This complete service repair workshop manual PDF download for the Komatsu D31EX-21, D31PX-21, D37EX-21, D37PX-21 Bulldozer has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.
APPLICABLE MODELS :
Komatsu D31EX-21 – S/N: 50001 and up
Komatsu D31PX-21 – S/N: 50001 and up
Komatsu D37EX-21 – S/N: 5001 and up
Komatsu D37PX-21 – S/N: 5001 and up
TABLE OF CONTENTS :
– GENERAL
– STRUCTURE AND FUNCTION
– MAINTENANCE STANDARD
– TESTING AND ADJUSTING
– DISASSEMBLY AND ASSEMBLY
– OTHERS
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM025607
Total Pages : 407
This (OEM) Komatsu Shop Manual has detailed illustrations as well as step by step instructions, It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic. With step by step instruction & highly detailed exploded pictures & diagrams to show you how to complete the required job correctly & efficiently Using. Provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.
This service repair workshop manual PDF download has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!
This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having PDF files instead of a hard-printed manual is that you can use the Search feature in Acrobat to find just what your looking for and just print out the exact pages you need or all manual.
Instant download means no shipping cost or waiting for a CD to arrive in the mail…you will receive this manual today via instant download on completion of payment via our secure payment processor. We accept all major credit/debit cards/paypal.
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Komatsu D31EX-21, D31PX-21, D37EX-21, D37PX-21 Bulldozer OEM Manual PDF Download
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COVER
CONTENTS
01 GENERAL
SPECIFICATION DRAWING
SPECIFICATIONS
WEIGHT TABLE
TABLE OF FUEL, COOLANT AND LUBRICANTS
10 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
COOLING SYSTEM
ENGINE CONTROL
POWER TRAIN
POWER TRAIN SYSTEM
HST HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAM
STEERING, BRAKE CONTROL
DAMPER
SOLENOID VALVE
FINAL DRIVE
HST PUMP
SAFETY-SUCTION VALVE
CUT-OFF VALVE
CHARGE SAFETY VALVE
CHARGE PUMP
HST BRAKE QUICK RETURN CIRCUIT
TOWING VALVE
PARKING BRAKE VALVE
AS VALVE
HST MOTOR
STEERING, DIRECTIONAL PPC VALVE
AUTOMATIC GEARSHIFTING VALVE
INCHING VALVE
FRAME ASSEMBLY
TRACK FRAME, RECOIL SPRING
IDLER
TRACK ROLLER
CARRIER ROLLER
SPROCKET
TRACK SHOE
ARRANGEMENT OF HYDRAULIC EQUIPMENT FOR WORK EQUIPMENT
WORK EQUIPMENT CONTROL
HYDRAULIC TANK, FILTER
HYDRAULIC PUMP
WORK EQUIPMENT CYLINDER
CONTROL VALVE
CLSS
WORK EQUIPMENT PPC VALVE
WORK EQUIPMENT
CUTTING EDGE, END BIT
CAB RELATED
SAFETY MECHANISM WHEN STARTING ENGINE
GEARSHIFT CONTROL SYSTEM
PARKING BRAKE CONTROL SYSTEM
COMPONENT EQUIPMENT OF SYSTEM
MONITOR SYSTEM
SENSORS
20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
TESTING AND ADJUSTING
TOOLS LIST FOR TESTING AND ADJUSTING
MEASURING ENGINE SPEED
MEASURING EXHAUST COLOR
MEASURING BLOW-BY PRESSURE
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
ADJUSTING VALVE CLEARANCE
TESTING ADJUSTING FUEL INJECTION TIMING
MEASURING COMPRESSION PRESSURE
ADJUSTING ENGINE STOP SOLENOIDE LINKAGE
MEASURING ENGINE OIL PRESSURE
BLEEDING AIR FROM FUEL CIRCUIT
TESTING AND ADJUSTING TENSION OF AIR CONDITIONER COMPRESSOR BELT
MEASURING AND ADJUSTING HST OIL PRESSURE
MEASURING SOLENOID VALVE OUTPUT PRESSURE
MEASURING AND ADJUSTING WORK EQUIPMENT MAIN RELIEF PRESSURE
MEASURING PPC VALVE OUTPUT PRESSURE
MEASURING LEAKAGE INSIED CYLINDER
BLEEDING AIR FROM HYDRAULIC CYLINDERS
TESTING AND ADJUSTING TRACK SHOE TENSION
TESTING AND ADJUSTING TRAVEL DEVIATION
ADJUSTING FUEL CONTROL LINKAGE
ADJUSTING DECELERATOR PEDAL LINKAGE
ADJUSTING BRAKE PEDAL LINKAGE
ADJUSTING STEERING/DIRECTIONAL/GEAR SHIFT LEVER AND LOCK LEVER
ADJUSTING BLADE CONTROL LEVER AND LOCK LEVER
ADJUSTING WORK EQUIPMENT PPC VALVE
PROCEDURE FOR RELEASING PARKING BRAKE
PROCEDURE FOR INSPECTING DIODE
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
CHECKS BEFORE TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHARTS
TYPES AND LOCATIONS OF CONNECTORS
CONNECTOR ARRANGEMENT DIAGRAM
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
TROUBLESHOOTING FOR ELECTRICAL SYSTEM (E-MODE)
TABLE OF FAILURE MODES AND CAUSES (ELECTRICAL SYSTEM)
ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM
E-1. WHEN STARTING SWITCH IS TURNED ON, STARTING MOTOR DOES NOT ROTATE
E-2. ENGINE DOES NOT START (ENGINE STOP SOLENOID DOES NOT OPERATE NORMALLY)
E-3. HEADLAMP DOES NOT LIGHT UP
E-4. WHEN STARTING SWITCH IS TURNED TO HEAT POSITION, ENGINE IS NOT HEATED
E-5. WINDSHIELD WIPER DOES NOT OPERATE
E-6. WASHING WATER DOES NOT SPOUT
E-7. AIR CONDITIONER DOES NOT WORK
a) AIR DOES NOT BLOW OUT
b) AIR IS NOT COOLED
E-8. PARKING BRAKE CANNOT BE RELEASED (PARKING BRAKE SOLENOID DOES NOT OPERATE)
E-9. TRAVEL SPEED CONTROL IS ABNORMAL
a) WHEN GEAR SHIFT SWITCH IS PRESSED,GEAR SPEED DOES NOT CHANGE OR GEAR SPEED CHANGES BY ITSELF (GEAR SHIFT SWITCH OR CONTROLLER IS ABNORMAL)
b) GEAR SPEED CANNOT BE SELECTED NORMALLY (TRAVEL SPEED CHANGEOVER SOLENOID IS ABNORMAL)
E-10. BACKUP ALARM DOES NOT SOUND DURING REVERSE TRAVEL
E-11. HORN DOES NOT SOUND
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)
TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC AND MECHANICAL SYSTEMS)
H-1. MACHINE DOES NOT TRAVEL IN EITHER DIRECTION OR IT STOPS SUDDENLY
H-2. MACHINE DOES NOT TRAVEL IN ONE DIRECTION
H-3. MACHINE TRAVELS WHILE TRAVEL LEVER IS IN NEUTRAL
H-5. MACHINE DEVIATES WHILE TRAVEL LEVER IS IN PARTIAL POSITION
H-7. MACHINE SWHINGS MOMENTARILY WHEN IT STARTS ON FLAT GROUND
H-11. TURNING TIME LAG IS LARGE
H-12. WHEN OPERATOR INTENDS TO TURN GARDUALLY, MACHINE TURNS SHARPLY
H-13. MACHINE DOES NOT RETURN QUICKLY TO STRAIGHT TRAVEL POSITION
H-14. MACHINE IS NOT DECELERATED SMOOTHLY OR TRAVEL SPEED CANNOT BE CONTROLLED ON DOWNHILL GROUND
H-15. MACHINE DEVIATES WHEN IT IS DECELERATED
H-4. MACHINE DEVIATES WHEN TRAVEL LEVER IS MOVED TO STROKE END
H-6. MACHINE MOVES BACK WHEN OPERATOR STARTS ON UPHILL GROUND
H-8. MACHINE STARTS SHARPLY
H-9. MACHINE SWINGS MOMENTARLLY WHEN IT STARTS
H-10. STARTING TIME LAG IS LARGE
H-16. MAXIMUM TRAVEL SPEED IS LOW OR OUTPUT POWER IS INSUFFICIENT OR ACCELERATION IS LOW
H-17. ENGINE STALLS
H-18. HST NOISE IS LARGE
H-19. HST OIL TEMPERATURE RISES TOO HIGH
H-20. GEAR SPEED DOES NOT CHANGE
H-21. ABNORMAL SOUND IS HEARD FROM AROUND WORK EQUIPMENT PUMP OR HST PUMP
H-22. ANY WORK EQUIPMENT DOES NOT MOVE
H-23. SPEED OR POWER OF EACH WORK EQUIPMENT IS LOW
H-24. SPEED OR POWER OF BLADE LIFT OF BLADE TILT CYLINDER IS LOW
H-25. SPEED OR POWER OF BLADE ANGLE CYLINDER IS LOW
H-26. HYDRAULIC DRIFT OF BLADE LIFT CYLINDER IS LARGE
H-27. HYDRAULIC DRIFT OF BLADE TILT CYLINDER IS LARGE
H-28. HYDRAULIC DRIFT OF BLADE ANGLE CYLINDER IS LARGE
TROUBLESHOOTING FOR MACHINE MONITOR SYSTEM (M-MODE)
TABLE OF FAILURE MODES AND CAUSES (MACHINE MONITOR SYSTEM)
ELECTRIC CIRCUIT DIAGRAM FOR EACH SYSTEM
M-1. WHEN STARTING SWITCH IS TURNED ON , MONITOR PANEL IS NOT TURNED ON
M-2. TROUBLE IN PREHEATING CAUTION LAMP
a) PREHEATING MONITOR DOES NOT LIGHT UP
b) PREHEATING MONITOR KEEPS LIGHTING UP
M-3. CAUTION ITEM LIGHTS UP
a) CHARGE CAUTION LAMP LIGHTS UP WHILE ENGINE IS RUNNING
b) OIL PRESSURE CAUTION LAMP LIGHTS UP WHILE ENGINE IS RUNNING
c) HST FILTER CLOGGING CAUTION LAMP LIGHTS UP (WHILE FILTER IS NOT CLOGGED)
M-4. TROUBLE IN HST OIL TEMPERATURE GAUGE
a) GAUGE DOES NOT RISE ABOVE C (LOWEST POINT)
b) GAUGE DOES NOT LOWER BELOW H (HIGHEST POINT)
c) HST OIL TEMPERATURE INDICATED BY GAUGE IS DIFFERENT FROM ACTUAL TEMPERATURE
M-5. TROUBLE IN ENGINE WATER TEMPERATURE GAUGE
a) GAUGE DOES NOT RISE ABOVE C (LOWEST POINT)
b) GAUGE DOES NOT LOWER BELOW H (HIGHEST POINT)
c) ENGINE WATER TEMPERATURE INDICATED BY GAUGE IS DIFFERENT FROM ACTUAL TEMPERATURE
M-6. TROUBLE IN FUEL LEVEL GAUGE
a) GAUGE DOES NOT RISE ABOVE E (LOWEST POINT)
b) GAUGE DOES NOT LOWER BELOW F (HIGHEST POINT)
c) FUEL LEVEL INDICATED BY GAUGE IS DIFFERENT FROM ACTUAL LEVEL
M-7. SERVICE METER DOES NOT OPERATE AFTER ENGINE IS STARTED
M-8. MONITOR PANEL LAMP DOES NOT LIGHT UP (WHILE HEADLAMP IS NORMAL)
M-9. TROUBLE IN DISPLAY OF TRAVEL SPEED (WHILE ACTUAL TRAVEL SPEED IS NORMAL)
a) TRAVEL SPEED IS NOT DISPLAYED
b) DISPLAYED SPEED IS DIFFERENT FROM ACTUAL TRAVEL SPEED
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
PRECAUTIONS WHEN CARRYING OUT OPERATION
SPECIAL TOOL LIST
SKETCHES OF SPECIAL TOOLS
REMOVAL OF FUEL INJECTION PUMP ASSEMBLY
INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY
REMOVAL OF CYLINDER HEAD ASSEMBLY
INSTALLATION OF CYLINDER HEAD ASSEMBLY
REMOVAL OF ENGINE FRONT SEAL
INSTALLATION OF ENGINE FRONT SEAL
REMOVAL OF ENGINE REAR SEAL
INSTALLATION OF ENGINE REAR SEAL
REMOVAL OF RADIATOR GUARD ASSEMBLY
INSTALLATION OF RADIATOR GUARD ASSEMBLY
DISASSEMBLY OF RADIATOR, OIL COOLER, AND CHARGE AIR COOLER ASSEMBLIES
ASSEMBLY OF RADIATOR, OIL COOLER, AND CHARGE AIR COOLER ASSEMBLIES
REMOVAL OF ENGINE ASSEMBLY
INSTALLATION OF ENGINE ASSEMBLY
REMOVAL OF DAMPER
INSTALLATION OF DAMPER
REMOVAL OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY
INSTALLATION OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY
DISASSEMBLY OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY
ASSEMBLY OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY
REMOVAL OF IDLER AND RECOIL SPRING ASSEMBLY
INSTALLATION OF IDLER AND RECOIL SPRING ASSEMBLY
DISASSEMBLY OF RECOIL SPRING ASSEMBLY
ASSEMBLY OF RECOIL SPRING ASSEMBLY
DISASSEMBLY OF IDLER ASSEMBLY
ASSEMBLY OF IDLER ASSEMBLY
DISASSEMBLY OF TRACK ROLLER ASSEMBLY
ASSEMBLY OF TRACK ROLLER ASSEMBLY
DISASSEMBLY OF CARRIER ROLLER ASSEMBLY
ASSEMBLY OF CARRIER ROLLER ASSEMBLY
SPREADING TRACK SHOE ASSEMBLY
INSTALLATION OF TRACK SHOE ASSEMBLY
REMOVAL OF HST PUMP ASSEMBLY
INSTALLATION OF HST PUMP ASSEMBLY
REMOVAL OF MAIN CONTROL VALVE ASSEMBLY
INSTALLATION OF MAIN CONTROL VALVE ASSEMBLY
DISASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY
ASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY
DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLIES
ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLIES
REMOVAL OF BLADE ASSEMBLY
INSTALLATION OF BLADE ASSEMBLY
REMOVAL OF OPERATOR’S SEAT TRAME ASSEMBLY
INSTALLATION OF OPERATOR’S SEAT FRAME ASSEMBLY
REMOVAL OF FUEL TANK ASSEMBLY
INSTALLATION OF FUEL TANK ASSEMBLY
REMOVAL OF HYDRAULIC TANK ASSEMBLY
INSTALLATION OF HYDRAULIC TANK ASSEMBLY
90 OTHERS
HYDRAULIC CIRCUIT DIAGRAM (1/2)(D31EX-21 SERIAL NO.50001-50097 D31PX-21 SERIAL NO.50001-50181 D37EX-21 SERIAL NO. 5001-5104 D37PX-21 SERIAL NO. 5001-5090)
HYDRAULIC CIRCUIT DIAGRAM (1/2)(D31EX-21 SERIAL NO.50098 AND UP D31PX-21 SERIAL NO.50182 AND UP D37EX-21 SERIAL NO.5105 AND UP D37PX-21 SERIAL NO.5091 AND UP)
HYDRAULIC CIRCUIT DIAGRAM (2/2)
HYDRAULIC CIRCUIT DIAGRAM (2/2) (FOR D37EX, PX-21 EU SPEC.)
ELECTRICAL CIRCUIT DIAGRAM (1/2)
ELECTRICAL CIRCUIT DIAGRAM (2/2)
ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER
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