E-24 Air conditioner does not operate................................................................................................................ 836 E-25 Windshield wiper and window washer do not operate............................................................................................... 841 E-26 KOMTRAX system does not operate normally........................................................................................................ 854 500 Troubleshooting of hydraulic and mechanical system (H-mode).......................................................................................... 859 Information in troubleshooting table................................................................................................................. 861 H-1 Right and left travel systems do not operate forward and in reverse (No travel systems operate).................................................. 862 H-2 Right or left travel system does not operate forward and in reverse (Only right or left travel system does not operate).......................... 864 H-3 Right or left travel system does not operate forward or in reverse (Only 1 system does not operate).............................................. 865 H-4 Speed or power of travel is low.................................................................................................................. 866 H-5 Gear is not shifted.............................................................................................................................. 867 H-6 Large shocks are made when machine starts and stops travel....................................................................................... 868 H-7 Machine deviates largely during travel........................................................................................................... 869 H-8 Hydraulic drift of travel is large............................................................................................................... 870 H-9 Engine stalls or engine speed lowers extremely during travel..................................................................................... 871 H-10 Abnormal sound comes out from around HST pump and motor......................................................................................... 872 H-11 Work equipment dose not operate at all.......................................................................................................... 873 H-12 Speed or power of whole work equipment is low................................................................................................... 874 H-13 Speed or power of lifting blade is low.......................................................................................................... 875 H-14 Speed or power of tilting blade is low.......................................................................................................... 876 H-15 Speed or power of angling blade is low.......................................................................................................... 877 H-16 Time lag in lifting blade is large.............................................................................................................. 878 H-17 Hydraulic drift of lifting blade is large....................................................................................................... 878 H-18 Hydraulic drift of tilting blade is large....................................................................................................... 878 H-19 Abnormal sound comes out from around work equipment pump and control valve...................................................................... 879 H-20 HST oil temperature (Hydraulic oil temperature) rises too high.................................................................................. 880 H-21 Fan speed is abnormal (High, low, or 0 rpm)..................................................................................................... 882 H-22 Abnormal sound is heard from around fan......................................................................................................... 883 600 Troubleshooting of engine (S-mode)................................................................................................................... 885 Troubleshooting of engine (S-mode)................................................................................................................... 887 S-1 Starting performance is poor..................................................................................................................... 890 S-2 Engine does not start............................................................................................................................ 891 S-3 Engine does not pick up smoothly................................................................................................................. 894 S-4 Engine stops during operations................................................................................................................... 895 S-5 Engine does not rotate smoothly.................................................................................................................. 896 S-6 Engine lacks output (or lacks power)............................................................................................................. 897 S-7 Exhaust smoke is black (incomplete combustion)................................................................................................... 898 S-8 Oil consumption is excessive (or exhaust smoke is blue).......................................................................................... 899 S-9 Oil becomes contaminated quickly................................................................................................................. 900 S-10 Fuel consumption is excessive................................................................................................................... 901 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)........................................................................... 902 S-12 Oil pressure drops.............................................................................................................................. 903 S-13 Oil level rises (Entry of coolant or fuel)...................................................................................................... 904 S-14 Coolant temperature becomes too high (overheating).............................................................................................. 905 S-15 Abnormal noise is made.......................................................................................................................... 906 S-16 Vibration is excessive.......................................................................................................................... 907 50 Disassembly and assembly.................................................................................................................................. 909 100 General information on disassemblyand assembly....................................................................................................... 909 How to read this manual.............................................................................................................................. 910 Coating materials list............................................................................................................................... 912 Special tools list................................................................................................................................... 915 Sketches of special tools............................................................................................................................ 918 200 Engine and cooling system............................................................................................................................ 923 Removal and installation of fuel supply pump assembly................................................................................................ 924 Removal and installation of fuel injector assembly................................................................................................... 927 Removal and installation of front seal assembly...................................................................................................... 930 Removal and installation of rear seal assembly....................................................................................................... 932 Removal and installation of cylinder head assembly................................................................................................... 935 Removal and installation of engine and HST pump assembly............................................................................................. 942 Removal and installation of front guard assembly..................................................................................................... 946 Removal and installation of radiator assembly........................................................................................................ 948 Removal and installation of hydraulic oil cooler assembly............................................................................................ 950 Removal and installation of aftercooler assembly..................................................................................................... 952 Removal and installation of cooling fan and motor assembly........................................................................................... 954 Removal and installation of cooling fan drive motor assembly......................................................................................... 956 Removal and installation of fuel tank assembly....................................................................................................... 958 300 Power train.......................................................................................................................................... 961 Removal and installation of HST pump assembly........................................................................................................ 962 Removal and installation of HST motor and final drive assembly....................................................................................... 964 Disassembly and assembly of final drive assembly..................................................................................................... 966 400 Undercarriage and frame.............................................................................................................................. 977 Spreading and installation of track shoe assembly.................................................................................................... 978 Removal and installation of idler and recoil spring assembly......................................................................................... 980 Disassembly and assembly of idler assembly........................................................................................................... 981 Disassembly and assembly of recoil spring assembly................................................................................................... 984 Disassembly and assembly of track roller assembly.................................................................................................... 988 Disassembly and assembly of carrier roller assembly.................................................................................................. 992 500 Hydraulic system..................................................................................................................................... 997 Removal and installation of hydraulic tank assembly.................................................................................................. 998 Removal and installation of control valve assembly...................................................................................................1000 Disassembly and assembly of control valve assembly...................................................................................................1001 Disassembly and assembly of hydraulic cylinder assembly..............................................................................................1003 600 Work equipment.......................................................................................................................................1009 Removal and installation of work equipment assembly..................................................................................................1010 700 Cab and its attachments..............................................................................................................................1015 Removal and installation of ROPS canopy and operator seat frame assembly.............................................................................1016 Removal and installation of ROPS cab and operator seat frame assembly................................................................................1019 Removal and installation of operator’s cab glass (Stuck glass).......................................................................................1023 800 Electrical system....................................................................................................................................1031 Removal and installation of HST controller assembly..................................................................................................1032 Removal and installation of KOMTRAX terminal assembly................................................................................................1033 90 Diagrams and drawings.....................................................................................................................................1035 100 Hydraulic diagrams and drawings......................................................................................................................1035 Work equipment hydraulic circuit diagram.............................................................................................................1037 200 Electrical diagrams and drawings.....................................................................................................................1045 Electrical circuit diagram...........................................................................................................................1047 Cab electrical circuit diagram.......................................................................................................................1061 Air conditioner circuit diagram......................................................................................................................1065 Connector list and stereogram........................................................................................................................1067
DESCRIPTION:
KOMATSU D31EX-22 D31PX-22 D37EX-22 D37PX-22 BULLDOZER SHOP MANUAL SEN04343-12 – PDF DOWNLOAD
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. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and 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. 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.
30. 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.
40. 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.
50. 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. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
A. Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
B. Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
S.S 28/12/24
