Komatsu D31EX -22 Install guide

BULLDOZER
SEN04343-09
D31EX
-22
D31PX
-22
D37EX
-22
D37PX
-22
SERIAL NUMBERS
60001
and up

Find manuals at https://best-manuals.com

D31/37-22 00-100 1
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 00
100 Index
Composition of shop manual .......................................................................................................................... 2
Table of contents............................................................................................................................................. 4
Find manuals at https://best-manuals.com

SEN04352-09
00-100 2 D31/37-22
Composition of shop manual
100 Index
Composition of shop manual 1
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. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
qPlace a divider on the top of each section in the file after matching the Tub No. with No. indi-
cated next to each Section Name shown in the table below:
qFile overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs .....................................................................SEN04343-09
00 Index and foreword ....................................................................................................................SEN04344-09
100 Index..................................................................................................................................SEN04352-09
q
200 Foreword and general information.....................................................................................SEN04353-02
01 General ......................................................................................................................................SEN04345-00
100 Specification and technical data.........................................................................................SEN04354-00
10 Structure, function and maintenance standard...........................................................................SEN04346-01
100 Engine and cooling system................................................................................................SEN04484-00
200 Power train.........................................................................................................................SEN04485-00
300 Undercarriage and frame...................................................................................................SEN04486-00
410 Hydraulic system, Part 1....................................................................................................SEN04487-00
420 Hydraulic system, Part 2....................................................................................................SEN04488-00
500 Work equipment.................................................................................................................SEN04489-00
600 Cab and its attachments ....................................................................................................SEN04490-00
700 Electrical system................................................................................................................SEN04491-01
q
20 Standard value table...................................................................................................................SEN04347-02
100 Standard service value table..............................................................................................SEN04501-02
30 Testing and adjusting .................................................................................................................SEN04348-03
110 Testing and adjusting, Part 1..............................................................................................SEN04502-02
120 Testing and adjusting, Part 2..............................................................................................SEN04503-01
130 Testing and adjusting, Part 3..............................................................................................SEN04504-02
q
40 Troubleshooting..........................................................................................................................SEN04349-02
100 Failure code table and fuse locations ................................................................................SEN04505-01
q
200 General information on troubleshooting.............................................................................SEN04506-01
310 Troubleshooting by failure code (Display of code), Part 1 .................................................SEN04507-01
320 Troubleshooting by failure code (Display of code), Part 2 .................................................SEN04508-02
q
330 Troubleshooting by failure code (Display of code), Part 3 .................................................SEN04509-00
340 Troubleshooting by failure code (Display of code), Part 4 .................................................SEN04510-00
350 Troubleshooting by failure code (Display of code), Part 5.................................................SEN04511-00
400 Troubleshooting of electrical system (E-mode)..................................................................SEN04512-01
q
500 Troubleshooting of hydraulic and mechanical system (H-mode).......................................SEN04513-00
600 Troubleshooting of engine (S-mode)..................................................................................SEN04514-01
Find manuals at https://best-manuals.com

SEN04352-09
D31/37-22 00-100 3
Composition of shop manual
100 Index
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
100 Hydraulic diagrams and drawings......................................................................................SEN04355-02
200 Electrical diagrams and drawings.......................................................................................SEN04356-02
q
Find manuals at https://best-manuals.com

SEN04352-09
00-100 4 D31/37-22
Table of contents
100 Index
Table of contents 1
00 Index and foreword
100 Index..........................................................................................................................................SEN04352-09
Composition of shop manual......................................................................................................................... 2
Table of contents........................................................................................................................................... 4
200 Foreword and general information.............................................................................................SEN04353-02
Safety notice ................................................................................................................................................. 2
How to read the shop manual....................................................................................................................... 7
Explanation of terms for maintenance standard............................................................................................ 9
Handling of electric equipment and hydraulic component............................................................................. 11
Handling of connectors newly used for engines............................................................................................ 20
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table................................................................................................................... 32
Conversion table........................................................................................................................................... 36
01 General
100 Specification and technical data.................................................................................................SEN04354-00
Specification dimensional drawing................................................................................................................ 2
Specifications................................................................................................................................................ 4
Weight table .................................................................................................................................................. 12
Table of fuel, coolant and lubricants.............................................................................................................. 16
10 Structure, function and maintenance standard
100 Engine and cooling system........................................................................................................SEN04484-00
Engine system parts...................................................................................................................................... 2
Cooling system.............................................................................................................................................. 3
Cooling fan pump.......................................................................................................................................... 4
Cooling fan motor.......................................................................................................................................... 5
Oil cooler bypass valve................................................................................................................................. 10
200 Power train.................................................................................................................................SEN04485-00
Power train.................................................................................................................................................... 2
Power train system........................................................................................................................................ 3
Damper ......................................................................................................................................................... 4
HST hydraulic equipment arrangement diagram .......................................................................................... 5
Steering and brake control............................................................................................................................ 6
Solenoid valve............................................................................................................................................... 8
Final drive...................................................................................................................................................... 15
HST pump..................................................................................................................................................... 18
HST motor..................................................................................................................................................... 30
Charge pump ................................................................................................................................................ 40
300 Undercarriage and frame...........................................................................................................SEN04486-00
Main frame.................................................................................................................................................... 2
Track frame and idler cushion....................................................................................................................... 4
Idler............................................................................................................................................................... 6
Track roller .................................................................................................................................................... 8
Carrier roller.................................................................................................................................................. 10
Sprocket........................................................................................................................................................ 12
Track shoe..................................................................................................................................................... 14
410 Hydraulic system, Part 1............................................................................................................SEN04487-00
Arrangement of hydraulic equipment for work equipment............................................................................. 2
Work equipment control................................................................................................................................ 4
Hydraulic tank and filter................................................................................................................................. 6
Work equipment and fan pump..................................................................................................................... 8
Control valve................................................................................................................................................. 16
Find manuals at https://best-manuals.com

SEN04352-09
D31/37-22 00-100 5
Table of contents
100 Index
CLSS............................................................................................................................................................. 28
Functions and operation of each valve.......................................................................................................... 31
420 Hydraulic system, Part 2 ...........................................................................................................SEN04488-00
Blade PPC valve............................................................................................................................................ 2
Accumulator................................................................................................................................................... 11
500 Work equipment ........................................................................................................................SEN04489-00
Work equipment ............................................................................................................................................ 2
Cutting edge and end bit ............................................................................................................................... 6
Ripper............................................................................................................................................................ 7
Work equipment cylinder............................................................................................................................... 8
Piston valve................................................................................................................................................... 11
600 Cab and its attachments............................................................................................................SEN04490-00
ROPS cab...................................................................................................................................................... 2
Cab mount..................................................................................................................................................... 3
Canopy mount............................................................................................................................................... 4
Air conditioner................................................................................................................................................ 5
700 Electrical system .......................................................................................................................SEN04491-01
Monitor system.............................................................................................................................................. 2
Engine control................................................................................................................................................ 4
Engine control system................................................................................................................................... 5
Cooling control system.................................................................................................................................. 6
HST control system....................................................................................................................................... 8
Parking brake control system........................................................................................................................ 14
KOMTRAX system ........................................................................................................................................ 16
Component equipment of system.................................................................................................................. 18
PCCS lever (for steering) .............................................................................................................................. 27
Sensor........................................................................................................................................................... 30
20 Standard value table
100 Standard service value table .....................................................................................................SEN04501-02
Standard service value table for engine ........................................................................................................ 2
Standard service value table for chassis ....................................................................................................... 4
30 Testing and adjusting
110 Testing and adjusting, Part 1.....................................................................................................SEN04502-02
Tools for testing, adjusting, and troubleshooting ........................................................................................... 3
Measuring engine speed............................................................................................................................... 7
Measuring intake air pressure (boost pressure)............................................................................................ 8
Testing exhaust temperature......................................................................................................................... 10
Measuring exhaust gas color (boost pressure) ............................................................................................. 11
Adjusting valve clearance.............................................................................................................................. 12
Testing compression pressure....................................................................................................................... 14
Measuring blow-by pressure ......................................................................................................................... 16
Testing oil pressure........................................................................................................................................ 18
Handling fuel system equipment ................................................................................................................... 19
Releasing residual pressure in fuel system................................................................................................... 19
Bleeding air from fuel circuit.......................................................................................................................... 20
Testing fuel pressure ..................................................................................................................................... 23
Testing leakage from pressure limiter and return rate from injector .............................................................. 24
Testing leakage in fuel system....................................................................................................................... 27
Measuring fan circuit pressure and fan speed............................................................................................... 28
Adjustment of fan speed sensor.................................................................................................................... 29
Handling reduced cylinder mode operation................................................................................................... 30
Handling no-injection cranking operation ...................................................................................................... 30
Check of muffler and muffler stack for looseness and damage.....................................................................31
Check of muffler function............................................................................................................................... 31
Check of installed condition of cylinder head and manifolds......................................................................... 32
Find manuals at https://best-manuals.com

SEN04352-09
00-100 6 D31/37-22
Table of contents
100 Index
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........................................................................................................................... 2
Testing and adjusting HST oil pressure......................................................................................................... 4
Measuring solenoid valve output oil pressure............................................................................................... 9
Testing travel deviation.................................................................................................................................. 12
Adjusting parking brake lever........................................................................................................................ 13
Simple brake performance test procedure.................................................................................................... 15
Adjusting brake pedal.................................................................................................................................... 16
Method of releasing parking brake (Procedure for emergency escape)....................................................... 18
Testing and adjusting idler clearance............................................................................................................ 20
Testing and adjusting track shoe tension...................................................................................................... 21
Testing work equipment oil pressure............................................................................................................. 22
Testing work equipment PPC valve output oil pressure................................................................................ 24
Adjusting play of work equipment PPC valve................................................................................................ 26
Adjusting work equipment lock lever............................................................................................................. 27
Testing internal leakage of work equipment cylinder..................................................................................... 28
Releasing residual pressure in hydraulic circuit............................................................................................ 30
Bleeding air from hydraulic circuit ................................................................................................................. 31
Adjusting play of blade center ball ................................................................................................................ 32
Procedure for testing diodes......................................................................................................................... 33
Preparation work for troubleshooting for electrical system ........................................................................... 34
How to start operation of KOMTRAX terminal .............................................................................................. 38
Lamp display of KOMTRAX terminal ............................................................................................................ 41
130 Testing and adjusting, Part 3......................................................................................................SEN04504-02
Special functions of monitor panel (EMMS).................................................................................................. 2
Items to be adjusted when electric/hydraulic devices are adjusted/replaced................................................ 62
Adjustment procedure after replacement of HST controller.......................................................................... 63
Adjustment procedure after replacement of monitor panel ........................................................................... 65
Pm-clinic service (D31EX-22, D31PX-22)..................................................................................................... 67
Pm-clinic service (D37EX-22, D37PX-22)..................................................................................................... 75
40 Troubleshooting
100 Failure code table and fuse locations ........................................................................................SEN04505-01
Failure code table.......................................................................................................................................... 2
Before carrying out troubleshooting for electrical system (E-mode) ............................................................. 8
200 General information on troubleshooting.....................................................................................SEN04506-01
Points to remember when troubleshooting.................................................................................................... 2
Sequence of events in troubleshooting......................................................................................................... 3
Testing before troubleshooting...................................................................................................................... 4
Classification and procedures of troubleshooting ......................................................................................... 5
Information contained in troubleshooting table ............................................................................................. 8
Connection table for connector pin numbers ................................................................................................ 10
T- branch box and T- branch adapter table................................................................................................... 46
310 Troubleshooting by failure code (Display of code), Part 1 .........................................................SEN04507-01
Failure code [6091NX] HST charge filter element: Clogging ........................................................................ 3
Failure code [AA10NX] Air cleaner: Clogging............................................................................................... 4
Failure code [AB00MA] Alternator: Malfunction............................................................................................ 6
Failure code [B@BAZG] Engine oil: Lowering of oil pressure....................................................................... 7
Failure code [B@BCNS] Coolant: Overheat................................................................................................. 8
Failure code [B@CRNS] HST oil: Overheating............................................................................................. 9
Failure code [B@CRZG] HST oil: Lowering of oil pressure.......................................................................... 10
Failure code [CA111] Engine controller: Abnormality in controller ................................................................ 11
Failure code [CA115] Abnormal engine Ne and Bkup speed sensors: Abnormal speed sensor signal........ 14
Failure code [CA122] Charge pressure sensor tool high: Excessively high voltage detected ...................... 15
Find manuals at https://best-manuals.com

SEN04352-09
D31/37-22 00-100 7
Table of contents
100 Index
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 ................. 22
Failure code [CA145] Coolant temperature sensor too low: Excessively low voltage detected .................... 24
Failure code [CA153] Charge air temperature sensor too high: Excessively high voltage detected............. 26
Failure code [CA154] Charge temperature sensor too low: Excessively low voltage detected..................... 28
Failure code [CA187] Sensor power source 2 too low: Excessively low voltage detected............................ 29
Failure code [CA221] Atmospheric pressure sensor too high: Excessively high voltage detected ............... 30
Failure code [CA222] Atmospheric pressure sensor too low: Excessively low voltage detected.................. 32
Failure code [CA227] Sensor power source 2 too high: Excessively high voltage detected......................... 34
Failure code [CA234] Engine over speed: Excessively high speed .............................................................. 36
Failure code [CA238] Abnormal power source for Ne speed sensor: Excessively low voltage detected...... 38
Failure code [CA271] IMV/PCV1 short circuit: Short circuit........................................................................... 40
Failure code [CA272] IMV/PCV1 disconnection: Disconnection ................................................................... 42
320 Troubleshooting by failure code (Display of code), Part 2.........................................................SEN04508-02
Failure code [CA322] Injector No. 1 system disconnection or short circuit: disconnection, short circuit....... 4
Failure code [CA324] Injector No. 3 system disconnection or short circuit: disconnection, short circuit....... 6
Failure code [CA331] Injector No. 2 system disconnection or short circuit: disconnection, short circuit....... 8
Failure code [CA332] Injector No. 4 system disconnection or short circuit: disconnection, short circuit....... 10
Failure code [CA351] Injector drive circuit abnormality: Abnormal circuit ..................................................... 12
Failure code [CA352] Sensor power source 1 too low:Excessively low voltage detected............................ 14
Failure code [CA386] Sensor power source 1 too high: Excessively high voltage detected......................... 16
Failure code [CA428] Water in fuel sensor too high: Excessively high voltage detected.............................. 18
Failure code [CA429] Water in fuel sensor too low: Excessively low voltage detected................................. 20
Failure code [CA435] Abnormal engine oil pressure switch: Abnormal signal circuit.................................... 22
Failure code [CA441] Power source voltage too low: Excessively low voltage detected .............................. 23
Failure code [CA442] Power source voltage too high:
Excessively high voltage has occurred in the controller power source circuit......................................... 24
Failure code [CA449] Common rail pressure too high (2): Excessively high pressure trouble occurred....... 25
Failure code [CA451] Common rail pressure sensor too high: Excessively high voltage detected............... 26
Failure code [CA452] Common rail pressure sensor too low: Excessively low voltage detected.................. 28
Failure code [CA553] Common rail pressure too high (1): Excessively high pressure detected................... 29
Failure code [CA559] Loss of pressure feed from supply pump (1): Loss of pressure feed detected........... 30
Failure code [CA689] Abnormal engine Ne speed sensor: Abnormal signal................................................. 34
Failure code [CA731] Abnormal engine Bkup speed sensor phase: Abnormal phase.................................. 36
Failure code [CA757] Loss of all engine controller data: Loss of all data...................................................... 37
Failure code [CA778] Abnormal engine Bkup speed sensor: Abnormal Bkup signal.................................... 38
Failure code [CA1633] Abnormal KOMNET: Abnormal communication........................................................ 40
Failure code [CA2185] Decelerator pedal sensor power source too high:
Excessively high voltage detected........................................................................................................... 42
Failure code [CA2186] Decelerator pedal sensor power source too low:
Excessively low voltage detected............................................................................................................ 44
Failure code [CA2249] Loss of pressure feed from supply pump (2): Loss of pressure feed detected......... 45
Failure code [CA2311] Abnormal IMV solenoid: Abnormal resistance.......................................................... 46
Failure code [CA2555] Air intake heater relay disconnection: Disconnection ............................................... 48
Failure code [CA2556] Air intake heater relay short circuit: Short circuit ......................................................50
330 Troubleshooting by failure code (Display of code), Part 3.........................................................SEN04509-00
Failure code [D130KA] Neutral safety relay: Disconnection.......................................................................... 4
Failure code [D130KB] Neutral safety relay: Short circuit ............................................................................. 6
Failure code [DAFRKR] CAN communication (Monitor panel ? HST controller):
Defective communication (Abnormality in objective component system)................................................ 8
Failure code [DAFRMC] CAN communication (Monitor panel ? ENGINE controller):
Defective communication (Abnormality in objective component system)................................................ 11
Failure code [DAJ000] HST controller: Memory error ................................................................................... 14
Failure code [DAJ0KK] HST controller: Lowing of source voltage ................................................................ 16
Failure code [DAJ0KQ] HST controller: Machine code error......................................................................... 18
Failure code [DAJ0KT] HST controller: Memory error................................................................................... 19
Find manuals at https://best-manuals.com

SEN04352-09
00-100 8 D31/37-22
Table of contents
100 Index
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) ............................................... 24
Failure code [DB2RKR] CAN communication (HST controller ? Engine controller):
Defective communication (Abnormality in objective component system) ............................................... 27
Failure code [DD12KA] Shift up switch: Disconnection................................................................................. 30
Failure code [DD12KB] Shift up switch: Short circuit.................................................................................... 32
Failure code [DD13KA] Shift down switch: Disconnection............................................................................ 34
Failure code [DD13KB] Shift down switch: Short circuit................................................................................ 36
Failure code [DD14KB] Travel lock limit switch 1: Short circuit..................................................................... 38
Failure code [DD1NL4] Fan rotation selector switch: Disagreement of ON, OFF Signals............................ 40
Failure code [DDDCKB] Reverse travel speed switch: Short circuit ............................................................. 42
Failure code [DDP6KA] Brake oil pressure sensor: Disconnection............................................................... 44
Failure code [DDP6KB] Brake oil pressure sensor: Short circuit ..................................................................46
Failure code [DDP6MA] Brake oil pressure sensor: Malfunction.................................................................. 48
Failure code [DDQ2KA] Travel lock limit switch 1: Disconnection ................................................................ 50
Failure code [DDT0L4] Shift mode switch: Disagreement of ON/ OFF Signals............................................ 52
Failure code [DDU1FS] Travel lock limit switches 1 and 2: Fixing................................................................ 54
Failure code [DDU1KA] Travel lock limit switch 2: Disconnection................................................................. 56
Failure code [DDU1KY] Travel lock limit switch 2: Short circuit with power supply line................................ 58
Failure code [DGS1KA] HST oil temperature sensor: Disconnection........................................................... 60
Failure code [DGS1KX] HST oil temperature sensor: Out of Input signal range .......................................... 62
340 Troubleshooting by failure code (Display of code), Part 4 .........................................................SEN04510-00
Failure code [DHH5KA] Left HST pump pressure sensor: Disconnection .................................................... 4
Failure code [DHH5KB] Left HST pump pressure sensor: Short circuit........................................................ 6
Failure code [DHH6KA] Right HST pump pressure sensor: Disconnection.................................................. 8
Failure code [DHH6KB] Right HST pump pressure sensor: Short circuit ..................................................... 10
Failure code [DK10KA] Fuel dial sensor: Disconnection............................................................................... 12
Failure code [DK10KB] Fuel dial sensor: Short circuit.................................................................................. 14
Failure code [DK30KA] Steering angle sensor 1: Disconnection.................................................................. 16
Failure code [DK30KB] Steering angle sensor 1: Short circuit...................................................................... 18
Failure code [DK30KX] Steering angle sensor: Out of input signal range..................................................... 20
Failure code [DK30KZ] Steering angle sensor: Disconnection or short circuit.............................................. 21
Failure code [DK30L8] Steering angle sensor: Disagreement of analog signals.......................................... 22
Failure code [DK31KA] Steering angle sensor 2: Disconnection.................................................................. 24
Failure code [DK31KB] Steering angle sensor 2: Short circuit...................................................................... 26
Failure code [DK40KA] Brake pedal sensor: Disconnection.........................................................................28
Failure code [DK40KB] Brake pedal sensor: Short circuit............................................................................. 30
Failure code [DK55KX] Directional potentiometer: Out of input signal range ............................................... 32
Failure code [DK55KZ] Directional potentiometer: Disconnection or short circuit......................................... 33
Failure code [DK55L8] Directional potentiometer: Disagreement of analog signals..................................... 34
Failure code [DK56KA] Directional potentiometer 1: Disconnection............................................................. 36
Failure code [DK56KB] Directional potentiometer 1: Short circuit................................................................. 38
Failure code [DK57KA] Directional potentiometer 2: Disconnection............................................................. 40
Failure code [DK57KB] Directional potentiometer 2: Short circuit................................................................. 42
Failure code [DLM0KX] HST motor speed sensors: Out of input signal range............................................. 44
Failure code [DLM1KA] Left HST motor speed sensor: Disconnection ........................................................ 46
Failure code [DLM1KB] Left HST motor speed sensor: Short circuit............................................................ 48
Failure code [DLM1MA] Left HST motor speed sensor: Malfunction............................................................ 50
Failure code [DLM2KA] Right HST motor speed sensor: Disconnection...................................................... 52
Failure code [DLM2KB] Right HST motor speed sensor: Short circuit.......................................................... 54
Failure code [DLM2MA] Right HST motor speed sensor: Malfunction.......................................................... 56
Failure code [DLM3KA] Fan speed sensor: Disconnection...........................................................................58
Failure code [DLM3KB] Fan speed sensor: Short circuit.............................................................................. 60
350 Troubleshooting by failure code (Display of code), Part 5 .........................................................SEN04511-00
Failure code [DN21FS] Brake pedal and proximity switch: Fixing ................................................................ 4
Failure code [DV00KB] Caution buzzer: Short circuit ................................................................................... 6
Find manuals at https://best-manuals.com