Related Manuals for Komatsu D31EX -22
Summary of Contents for Komatsu D31EX -22
- Page 1 SEN04343-09 BULLDOZER D31EX D31PX D37EX D37PX 60001 SERIAL NUMBERS and up...
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Page 3: Index And Foreword 100 Index
SEN04352-09 BULLDOZER D31EX-22 D31PX-22 D37EX-22 D37PX-22 Machine model Serial number D31EX-22 60001 and up D31PX-22 60001 and up D37EX-22 60001 and up D37PX-22 60001 and up 00 Index and foreword 100 Index Composition of shop manual .......................... 2 Table of contents ............................. 4 D31/37-22 00-100 Find manuals at https://best-manuals.com... - Page 4 100 Index SEN04352-09 Composition of shop manual Composition of shop manual The contents of this shop manual are shown together with Form No. in a list. Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly. The marks shown to the right of Form No.
- Page 5 100 Index SEN04352-09 Composition of shop manual 50 Disassembly and assembly ......................SEN04350-01 100 General information on disassembly and assembly............SEN04724-01 200 Engine and cooling system ....................SEN04725-01 300 Power train .........................SEN04726-01 400 Undercarriage and frame ....................SEN04727-01 500 Hydraulic system ........................SEN04728-00 600 Work equipment .........................SEN04729-00 700 Cab and its attachments.....................SEN04730-00 800 Electrical system ........................SEN04731-00 90 Diagrams and drawings......................SEN04351-04...
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Page 6: Table Of Contents
100 Index SEN04352-09 Table of contents Table of contents 00 Index and foreword 100 Index ............................SEN04352-09 Composition of shop manual......................... Table of contents ............................200 Foreword and general information .....................SEN04353-02 Safety notice ..............................How to read the shop manual ........................Explanation of terms for maintenance standard.................... - Page 7 100 Index SEN04352-09 Table of contents CLSS ................................28 Functions and operation of each valve......................31 420 Hydraulic system, Part 2 ......................SEN04488-00 Blade PPC valve............................Accumulator..............................11 500 Work equipment ........................SEN04489-00 Work equipment ............................Cutting edge and end bit ..........................Ripper ................................
- Page 8 100 Index SEN04352-09 Table of contents Check of engine piping for damage and looseness ..................32 Testing and adjusting alternator belt tension....................33 Testing and adjusting air conditioner compressor belt tension..............34 120 Testing and adjusting, Part 2......................SEN04503-01 Adjusting decelerator pedal........................... Testing and adjusting HST oil pressure......................
- Page 9 100 Index SEN04352-09 Table of contents Failure code [CA123] Charge pressure sensor too low: Excessively low voltage detected ......17 Failure code [CA131] Decelerator pedal sensor tool high: Excessively high voltage detected ..... 18 Failure code [CA132] Decelerator pedal sensor too low: Excessively low voltage detected......20 Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected ....
- Page 10 100 Index SEN04352-09 Table of contents Failure code [DAJ5KK] HST controller sensor 5 V power supply No.1: Lowing of source voltage/Input ..20 Failure code [DAJ6KK] HST controller sensor 5 V power supply No.2: Lowing of source voltage/Input ..22 Failure code [DAJRKR] CAN communication (HST controller ? Monitor panel): Defective communication (Abnormality in objective component system) ..........
- Page 11 100 Index SEN04352-09 Table of contents Failure code [DV20KB] Back alarm buzzer: Short circuit ................Failure code [DW4BKA] Parking brake solenoid valve: Disconnection ............Failure code [DW4BKB] Parking brake solenoid valve: Short circuit............. 10 Failure code [DW4BKY] Parking brake solenoid valve: Short circuit with power supply line ......12 Failure code [DW7BKA] Fan reverse solenoid valve: Disconnection ............
- Page 12 100 Index SEN04352-09 Table of contents 500 Troubleshooting of hydraulic and mechanical system (H-mode) ..........SEN04513-00 Information in troubleshooting table ......................H-1 Right and left travel systems do not operate forward and in reverse (No travel systems operate) ..H-2 Right or left travel system does not operate forward and in reverse (Only right or left travel system does not operate) ...........................
- Page 13 100 Index SEN04352-09 Table of contents Removal and installation of front guard assembly..................24 Removal and installation of radiator assembly ....................26 Removal and installation of hydraulic oil cooler assembly ................28 Removal and installation of aftercooler assembly ..................30 Removal and installation of cooling fan and motor assembly................
- Page 14 SEN04352-09 D31/37-22 Bulldozer Form No. SEN04352-09 00-100...
- Page 15 SEN04353-02 BULLDOZER D31EX-22 D31PX-22 D37EX-22 D37PX-22 Machine model Serial number D31EX-22 60001 and up D31PX-22 60001 and up D37EX-22 60001 and up D37PX-22 60001 and up 00 Index and foreword 200 Foreword and general information Safety notice ..............................2 How to read the shop manual ......................... 7 Explanation of terms for maintenance standard .....................
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Page 16: Composition Of Shop Manual
Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. -
Page 17: Cooling System
200 Foreword and general information SEN04353-02 Safety notice Preparations for work Before adding oil or making any repairs, park the machine on a hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. -
Page 18: Table Of Contents
200 Foreword and general information SEN04353-02 Safety notice 12) When assembling or installing parts, Limit the hanging angle to 60°, as a rule. always tighten them to the specified Do not sling a heavy load with ropes form- torques. When installing protective parts ing a wide hanging angle from the hook. -
Page 19: Cooling Fan Motor
200 Foreword and general information SEN04353-02 Safety notice Precautions for using overhead hoist crane When raising a heavy part (heavier than 25 kg), use a hoist, etc. In Disas- sembly and assembly, the weight of a part heavier than 25 kg is indicated after the mark of Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over... -
Page 20: Steering And Brake Control
200 Foreword and general information SEN04353-02 Safety notice Selecting wire ropes Connection Select adequate ropes depending on the When installing the air conditioner cir- weight of parts to be hoisted, referring to cuit hoses and tubes, take care that the table below. dirt, dust, water, etc. -
Page 21: 200 Foreword And General Information
Engine volume This section explains the method of reproducing, repairing, and replacing parts. Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work. D31/37-22... -
Page 22: Solenoid Valve
200 Foreword and general information SEN04353-02 How to read the shop manual Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table. Revised edition mark When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1. -
Page 23: Explanation Of Terms For Maintenance Standard
200 Foreword and general information SEN04353-02 Explanation of terms for maintenance standard Explanation of terms for maintenance standard The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the machine maintenance work. The following terms are used to explain the criteria. Standard size and tolerance To be accurate, the finishing size of parts is a little different from one to another. -
Page 24: Oil Cooler Bypass Valve
200 Foreword and general information SEN04353-02 Explanation of terms for maintenance standard Standard clearance and standard value Clearance limit The clearance made when new parts are Parts can be used until the clearance assembled is called the “standard clear- between them is increased to a certain ance“, which is indicated by the range limit. -
Page 25: Handling Of Electric Equipment And Hydraulic Component
200 Foreword and general information SEN04353-02 Handling of electric equipment and hydraulic component Handling of electric equipment and hydraulic component To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be carried out. -
Page 26: Weight Table
200 Foreword and general information SEN04353-02 Handling of electric equipment and hydraulic component Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the sol- dering may be damaged, or the wiring... - Page 27 200 Foreword and general information SEN04353-02 Handling of electric equipment and hydraulic component Removing, installing, and drying connec- tors and wiring harnesses Disconnecting connectors Hold the connectors when discon- necting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart.
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Page 28: Track Shoe
200 Foreword and general information SEN04353-02 Handling of electric equipment and hydraulic component Connecting connectors Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or dam- age to the connector pins. -
Page 29: Final Drive
200 Foreword and general information SEN04353-02 Handling of electric equipment and hydraulic component Heavy duty wire connector (DT 8-pole, 12- Disconnection Connection (Example of pole) incomplete setting of (a)) Disconnection (Left of figure) While pressing both sides of locks (a) and (b), pull out female connector (2). -
Page 30: Table Of Fuel, Coolant And Lubricants
200 Foreword and general information SEN04353-02 Handling of electric equipment and hydraulic component Drying wiring harness If there is any oil or dirt on the wiring har- ness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. - Page 31 200 Foreword and general information SEN04353-02 Handling of electric equipment and hydraulic component Handling controller The controller contains a microcomputer and electronic control circuits. These con- trol all of the electronic circuits on the machine, so be extremely careful when handling the controller.
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Page 32: Hst Pump
200 Foreword and general information SEN04353-02 Handling of electric equipment and hydraulic component Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful. - Page 33 200 Foreword and general information SEN04353-02 Handling of electric equipment and hydraulic component Change hydraulic oil when the temperature is high When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm.
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Page 34: Handling Of Connectors Newly Used For Engines
200 Foreword and general information SEN04353-02 Handling of connectors newly used for engines Handling of connectors newly used for engines a Mainly, following engines are object for follow- Pull lock type (PACKARD-2) ing connectors. 95 – 170, 12V140 engines 95E-5 Various temperature sensors 107E-1 Example) - Page 35 200 Foreword and general information SEN04353-02 Handling of connectors newly used for engines Push lock type 95, 107, 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03) Disconnect connector (3) according to the fol- lowing procedure. While pressing lock (C), pull out connector (3) in the direction of the arrow.
- Page 36 200 Foreword and general information SEN04353-02 Handling of connectors newly used for engines 95, 125 – 170, 12V140 engines Turn-housing type (Round green connector) While pressing lock (E) of the connector, 140 engine pull out connector (5) in the direction of Example) the arrow.
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Page 37: How To Read Electric Wire Code
200 Foreword and general information SEN04353-02 How to read electric wire code How to read electric wire code a The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting. In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym- bols. - Page 38 200 Foreword and general information SEN04353-02 How to read electric wire code Dimensions (Table 2) Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) Number of strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 eter of strand Conductor Sectional 0.51...
- Page 39 200 Foreword and general information SEN04353-02 How to read electric wire code Color codes table (Table 3) Color Code Color of wire Color Code Color of wire Black Light green & White Brown Light green & Yellow Brown & Black Blue &...
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Page 40: Precautions When Carrying Out Operation
200 Foreword and general information SEN04353-02 Precautions when carrying out operation Precautions when carrying out operation [When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly. - Page 41 200 Foreword and general information SEN04353-02 Precautions when carrying out operation Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
- Page 42 200 Foreword and general information SEN04353-02 Precautions when carrying out operation Checking muffler and exhaust pipe for damage and looseness Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage. If any part is damaged, replace it. Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for looseness.
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Page 43: Method Of Disassembling And Connecting Push-Pull Type Coupler
200 Foreword and general information SEN04353-02 Method of disassembling and connecting push-pull type coupler Method of disassembling and connecting push-pull type coupler Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. -
Page 44: Hst Motor
200 Foreword and general information SEN04353-02 Method of disassembling and connecting push-pull type coupler Type 2 Disconnection Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexag- onal portion at the male end. (Fig. 6) While holding the condition of Step 1), turn lever (8) to the right (clockwise). - Page 45 200 Foreword and general information SEN04353-02 Method of disassembling and connecting push-pull type coupler Type 3 Disconnection Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexag- onal portion at the male end. (Fig. 10) While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal por-...
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Page 46: Standard Tightening Torque Table
200 Foreword and general information SEN04353-02 Standard tightening torque table Standard tightening torque table Table of tightening torques for bolts and nuts a Unless there are special instructions, tighten metric nuts and bolts to the torque below. a The following table applies to the bolts in Fig. A. Thread diameter of bolt Width across flats Tightening torque... - Page 47 200 Foreword and general information SEN04353-02 Standard tightening torque table Table of tightening torques for split flange bolts a Unless there are special instructions, tighten split flange bolts to the torque below. Thread diameter of bolt Width across flats Tightening torque 59 –...
- Page 48 200 Foreword and general information SEN04353-02 Standard tightening torque table Table of tightening torques for hoses (taper seal type and face seal type) a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the torque below.
- Page 49 200 Foreword and general information SEN04353-02 Standard tightening torque table Table of tightening torques for 102, 107 and 114 engine series (Eye joints) a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine series to the torque below.
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Page 50: Conversion Table
200 Foreword and general information SEN04353-02 Conversion table Conversion table Method of using the conversion table The conversion table in this section is provided to enable simple conversion of figures. For details of the method of using the conversion table, see the example given below. Example: Method of using the conversion table to convert from millimeters to inches Convert 55 mm into inches. - Page 51 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...