Komatsu D31EX, PX-21 and D37EX, PX-12 - Repair, Service Manual and Electrical Wiring Diagrams

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KOMATSU D31EX, PX-21 & D37EX, PX21 - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS

- English Service Manual and Wiring Diagrams, to Komatsu D31EX, PX-21 and D37EX, PX-12.
 

CONTENTS:

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