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Komatsu D31/D37/D39 EX/PX-21 Bulldozer Operator Manual PDF
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- Komatsu D31EX, PX-21 D37EX, PX-21 D39EX, PX-21 Bulldozer Operation & Maintenance Manual
- PUBLICATION NUMBER:EEAM023900
- SERIAL NUMBER:
D31EX-21 – 50501 and up
D31PX-21 – 50501 and up
D37EX-21 – 5501 and up
D37PX-21 – 5501 and up
D39EX-21 -1501 and up
D39PX-21 -1501 and up
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Description
Komatsu D31EX, PX-21 D37EX, PX-21 D39EX, PX-21 Bulldozer Operation & Maintenance Manual
Description:
Komatsu D31EX, PX-21 D37EX, PX-21 D39EX, PX-21 Bulldozer Operation & Maintenance Manual
This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation and maintenance.
Table Of Contents:
Komatsu D31EX, PX-21 D37EX, PX-21 D39EX, PX-21 Bulldozer Operation & Maintenance Manual
FOREWORD.............................................................................................. 3 FOREWORD.......................................................................................... 4 SAFETY INFORMATION................................................................................ 5 NOISE......................................................................................... 7 VIBRATION..................................................................................... 7 INTRODUCTION...................................................................................... 8 FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE.................................................. 8 NECESSARY INFORMATION............................................................................. 9 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE.................................. 9 ENGINE SERIAL NO. PLATE....................................................................... 9 POSITION OF SERVICE METER..................................................................... 10 TABLE OF ENTER SERIAL NO. AND DISTRIBUTORN.................................................... 10 MACHINE SERIAL PLATE.......................................................................... 11 FOREWORD...................................................................................... 12 SAFETY........................................................................................ 12 OPERATION..................................................................................... 13 MAINTENANCE................................................................................... 16 SPECIFICATIONS................................................................................ 17 ATTACHMENTS, OPTIONS.......................................................................... 18 INDEX......................................................................................... 18 COLOPHON...................................................................................... 18 SAFETY................................................................................................ 19 SAFETY............................................................................................ 20 SAFETY LABELS..................................................................................... 22 POSITIONS OF SAFETY PICTOGRAMS................................................................ 22 SAFETY LABELS................................................................................. 23 GENERAL PRECAUTIONS............................................................................... 28 PRECAUTIONS FOR OPERATION......................................................................... 37 STARTING ENGINE............................................................................... 37 OPERATION..................................................................................... 39 TRANSPORTATION................................................................................ 42 BATTERY....................................................................................... 43 TOWING........................................................................................ 45 PRECAUTIONS FOR MAINTENANCE....................................................................... 46 OPERATION............................................................................................. 53 GENERAL VIEW...................................................................................... 54 GENERAL VIEW OF MACHINE....................................................................... 54 GENERAL VIEW OF CONTROLS AND GAUGES........................................................... 55 EXPLANATION OF COMPONENTS......................................................................... 57 FRONT PANEL................................................................................... 57 CHECK MONITOR SYSTEM...................................................................... 58 EMERGENCY CAUTION ITEMS................................................................... 59 CAUTION CAUTION ITEMS..................................................................... 61 METER GROUP............................................................................... 63 LAMPS..................................................................................... 72 METHOD OF USING MAINTENANCE MODE.......................................................... 73 SWITCHES...................................................................................... 82 CONTROL LEVERS AND PEDALS..................................................................... 87 FUSE.......................................................................................... 93 ELECTRIC POWER TAKE-OUT ADAPTER............................................................... 94 DOOR - OPEN LOCK.............................................................................. 95 SASH GLASS INTERMEDIATE LOCK.................................................................. 95 CAP, COVER WITH LOCK.......................................................................... 96 METHOD OF OPENING AND CLOSING CAP WITH LOCK............................................... 96 METHOD OF OPENING AND CLOSING COVER WITH LOCK............................................. 97 DOOR POCKET................................................................................... 97 ASHTRAY....................................................................................... 98 LUNCHBOX HOLDER BELT.......................................................................... 98 CUP HOLDER.................................................................................... 98 TOOL BOX...................................................................................... 99 GREASE PUMP HOLDER............................................................................ 99 CAR STEREO, HANDLING..........................................................................100 EXPLANATION OF COMPONENTS.................................................................100 METOD OF OPERATION........................................................................105 PRECAUTION WHEN USING.....................................................................107 AIR CONDITIONER, HANDLING.....................................................................108 EXPLANATION OF PARTS......................................................................108 PREVENTION METHOD OF ENTRY OF DUST........................................................110 PRECAUTION WHEN USING AIR CONDITIONER.....................................................110 INSPECTION DURING OFF-SEASON..............................................................110 PROCEDURE FOR REPLACING RECEIVER..........................................................111 CLEANING AIR FILTER.......................................................................111 ACCUMULATOR, HANDLING.........................................................................112 METHOD OF RELEASING PRESSURE IN OPERATING CIRCUIT ON MACHINE EQUIPPED WITH ACCUMULATOR....112 OPERATION.........................................................................................113 CHECK BEFORE STARTING ENGINE, ADJUST..........................................................113 WALK-AROUND CHECK.........................................................................113 CHECK BEFORE STARTING.....................................................................115 ADJUSTMENT................................................................................124 OPERATION AND CHECK BEFORE STARTING ENGINE................................................127 STARTING ENGINE...............................................................................129 NORMAL STARTING...........................................................................129 STARTING IN COLD WEATHER..................................................................131 OPERATIONS AND CHECKS AFTER STARTING ENGINE...................................................133 BREAKING IN THE NEW MACHINE...............................................................133 WARMING UP OPERATIONS.....................................................................133 STARTING IN COLD WEATHER..................................................................134 STOPPING ENGINE...............................................................................136 MACHINE OPERATION.............................................................................137 MOVING MACHINE............................................................................137 STOPPING MACHINE..........................................................................140 SHIFTING GEARS................................................................................141 SHIFTING BETWEEN FORWARD AND REVERSE..........................................................142 STEERING MACHINE..............................................................................143 NORMAL TURNING............................................................................143 TURNING WHILE DESCENDING A SLOPE..........................................................144 PRECAUTIONS FOR OPERATION.....................................................................145 PAY ATTENTION TO GAUGES...................................................................145 PERMISSIBLE WATER DEPTH...................................................................145 METHOD OF USING BRAKES....................................................................145 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS...............................................145 PRECAUTIONS ON SLOPES.....................................................................146 IT IS PROHIBITED TO KEEP THE DOOR OPEN DURING OPERATIONS..................................146 IT IS PROHIBITED TO MODIFY THE CAB GLASS IN ANY WAY THAT WILL OBSTRUCT THE VIEW...........146 PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB STAY............................................146 WORK POSSIBLE USING BULLDOZER.................................................................147 DOZING....................................................................................147 SMOOTHING.................................................................................147 CUTTING INTO HARD OR FROZEN GROUND OR DITCHING............................................148 FELLING TREES, REMOVING STUMPS............................................................148 SIDE-CUTTING OPERATIONS...................................................................148 PARKING MACHINE...............................................................................149 CHECK AFTER FINISHING WORK....................................................................150 BEFORE STARTING ENGINE....................................................................150 AFTER STARTING ENGINE.....................................................................150 LOCKING.......................................................................................151 TIPS FOR LONGER UNDERCARRIAGE LIFE............................................................152 OPERATION METHOD..........................................................................152 INSPECTION AND ADJUSTMENT.................................................................152 INSPECTION AND REPAIR.....................................................................153 TRANSPORTATION....................................................................................155 TRANSPORTATION MEANS..........................................................................155 PRECAUTIONS WHEN REMOVING WORK EQUIPMENT......................................................155 REMOVING CAB..................................................................................155 LOADING, UNLOADING WORK.......................................................................156 LIFTING MACHINE...............................................................................160 COLD WEATHER OPERATION............................................................................161 PRECAUTIONS FOR LOW TEMPERATURE...............................................................161 AFTER COMPLETION OF WORK......................................................................163 AFTER COLD WEATHER............................................................................163 LONG-TERM STORAGE.................................................................................164 BEFORE STORAGE................................................................................164 DURING STORAGE................................................................................164 AFTER STORAGE.................................................................................164 TROUBLESHOOTING...................................................................................165 AFTER RUNNING OUT OF FUEL.....................................................................165 MACHINE TOWING METHOD.........................................................................165 WHEN IT IS POSSIBLE TO START ENGINE.......................................................166 WHEN ENGINE DOES NOT START................................................................167 IF BATTERY IS DISCHARGED......................................................................172 REMOVE AND INSTALL BATTERY................................................................173 PRECAUTIONS FOR BATTERY CHARGING..........................................................173 STARTING ENGINE WITH BOOSTER CABLE........................................................174 WHEN ENGINE DOES NOT STOP.....................................................................176 OTHER TROUBLE.................................................................................177 ELECTRICAL SYSTEM.........................................................................177 MONITOR PANEL.............................................................................178 CHASSIS...................................................................................179 ENGINE....................................................................................180 MAINTENANCE...........................................................................................181 GUIDE TO MAINTENANCE..............................................................................182 OUTLINE OF SERVICE................................................................................185 OUTLINE OF OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC......................................185 OIL.......................................................................................185 FUEL......................................................................................185 COOLANT...................................................................................186 GREASE....................................................................................186 CARRYING OUT KOWA (Komatsu Oil Wear Analysis).............................................186 STORING OIL AND FUEL......................................................................187 FILTERS...................................................................................187 RELATING TO ELECTRIC SYSTEM...................................................................188 WEAR PARTS LIST...................................................................................189 WEAR PARTS LIST...............................................................................189 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE..............................191 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS..............................................191 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....................................................195 TORQUE LIST...................................................................................195 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.....................................................196 SAFETY CRITICAL PARTS.........................................................................196 MAINTENANCE SCHEDULE CHART........................................................................197 MAINTENANCE SCHEDULE CHART....................................................................197 WHEN REQUIRED.............................................................................197 CHECK BEFORE STARTING.....................................................................197 EVERY 50 HOURS SERVICE....................................................................197 EVERY 250 HOURS SERVICE...................................................................197 EVERY 500 HOURS SERVICE...................................................................197 EVERY 1000 HOURS SERVICE..................................................................197 EVERY 2000 HOURS SERVICE..................................................................198 EVERY 4000 HOURS SERVICE..................................................................198 SERVICE PROCEDURE.................................................................................199 WHEN REQUIRED.................................................................................199 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT..............................................199 CLEAN INSIDE OF COOLING SYSTEM............................................................203 CHECK TRACK SHOE TENSION, ADJUST..........................................................205 CHECK AND TIGHTEN TRACK SHOE BOLTS........................................................207 CHECK ELECTRICAL INTAKE AIR HEATER........................................................207 REVERSE AND REPLACE END BITS AND CUTTING EDGES............................................208 CHECK IDLER OIL LEVEL, ADD OIL............................................................209 ADJUST IDLER CLEARANCE....................................................................209 ADJUST PLAY IN CENTER BALL................................................................210 GREASE DOOR HINGE.........................................................................210 CHECK DOOR LOCK STRIKER...................................................................211 CHECK, ADJUST AIR CONDITIONER.............................................................211 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID................................................213 REPLACE WIPER BLADE.......................................................................213 PROCEDURE FOR BLEEDING AIR IN HYDRAULIC SYSTEM............................................214 PROCEDURE FOR RELEASING INTERNAL PRESSURE OF HYDRAULIC SYSTEM.............................215 CHECK BEFORE STARTING.........................................................................216 EVERY 50 HOURS SERVICE........................................................................217 DRAIN WATER, SEDIMENT FROM FUEL TANK......................................................217 EVERY 250 HOURS SERVICE.......................................................................218 LUBRICATING...............................................................................218 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL..............................................220 CHECK LEVEL OF BATTERY ELECTROLYTE........................................................221 CHECK BRAKE PERFORMANCE...................................................................223 CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)....................................224 EVERY 500 HOURS SERVICE.......................................................................225 REPLACE FUEL FILTER CARTRIDGE.............................................................225 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.........................228 REPLACE CORROSION RESISTOR CARTRIDGE......................................................229 CLEAN, CHECK RADIATOR FINS AND OIL COOLER FINS............................................230 EVERY 1000 HOURS SERVICE......................................................................231 CHANGE OIL IN FINAL DRIVE CASE............................................................231 CHECK FAN BELT TENSION, ADJUST............................................................231 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER................................................231 CHECK PLAY OF TURBOCHARGER ROTOR..........................................................232 CHECK FOR LOOSE ROPS MOUNT BOLTS..........................................................232 EVERY 2000 HOURS SERVICE......................................................................233 CHANGE OIL IN HYDRAULIC TANK, REPLACE OIL FILTER CARTRIDGE AND CLEAN SUCTION STRAINER.....233 CLEAN, CHECK TURBOCHARGER.................................................................235 CHECK VIBRATION DAMPER....................................................................235 CHECK ALTERNATOR, STARTING MOTOR..........................................................235 CHECK ENGINE VALVE CLEARANCE, ADJUST......................................................235 EVERY 4000 HOURS SERVICE......................................................................236 CHECK WATER PUMP..........................................................................236 SPECIFICATIONS........................................................................................237 SPECIFICATIONS....................................................................................238 ATTACHMENTS, OPTIONS..................................................................................241 GENERAL PRECAUTIONS...............................................................................242 PRECAUTIONS RELATED TO SAFETY.................................................................242 HANDLING HYDRAULIC RIPPER.........................................................................243 GENERAL VIEW..................................................................................243 EXPLANATION OF COMPONENTS.....................................................................244 OPERATION.....................................................................................245 CHECK BEFORE STARTING ENGINE, ADJUST......................................................245 PRECAUTIONS WHEN OPERATING................................................................245 ADUSTING POSTURE OF WORK EQUIPMENT........................................................245 TROUBLESHOOTING...............................................................................246 OTHER TROUBLE.............................................................................246 MAINTENANCE...................................................................................246 EVERY 250 HOURS SERVICE...................................................................246 DELUXE SEAT.......................................................................................247 HEADREST..........................................................................................249 EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT.....................................................250 INDEX.................................................................................................251 <A>...............................................................................................253 <C>...............................................................................................253 <D>...............................................................................................253 <E>...............................................................................................253 <F>...............................................................................................253 <G>...............................................................................................253 <H>...............................................................................................253 <I>...............................................................................................253 <L>...............................................................................................253 <M>...............................................................................................253 <N>...............................................................................................253 <O>...............................................................................................253 <P>...............................................................................................253 <R>...............................................................................................254 <S>...............................................................................................254 <T>...............................................................................................254 <U>...............................................................................................254 <W>...............................................................................................254 COLOPHON..............................................................................................255
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KOMATSU D31EX, PX-21 D37EX, PX-21 D39EX, PX-21 BULLDOZER OPERATION & MAINTENANCE MANUAL – PDF DOWNLOAD:
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