BULLDOZER D39EX, PX-21 (1501 AND UP)
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SEBM035005
MACHINE MODEL
SERIAL NUMBER
D31EX-21 D31PX-21 D37EX-21 D37PX-21 D39EX-21 D39PX-21
50501 and up 50501 and up 5501 and up 5501 and up 1501 and up 1501 and up
•
This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice.
•
D31, D37, D39EX, PX-21 mount the SAA4D102E-2 engine. For details of the engine, see the 102 Series Engine Shop Manual.
© 2007 All Rights Reserved Printed in Japan 11-07 (01)
00-1 (5)
GENERAL
CONTENTS No. of page
01 GENERAL ................................................................................................................................
01-1
10 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD .....................................................
10-1
20 TESTING AND ADJUSTING ...................................................................................
20-1
30 DISASSEMBLY AND ASSEMBLY
................................................................... 30-1
90 OTHERS.....................................................................................................................................
00-2 (1)
90-1
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FOREWORD
SAFETY NOTICE
SAFETY NOTICE
(Rev. 2007/03)
Important safety notice 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. To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. 1. General precautions k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. 1) Before carrying out any greasing or repairs, read all the safety plates stuck to the machine. For the locations of the safety plates and detailed explanation of precautions, see the Operation and Maintenance Manual. 2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. 3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • Always wear safety glasses when hitting parts with a hammer. • Always wear safety glasses when grinding parts with a grinder, etc. 4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator's compartment. 5) Only qualified workers must carry out work and operation which require license or qualification. 6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc. 7) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work. D31/37/39EX, PX-21
8) Before starting work, warm up your body thoroughly to start work under good condition. Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signs 5
Prohibition of operation and handling by unlicensed workers
6 Safety check before starting work 7
Wearing protective goggles (for cleaning or grinding work)
8
Wearing shielding goggles and protectors (for welding work)
9 Good physical condition and preparation 10
Precautions against work which you are not used to or you are used to too much
2. Preparations for work 1) Before adding oil or making any repairs, park the machine on hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. 2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 3) When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work. 4) Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
00-3 (5)
FOREWORD
3. Precautions during work 1) Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits. 3) Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts. 4) Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 6) When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. 7) When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires. 8) When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires. 9) As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. 10) Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is operated.
00-4 (5)
SAFETY NOTICE
11) When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. In addition, check that connecting parts are correctly installed. 12) When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 13) When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 14) When measuring hydraulic pressure, check that the measuring tools are correctly assembled. 15) Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. 16) If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.
D31/37/39EX, PX-21
FOREWORD
4. Precautions for sling work and making signs 1) Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is seen well from the operator's seat and where he can see the working condition easily. The sign maker must always stand in front of the load and guide the operator safely. • Do not stand under the load. • Do not step on the load. 2) Check the slings before starting sling work. 3) Keep putting on gloves during sling work. (Put on leather gloves, if available.) 4) Measure the weight of the load by the eye and check its center of gravity. 5) Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. 6) Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically. k Slinging with 1 rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 7) Limit the hanging angle to 60°, as a rule. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120°. If the 2 ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150°, each of them is subjected to a force as large as 39.2 kN {4,000 kg}.
D31/37/39EX, PX-21
SAFETY NOTICE
8) When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. 9) Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 10) Apply wire ropes to the middle portion of the hook. • Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.
11) Do not use twisted or kinked wire ropes. 12) When lifting up a load, observe the following. • Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. • After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads. • If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. • Do not lift up the load slantingly.
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FOREWORD
13) When lifting down a load, observe the following. • When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. • Check that the load is stable, and then remove the sling. • Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place. 5. Precautions for using mobile crane ★ Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. 6. Precautions for using overhead hoist crane k When raising a heavy part (heavier than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a part heavier than 25 kg is indicated after the mark of 4. 1) Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, electric shock prevention earth leakage breaker, crane collision prevention device, and power application warning lamp, and check safety. 2) Observe the signs for sling work. 3) Operate the hoist at a safe place. 4) Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail. 5) Do not sling a load slantingly. Do not move the crane while the slung load is swinging. 6) Do not raise or lower a load while the crane is moving longitudinally or laterally. 7) Do not drag a sling. 8) When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up. 9) Consider the travel route in advance and lift up a load to a safe height. 10) Place the control switch on a position where it will not be an obstacle to work and passage. 11) After operating the hoist, do not swing the control switch. 12) Remember the position of the main switch so that you can turn off the power immediately in an emergency. 13) If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the electric shock prevention earth leakage breaker, check that the devices related to that switch are not in operation state. 14) If you find an obstacle around the hoist, stop the operation.
00-6 (5)
SAFETY NOTICE
15) After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook. 7. Selecting wire ropes 1) Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below. Wire ropes (Standard “Z” twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal Allowable load diameter of rope mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4
★ The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).
D31/37/39EX, PX-21
FOREWORD
SAFETY NOTICE
8. Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 1) Disconnection k Collect the air conditioner refrigerant (R134a) from the air conditioner circuit in advance. ★ Ask professional traders for collecting and filling operation of refrigerant (R134a). ★ Never release the refrigerant (R134a) to the atmosphere. k If the refrigerant gas (R134a) gets in your eyes, you may lose your sight. Accordingly, when collecting or filling it, you must be qualified for handling the refrigerant and put on protective goggles. 2) Connection 1] When installing the air conditioner circuit hoses and tubes, take care that dirt, dust, water, etc. will not enter them. 2] When connecting the air conditioner hoses and tubes, check that O-rings (1) are fitted to their joints. 3] Check that each O-ring is not damaged or deteriorated. 4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8, ZEXEL: ZXL100PG (equivalent to PAG46)) to its O-rings. ★ Example of O-ring (Fitted to every joint of hoses and tubes)
★ For tightening torque, see the precautions for installation in each section of “Disassembly and assembly”.
D31/37/39EX, PX-21
00-7 (5)
FOREWORD
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL • • •
Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult KOMATSU distributors. Materials and specifications are subject to change without notice. Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the engine volume of the engine model mounted on the machine.
1. Composition of shop manual This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections. 00. FOREWORD This section explains the safety and basic information. 01. GENERAL This section explains the specifications of the machine. 10. STRUCTURE AND FUNCTION, MAINTENANCE STANDARD This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service. 20. TESTING AND ADJUSTING Standard value table This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. Testing and adjusting This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting. Troubleshooting This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume. 30. DISASSEMBLY AND ASSEMBLY This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained. 90. OTHERS (chassis volume)/Repair and replacement of parts (engine volume) • Chassis volume This section gives hydraulic circuit diagrams and electrical circuit diagrams. • Engine volume This section explains the method of reproducing, repairing, and replacing parts. 2. Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most upto-date information before you start any work.
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D31/37/39EX, PX-21
FOREWORD
HOW TO READ THE SHOP MANUAL
3. Filing method • See the page number on the bottom of the page. File the pages in correct order. • Following examples show how to read the page number. Example 1 (Chassis volume): 10 - 3 Item number (10. Structure and Function, Maintenance Standard) Consecutive page number for each item. Example 2 (Engine volume): 12 - 5 Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. •
Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example: 12-203 10-4 12-203-1 10-4-1 Added pages 12-203-2 10-4-2 12-204 10-5
•
Revised edition mark When a manual is revised, an edition mark ((1) (2) (3)....) is recorded on the bottom of the pages.
•
Revisions Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.
4. Symbols Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically. Symbol
Item
k
Safety
a
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing work.
4
Weight
Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
3
Tightening torque
2
Coat
5
Oil, coolant
6
Drain
Remarks Special safety precautions are necessary when performing work.
Places that require special attention for tightening torque during assembly. Places to be coated with adhesives, etc. during assembly. Places where oil, etc. must be added, and capacity. Places where oil, etc. must be drained, and quantity to be drained.
5. Units In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
D31/37/39EX, PX-21
00-9 (5)
FOREWORD
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD The maintenance standard values necessary for judgment of products and parts are described by the following terms. 1. Standard size and tolerance • To be accurate, the finishing size of parts is a little different from one to another. • To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated. • The above size set temporarily is called the “standard size” and the range of difference from the standard size is called the “tolerance”. • The tolerance with the symbols of + or – is indicated on the right side of the standard size. Example: Standard size
Tolerance –0.022 –0.126
120
★ The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)]. Example) 120 (–0.022/–0.126) •
Usually, the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance. Indication of size of rotating shaft and hole and relationship drawing of them
•
Example: Standard size 60
00-10 (5)
Tolerance Shaft –0.030 –0.076
Hole +0.046 +0
D31/37/39EX, PX-21
FOREWORD
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
2. Standard clearance and standard value • The clearance made when new parts are assembled is called the “standard clearance“, which is indicated by the range from the minimum clearance to the maximum clearance. • When some parts are repaired, the clearance is generally adjusted to the standard clearance. • A value of performance and function of new products or equivalent is called the “standard value“, which is indicated by a range or a target value. • When some parts are repaired, the value of performance/function is set to the standard value. 3. Standard interference • When the diameter of a hole of a part shown in the given standard size and tolerance table is smaller than that of the mating shaft, the difference between those diameters is called the “interference”. • The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the hole to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the “standard interference”. • After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range.
5. Clearance limit • Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the “clearance limit”. • If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired. 6. Interference limit • The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the “interference limit”. • The interference limit shows the repair limit of the part of smaller tolerance. • If the interference between the parts exceeds the interference limit, they must be replaced or repaired.
4. Repair limit and allowable value • The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the “repair limit”. • If a part is worn to the repair limit must be replaced or repaired. • The performance and function of a product lowers while it is used. A value below which the product can be used without causing a problem is called the “allowable value”. • If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated from various tests or experiences in most cases, however, it must be judged after considering the operating condition and customer's requirement.
D31/37/39EX, PX-21
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FOREWORD
HOW TO READ ELECTRIC WIRE CODE
HOW TO READ ELECTRIC WIRE CODE ★ 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 symbols. The electric wire code is helpful in understanding the electric circuit diagram. Example: AEX
0.85
L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85 Indicates color of wire by color code. Color codes are shown in Table 3. Indicates size of wire by nominal No. Size (Nominal No.) is shown in Table 2. Indicates type of wire by symbol. Type, symbol, and material of wire are shown in Table 1. (Since AV and AVS are classified by size (nominal No.), they are not indicated.)
1.
Type, symbol, and material AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1) Type
Symbol
Low-voltage wire for automobile
AV
Thin-cover low-voltage wire for automobile
AVS
Heat-resistant low-voltAEX age wire for automobile
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Material Conductor Insulator Conductor
Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance
Insulator
Soft polyvinyl chloride
Conductor
Annealed copper for electric appliance Heat-resistant crosslinked polyethylene
Insulator
Using temperature range (°C)
Example of use General wiring (Nominal No. 5 and above)
–30 to +60 General wiring (Nominal No. 3 and below) General wiring in extremely –50 to +110 cold district, wiring at high-temperature place
D31/37/39EX, PX-21
FOREWORD
2.
HOW TO READ ELECTRIC WIRE CODE
Dimensions
(Table 2) Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5 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 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23 area (mm2) d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0 AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 – CovAV Standard – – – – – – – 4.6 er D AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. Number of strands/Diameter of strand Conductor Sectional area (mm2) d (approx.) AVS Standard CovAV Standard er D AEX Standard
8
15
20
30
40
50
60
85
100
50/0.45
84/0.45
41/0.80
70/0.80
85/0.80
7.95
13.36
20.61
35.19
42.73
54.29
63.84
84.96
109.1
3.7 – 5.5 5.3
4.8 – 7.0 7.0
6.0 – 8.2 8.2
8.0 – 10.8 10.8
8.6 – 11.4 11.4
9.8 – 13.0 13.0
10.4 – 13.6 13.6
12.0 – 16.0 16.0
13.6 – 17.6 17.6
108/0.80 127/0.80 169/0.80 217/0.80
“f” of nominal No. denotes flexible”.
D31/37/39EX, PX-21
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FOREWORD
3.
HOW TO READ ELECTRIC WIRE CODE
Color codes table
(Table 3) Color Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR
Color of wire Black Brown Brown & Black Brown & Red Brown & White Brown & Yellow Charcoal Dark green Green Green & Black Green & Blue Gray Green & Red Green & White Green & Yellow Blue Blue & Black Light green Light green & Black Light green & Red
Color Code LgW LgY LR LW LY O P R RB RG RL RW RY Sb Y YB YG YL YR YW
Color of wire Light green & White Light green & Yellow Blue & Red Blue & White Blue & Yellow Orange Pink Red Red & Black Red & Green Red & Blue Red & White Red & Yellow Sky Blue Yellow Yellow & Black Yellow &Green Yellow & Blue Yellow & Red Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the marking. Example: “GW” means that the background is Green and marking is White. 4.
Types of circuits and color codes
(Table 4) Type of wire Charge Ground Start Light Instrument Signal Type of circuit Others
00-14 (5)
AVS or AV R B R RW Y G L Br Lg O Gr P Sb Dg Ch
AEX
WG
–
–
–
–
–
–
–
–
–
–
–
–
–
–
RB YR GW LW BrW LgR
RY YB GR LR BrR LgY
RG YG GY LY BrY LgB
RL YL GB LB BrB LgW
–
–
–
–
–
–
–
–
–
–
R B R D Y G L
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
YW GL
– – – –
Gr Br – –
D31/37/39EX, PX-21
FOREWORD
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.] 1. • • • •
Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering. When draining oil, prepare a container of adequate size to catch the oil. Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. • To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. • Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. • Check the number and thickness of the shims, and keep in a safe place. • When raising components, be sure to use lifting equipment of ample strength. • When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. • Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. ★ Precautions when handling piping during disassembly Fit the following plugs into the piping after disconnecting it during disassembly operations. 1) Face seal type hoses and tubes Nominal number 02 03 04 05 06 10 12 2)
Sleeve nut (elbow end)
07376-70210 07376-70315 07376-70422 07376-70522 07376-70628 07376-71034 07376-71234
02789-20210 02789-20315 02789-20422 02789-20522 02789-20628 07221-21034 07221-21234
Split flange type hoses and tubes Nominal number 04 05
3)
Plug (nut end)
Flange (hose end)
Sleeve head (tube end)
Split flange
07379-00400 07379-00500
07378-10400 07378-10500
07371-30400 07371-30500
If the part is not under hydraulic pressure, the following corks can be used. Nominal number
Part Number
06 08 10 12 14 16 18 20 22 24
07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430
Dimensions D d L 6 5 8 8 6.5 11 10 8.5 12 12 10 15 14 11.5 18 16 13.5 20 18 15 22 20 17 25 22 18.5 28 24 20 30
27
07049-02734
27
D31/37/39EX, PX-21
22.5
34
00-15 (5)
FOREWORD
2. • • • • • • • • • • • • •
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. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 – 3 drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
★ When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1) Start the engine and run at low idle. 2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cylinder 100 mm from the end of its stroke. 3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke. 4) After doing this, run the engine at normal speed. ★ When using the machine for the first time after repair or long storage, follow the same procedure. 3. Precautions when completing the operation 1) Refilling with coolant, oil and grease • If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate the coolant through the system. Then check the coolant level again. • If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. • If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the parts. ★ For details, see Testing and adjusting, “Bleeding air”. • Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts. 2) Checking cylinder head and manifolds for looseness Check the cylinder head and intake and exhaust manifold for looseness. If any part is loosened, retighten it. • For the tightening torque, see “Disassembly and assembly”. 3) Checking engine piping for damage and looseness Intake and exhaust system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and exhaust gas leakage. If any part is loosened or damaged, retighten or repair it. Cooling system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leakage. If any part is loosened or damaged, retighten or repair it. Fuel system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage. If any part is loosened or damaged, retighten or repair it.
00-16 (5)
D31/37/39EX, PX-21
FOREWORD
PRECAUTIONS WHEN CARRYING OUT OPERATION
4) Checking muffler and exhaust pipe for damage and looseness 1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage. If any part is damaged, replace it. 2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for looseness. If any bolt or nut is loosened, retighten it. 5) Checking muffler function Check the muffler for abnormal sound and sound different from that of a new muffler. If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly and assembly”.
D31/37/39EX, PX-21
00-17 (5)
FOREWORD
METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER k
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. k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container. Type 1 1. Disconnection 1) Hold adapter (1) and push hose joint (2) into mating adapter (3). (Fig. 1) ★ The adapter can be pushed in about 3.5 mm. ★ Do not hold rubber cap portion (4). 2) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against adapter (3) until it clicks. (Fig. 2) 3) Hold hose adapter (1) or hose (5) and pull it out. (Fig. 3) ★ Since some hydraulic oil flows out, prepare an oil receiving container.
2. Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (Fig. 4) ★ Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (Fig. 5) ★ When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.
00-18 (5)
D31/37/39EX, PX-21
FOREWORD
METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER
Type 2 1. Disconnection 1) Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6) 2) While holding the condition of Step 1), turn lever (8) to the right (clockwise). (Fig. 7) 3) While holding the condition of Steps 1) and 2), pull out whole body (7) to disconnect it. (Fig. 8)
2. Connection • Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)
D31/37/39EX, PX-21
00-19 (5)
FOREWORD
METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER
Type 3 1. Disconnection 1) Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10) 2) While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 11) 3) While holding the condition of Steps 1) and 2), pull out whole body (9) to disconnect it. (Fig. 12)
2. Connection • Hold the tightening portion and push body (9) straight until the sliding prevention ring contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)
00-20 (5)
D31/37/39EX, PX-21
FOREWORD
STANDARD TIGHTENING TORQUE TABLE
STANDARD TIGHTENING TORQUE TABLE 1. Table of tightening torques for bolts and nuts ★ Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using torque wrench) ★ The following table corresponds to the bolts in Fig. A. Thread diameter of bolt mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39
Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60
Tightening torque Nm 11.8 – 14.7 27 – 34 59 – 74 98 – 123 153 – 190 235 – 285 320 – 400 455 – 565 610 – 765 785 – 980 1,150 – 1,440 1,520 – 1,910 1,960 – 2,450 2,450 – 3,040 2,890 – 3,630
kgm 1.2 – 1.5 2.8 – 3.5 6.0 – 7.5 10.0 – 12.5 15.5 – 19.5 23.5 – 29.5 33.0 – 41.0 46.5 – 58.0 62.5 – 78.0 80.0 – 100.0 118 – 147 155 – 195 200 – 250 250 – 310 295 – 370
★ The following table corresponds to the bolts in Fig. B. Thread diameter of bolt mm 6 8 10 12 a Fig. A
D31/37/39EX, PX-21
Width across flats mm 10 13 14 27
Tightening torque Nm kgm 5.9 – 9.8 0.6 – 1.0 13.7 – 23.5 1.4 – 2.4 34.3 – 46.1 3.5 – 4.7 74.5 – 90.2 7.6 – 9.2 a Fig. B
00-21 (5)
FOREWORD
STANDARD TIGHTENING TORQUE TABLE
2. Table of tightening torques for split flange bolts ★ Unless there are special instructions, tighten split flange bolts to the torque below. Thread diameter of bolt mm 10 12 16
Width across flats mm 14 17 22
Tightening torque Nm 59 – 74 98 – 123 235 – 285
kgm 6.0 – 7.5 10.0 – 12.5 23.5 – 29.5
3. Table of tightening torques for O-ring boss piping joints ★ Unless there are special instructions, tighten O-ring boss piping joints to the torque below. Nominal No. 02 03,04 05,06 10,12 14
Thread diameter mm 14 20 24 33 42
Width across flats mm
Tightening torque Nm {kgm} Range Target 35 – 63 { 3.5 – 6.5} 44 { 4.5} 84 – 132 { 8.5 – 13.5} 103 {10.5} Varies depending 157 {16.0} on type of connec- 128 – 186 {13.0 – 19.0} tor. 363 – 480 {37.0 – 49.0} 422 {43.0} 746 – 1,010 {76.0 – 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs ★ Unless there are special instructions, tighten O-ring boss plugs to the torque below. Nominal No. 08 10 12 14 16 18 20 24 30 33 36 42 52
00-22 (5)
Thread diameter mm 8 10 12 14 16 18 20 24 30 33 36 42 52
Width across flats mm 14 17 19 22 24 27 30 32 32 – 36 – –
Tightening torque Nm {kgm} Range Target 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75} 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15} 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8} 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3} 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0} 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0} 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0} 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0} 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0} 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0} 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5} 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5} 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
D31/37/39EX, PX-21
FOREWORD
STANDARD TIGHTENING TORQUE TABLE
5. Table of tightening torques for hoses (taper seal type and face seal type) ★ Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the torque below. ★ Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque Nm {kgm} Nominal No. of hose
Width across flats
02
19
03 04 05 06 (10) (12) (14)
22 24 27 32 36 41 46 55
Range 34 – 54 { 3.5 – 5.5} 34 – 63 { 3.5 – 6.5} 54 – 93 { 5.5 – 9.5} 59 – 98 { 6.0 – 10.0} 84 – 132 { 8.5 – 13.5} 128 – 186 {13.0 – 19.0} 177 – 245 {18.0 – 25.0} 177 – 245 {18.0 – 25.0} 197 – 294 {20.0 – 30.0} 246 – 343 {25.0 – 35.0}
Target
44 { 4.5} 74 { 7.5} 78 { 8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0}
Taper seal Thread size (mm) – 14 – 18 22 24 30 33 36 42
Face seal Nominal No. Thread diameNumber of ter (mm) (Refthreads, type of erence) thread 9/16-18UN 14.3 – – 11/16-16UN 17.5 – – 13/16-16UN 20.6 1-14UNS 25.4 1-3/16-12UN 30.2 – – – – – –
6. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts) ★ Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114 engine series to the torque below. Tightening torque Bolts and nuts
Thread size mm 6 8 10 12 14
Nm 10 ± 2 24 ± 4 43 ± 6 77 ± 12 —
kgm 1.02 ± 0.20 2.45 ± 0.41 4.38 ± 0.61 7.85 ± 1.22 —
7. Table of tightening torques for 102, 107 and 114 engine series (Eye joints) ★ Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine series to the torque below. Thread size mm 6 8 10 12 14
D31/37/39EX, PX-21
Tightening torque Nm 8±2 10 ± 2 12 ± 2 24 ± 4 36 ± 5
kgm 0.81 ± 0.20 1.02 ± 0.20 1.22 ± 0.20 2.45 ± 0.41 3.67 ± 0.51
00-23 (5)
FOREWORD
STANDARD TIGHTENING TORQUE TABLE
8. Table of tightening torques for 102, 107 and 114 engine series (Taper screws) ★ Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114 engine series to the torque below. Thread size inch 1/16 1/8 1/4 3/8 1/2 3/4 1
00-24 (5)
Tightening torque Nm 3±1 8±2 12 ± 2 15 ± 2 24 ± 4 36 ± 5 60 ± 9
kgm 0.31 ± 0.10 0.81 ± 0.20 1.22 ± 0.20 1.53 ± 0.20 2.45 ± 0.41 3.67 ± 0.51 6.12 ± 0.92
D31/37/39EX, PX-21
FOREWORD
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 1.
Convert 55 mm into inches. 1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal line from (A). 2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). 3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2.
Convert 550 mm into inches. 1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the left) to convert it to 55 mm. 2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. 3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches
(A)
(B)
0 10 20 30 40
0 0 0.394 0.787 1.181 1.575
1 0.039 0.433 0.827 1.220 1.614
2 0.079 0.472 0.866 1.260 1.654
3 0.118 0.512 0.906 1.299 1.693
4 0.157 0.551 0.945 1.339 1.732
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.047 2.441 2.835 3.228 3.622
2.087 2.480 2.874 3.268 3.661
2.126 2.520 2.913 3.307 3.701
D31/37/39EX, PX-21
5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740
6 0.236 0.630 1.024 1.417 1.811
1 mm = 0.03937 in 7 8 9 0.276 0.315 0.354 0.669 0.709 0.748 1.063 1.102 1.142 1.457 1.496 1.536 1.850 1.890 1.929
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
00-25 (5)
FOREWORD
CONVERSION TABLE
Millimeters to inches 1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929
0 10 20 30 40
0 0 0.394 0.787 1.181 1.575
1 0.039 0.433 0.827 1.220 1.614
2 0.079 0.472 0.866 1.260 1.654
3 0.118 0.512 0.906 1.299 1.693
4 0.157 0.551 0.945 1.339 1.732
5 0.197 0.591 0.984 1.378 1.772
6 0.236 0.630 1.024 1.417 1.811
7 0.276 0.669 1.063 1.457 1.850
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.047 2.441 2.835 3.228 3.622
2.087 2.480 2.874 3.268 3.661
2.126 2.520 2.913 3.307 3.701
2.165 2.559 2.953 3.346 3.740
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
1 kg = 2.2046 lb 6 7 8 9 13.23 15.43 17.64 19.84 35.27 37.48 39.68 41.89 57.32 59.53 61.73 63.93 79.37 81.57 83.78 85.98 101.41 103.62 105.82 108.03
2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
Kilogram to pound
0 10 20 30 40
0 0 22.05 44.09 66.14 88.18
1 2.20 24.25 46.30 68.34 90.39
2 4.41 26.46 48.50 70.55 92.59
3 6.61 28.66 50.71 72.75 94.80
4 8.82 30.86 51.91 74.96 97.00
5 11.02 33.07 55.12 77.16 99.21
50 60 70 80 90
110.23 132.28 154.32 176.37 198.42
112.44 134.48 156.53 178.57 200.62
114.64 136.69 158.73 180.78 202.83
116.85 138.89 160.94 182.98 205.03
119.05 141.10 163.14 185.19 207.24
121.25 143.30 165.35 187.39 209.44
0 10 20 30 40
0 1 2 0 0.264 0.528 2.642 2.906 3.170 5.283 5.548 5.812 7.925 8.189 8.454 10.567 10.831 11.095
3 0.793 3.434 6.076 8.718 11.359
4 1.057 3.698 6.340 8.982 11.624
1 l = 0.2642 U.S.Gal 5 6 7 8 9 1.321 1.585 1.849 2.113 2.378 3.963 4.227 4.491 4.755 5.019 6.604 6.869 7.133 7.397 7.661 9.246 9.510 9.774 10.039 10.303 11.888 12.152 12.416 12.680 12.944
50 60 70 80 90
13.209 15.850 18.492 21.134 23.775
14.001 16.643 19.285 21.926 24.568
14.265 16.907 19.549 22.190 24.832
14.529 17.171 19.813 22.455 25.096
123.46 145.51 167.55 189.60 211.64
125.66 147.71 169.76 191.80 213.85
127.87 149.91 171.96 194.01 216.05
130.07 152.12 174.17 196.21 218.26
Liters to U.S. Gallons
00-26 (5)
13.473 16.115 18.756 21.398 24.040
13.737 16.379 19.020 21.662 24.304
14.795 17.435 20.077 22.719 25.361
15.058 17.700 20.341 22.983 25.625
15.322 17.964 20.605 23.247 25.889
15.586 18.228 20.870 23.511 26.153
D31/37/39EX, PX-21
FOREWORD
CONVERSION TABLE
Liters to U.K. Gallons 1 l = 0.21997 U.K.Gal 6 7 8 9 1.320 1.540 1.760 1.980 3.520 3.740 3.950 4.179 5.719 5.939 6.159 6.379 7.919 8.139 8.359 8.579 10.119 10.339 10.559 10.778
0 10 20 30 40
0 0 2.200 4.399 6.599 8.799
1 0.220 2.420 4.619 6.819 9.019
2 0.440 2.640 4.839 7.039 9.239
3 0.660 2.860 5.059 7.259 9.459
4 0.880 3.080 5.279 7.479 9.679
5 1.100 3.300 5.499 7.699 9.899
50 60 70 80 90
10.998 13.198 15.398 17.598 19.797
11.281 13.418 15.618 17.818 20.017
11.438 13.638 15.838 18.037 20.237
11.658 13.858 16.058 18.257 20.457
11.878 14.078 16.278 18.477 20.677
12.098 14.298 16.498 18.697 20.897
12.318 14.518 16.718 18.917 21.117
12.528 14.738 16.938 19.137 21.337
0 10 20 30 40
0 0 72.3 144.7 217.0 289.3
1 7.2 79.6 151.9 224.2 296.6
2 14.5 86.8 159.1 231.5 303.8
3 21.7 94.0 166.4 238.7 311.0
4 28.9 101.3 173.6 245.9 318.3
5 36.2 108.5 180.8 253.2 325.5
6 43.4 115.7 188.1 260.4 332.7
7 50.6 123.0 195.3 267.6 340.0
50 60 70 80 90
361.7 434.0 506.3 578.6 651.0
368.9 441.2 513.5 585.9 658.2
376.1 448.5 520.8 593.1 665.4
383.4 455.7 528.0 600.3 672.7
390.6 462.9 535.2 607.6 679.9
397.8 470.2 542.5 614.8 687.1
405.1 477.4 549.7 622.0 694.4
412.3 484.6 556.9 629.3 701.6
12.758 14.958 17.158 19.357 21.557
12.978 15.178 17.378 19.577 21.777
kgm to ft.lb 1 kgm = 7.233 ft.lb 8 9 57.9 65.1 130.2 137.4 202.5 209.8 274.9 282.1 347.2 354.4 419.5 491.8 564.2 636.5 708.8
426.8 499.1 571.4 643.7 716.1
100 110 120 130 140
723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 160 170 180 190
1084.9 1157.3 1129.6 1301.9 1374.3
1092.2 1164.5 1236.8 1309.2 1381.5
D31/37/39EX, PX-21
1099.4 1171.7 1244.1 1316.4 1388.7
1106.6 1179.0 1251.3 1323.6 1396.0
1113.9 1186.2 1258.5 1330.9 1403.2
1121.1 1193.4 1265.8 1338.1 1410.4
1128.3 1200.7 1273.0 1345.3 1417.7
1135.6 1207.9 1280.1 1352.6 1424.9
1142.8 1215.1 1287.5 1359.8 1432.1
1150.0 1222.4 1294.7 1367.0 1439.4
00-27 (5)
FOREWORD
CONVERSION TABLE
kg/cm2 to lb/in2
0 10 20 30 40
0 0 142.2 284.5 426.7 568.9
1 14.2 156.5 298.7 440.9 583.2
2 28.4 170.7 312.9 455.1 597.4
3 42.7 184.9 327.1 469.4 611.6
4 56.9 199.1 341.4 483.6 625.8
5 71.1 213.4 355.6 497.8 640.1
6 85.3 227.6 369.8 512.0 654.3
1 kg/cm2 = 14.2233 lb/in2 7 8 9 99.6 113.8 128.0 241.8 256.0 270.2 384.0 398.3 412.5 526.3 540.5 554.7 668.5 682.7 696.9
50 60 70 80 90
711.2 853.4 995.6 1,138 1,280
725.4 867.6 1,010 1,152 1,294
739.6 881.8 1,024 1,166 1,309
753.8 896.1 1,038 1,181 1,323
768.1 910.3 1,053 1,195 1,337
782.3 924.5 1,067 1,209 1,351
796.5 938.7 1,081 1,223 1,365
810.7 953.0 1,095 1,237 1,380
825.0 967.2 1,109 1,252 1,394
839.2 981.4 1,124 1,266 1,408
100 110 120 130 140
1,422 1,565 1,707 1,849 1,991
1,437 1,579 1,721 1,863 2,005
1,451 1,593 1,735 1,877 2,020
1,465 1,607 1,749 1,892 2,034
1,479 1,621 1,764 1,906 2,048
1,493 1,636 1,778 1,920 2,062
1,508 1,650 1,792 1,934 2,077
1,522 1,664 1,806 1,949 2,091
1,536 1,678 1,821 1,963 2,105
1,550 1,693 1,835 1,977 2,119
150 160 170 180 190
2,134 2,276 2,418 2,560 2,702
2,148 2,290 2,432 2,574 2,717
2,162 2,304 2,446 2,589 2,731
2,176 2,318 2,460 2,603 2,745
2,190 2,333 2,475 2,617 2,759
2,205 2,347 2,489 2,631 2,773
2,219 2,361 2,503 2,646 2,788
2,233 2,375 2,518 2,660 2,802
2,247 2,389 2,532 2,674 2,816
2,262 2,404 2,546 2,688 2,830
200 210 220 230 240
2,845 2,987 3,129 3,271 3,414
2,859 3,001 3,143 3,286 3,428
2,873 3,015 3,158 3,300 3,442
2,887 3,030 3,172 3,314 3,456
2,901 3,044 3,186 3,328 3,470
2,916 3,058 3,200 3,343 3,485
2,930 3,072 3,214 3,357 3,499
2,944 3,086 3,229 3,371 3,513
2,958 3,101 3,243 3,385 3,527
2,973 3,115 3,257 3,399 3,542
00-28 (5)
D31/37/39EX, PX-21
FOREWORD
CONVERSION TABLE
Temperature Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column) of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.
°C
°F
°C
°F
°C
°F
°C
1°C = 33.8°F °F
–40.4 –37.2 –34.4 –31.7 –28.9
–40 –35 –30 –25 –20
–40.0 –31.0 –22.0 –13.0 –4.0
–11.7 –11.1 –10.6 –10.0 –9.4
11 12 13 14 15
51.8 53.6 55.4 57.2 59.0
7.8 8.3 8.9 9.4 10.0
46 47 48 49 50
114.8 116.6 118.4 120.2 122.0
27.2 27.8 28.3 28.9 29.4
81 82 83 84 85
177.8 179.6 181.4 183.2 185.0
–28.3 –27.8 –27.2 –26.7 –26.1
–19 –18 –17 –16 –15
–2.2 –0.4 1.4 3.2 5.0
–8.9 –8.3 –7.8 –7.2 –6.7
16 17 18 19 20
60.8 62.6 64.4 66.2 68.0
10.6 11.1 11.7 12.2 12.8
51 52 53 54 55
123.8 125.6 127.4 129.2 131.0
30.0 30.6 31.1 31.7 32.2
86 87 88 89 90
186.8 188.6 190.4 192.2 194.0
–25.6 –25.0 –24.4 –23.9 –23.3
–14 –13 –12 –11 –10
6.8 8.6 10.4 12.2 14.0
–6.1 –5.6 –5.0 –4.4 –3.9
21 22 23 24 25
69.8 71.6 73.4 75.2 77.0
13.3 13.9 14.4 15.0 15.6
56 57 58 59 60
132.8 134.6 136.4 138.2 140.0
32.8 33.3 33.9 34.4 35.0
91 92 93 94 95
195.8 197.6 199.4 201.2 203.0
–22.8 –22.2 –21.7 –21.1 –20.6
–9 –8 –7 –6 –5
15.8 17.6 19.4 21.2 23.0
–3.3 –2.8 –2.2 –1.7 –1.1
26 27 28 29 30
78.8 80.6 82.4 84.2 86.0
16.1 16.7 17.2 17.8 18.3
61 62 63 64 65
141.8 143.6 145.4 147.2 149.0
35.6 36.1 36.7 37.2 37.8
96 97 98 99 100
204.8 206.6 208.4 210.2 212.0
–20.0 –19.4 –18.9 –18.3 –17.8
–4 –3 –2 –1 0
24.8 26.6 28.4 30.2 32.0
–0.6 0 0.6 1.1 1.7
31 32 33 34 35
87.8 89.6 91.4 93.2 95.0
18.9 19.4 20.0 20.6 21.1
66 67 68 69 70
150.8 152.6 154.4 156.2 158.0
40.6 43.3 46.1 48.9 51.7
105 110 115 120 125
221.0 230.0 239.0 248.0 257.0
–17.2 –16.7 –16.1 –15.6 –15.0
1 2 3 4 5
33.8 35.6 37.4 39.2 41.0
2.2 2.8 3.3 3.9 4.4
36 37 38 39 40
96.8 98.6 100.4 102.2 104.0
21.7 22.2 22.8 23.3 23.9
71 72 73 74 75
159.8 161.6 163.4 165.2 167.0
54.4 57.2 60.0 62.7 65.6
130 135 140 145 150
266.0 275.0 284.0 293.0 302.0
–14.4 –13.9 –13.3 –12.8 –12.2
6 7 8 9 10
42.8 44.6 46.4 48.2 50.0
5.0 5.6 6.1 6.7 7.2
41 42 43 44 45
105.8 107.6 109.4 111.2 113.0
24.4 25.0 25.6 26.1 26.7
76 77 78 79 80
168.8 170.6 172.4 174.2 176.0
68.3 71.1 73.9 76.7 79.4
155 160 165 170 175
311.0 320.0 329.0 338.0 347.0
D31/37/39EX, PX-21
00-29 (5)
01 GENERAL
Specification drawing .......................................01- 2 Specifications ...................................................01- 4 Weight table .....................................................01-12 Table of fuel, coolant and lubricants .................01-16
D31/37/39EX, PX-21
01-1
GENERAL
SPECIFICATION DRAWING
SPECIFICATION DRAWING
D31EX-21 Power angle, power tiltdozer with ROPS canopy D31PX-21 Power angle, power tiltdozer with ROPS canopy D31EX-21 Item
D31PX-21
Unit
400 mm Single shoe
600 mm Single shoe
600 mm Swamp shoe
Machine weight
kg
7,130
7,650 (7,630)
7,630 (7,610)
Engine model
—
Komatsu SAA4D102E-2-B diesel engine
kW {HP} /rpm
56 {75} /2,000
Engine rated horsepower A
Overall length
mm
B
Overall height (not including antenna) (to tip of exhaust pipe)
mm
C
Overall width
mm
Travel speed (Quick shift mode)
Travel speed (Variable shift mode)
4,015
3,995
3,975
2,700 2,645
2,720 2,665 3,200 (2,875)
2,435
FORWARD (1st/2nd/3rd)
km/h
4.3/5.6/8.5
REVERSE (1st/2nd/3rd)
km/h
4.3/6.5/8.5
FORWARD
km/h
0.8 – 8.5
REVERSE
km/h
0.8 – 8.5
Values in ( ) are for the machines equipped with narrow blade.
01-2
D31/37/39EX, PX-21
GENERAL
SPECIFICATION DRAWING
D37EX-21 Power angle, power tiltdozer with ROPS canopy D37PX-21 Power angle, power tiltdozer with ROPS canopy D37EX-21 Item
D37PX-21
Unit
400 mm Single shoe
600 mm Single shoe
600 mm Swamp shoe
Machine weight
kg
7,410
7,770 (7,720)
7,750 (7,700)
Engine model
—
Komatsu SAA4D102E-2-B diesel engine
kW {HP} /rpm
63 {85} /2,000
Engine rated horsepower A
Overall length
mm
B
Overall height (not including antenna) (to tip of exhaust pipe)
mm
C
Overall width
mm
Travel speed (Quick shift mode)
Travel speed (Variable shift mode)
4,055
4,035
4,015
2,700 2,645
2,720 2,665 3,250 (2,875)
2,720
FORWARD (1st/2nd/3rd)
km/h
3.4/5.6/8.5
REVERSE (1st/2nd/3rd)
km/h
4.1/6.5/8.5
FORWARD
km/h
0.8 – 8.5
REVERSE
km/h
0.8 – 8.5
Values in ( ) are for the machines equipped with narrow blade.
D39EX-21 Power angle, power tiltdozer with ROPS cab D39PX-21 Power angle, power tiltdozer with ROPS cab D39EX-21 Item
D39PX-21
Unit
460 mm Single shoe
635 mm Single shoe
700 mm Swamp shoe
Machine weight
kg
8,820
9,200 (9,140)
9,180 (9,120)
Engine model
—
Komatsu SAA4D102E-2-B diesel engine
kW {HP} /rpm
71 {95} /2,200
Engine rated horsepower A
Overall length
mm
4,240
4,220
B
Overall height (not including antenna) (to tip of exhaust pipe)
mm
2,770 2,720
2,790 2,740
C
Overall width
mm
Travel speed (Quick shift mode)
Travel speed (Variable shift mode)
3,330 (2,980)
2,740
FORWARD (1st/2nd/3rd)
km/h
3.4/5.6/8.5
REVERSE (1st/2nd/3rd)
km/h
4.1/6.5/8.5
FORWARD
km/h
0.8 – 8.5
REVERSE
km/h
0.8 – 8.5
Values in ( ) are for the machines equipped with narrow blade.
D31/37/39EX, PX-21
01-3
GENERAL
SPECIFICATIONS
SPECIFICATIONS D31EX-21 Machine model
400 mm Single shoe
Serial No.
50501 and up
D31PX-21 600 mm Single shoe
600 mm Swamp shoe
50501 and up
Operating weight Weight
• Bare tractor
5,800
6,250
6,230
kg
7,130
7,650 (7,630)
7,630 (7,610)
• With power angle tiltdozer + ROPS canopy
kg
7,470
7,990 (7,970)
7,970 (7,950)
Min. turning radius (bare tractor,counter-rotation)
m
1.7
1.8
1.8
Gradeability
deg
30
30
30
Stability (front, rear, left, right)
deg
35
35
35
Forward (1st/2nd/3rd)
km/h
3.4/5.6/8.5
3.4/5.6/8.5
3.4/5.6/8.5
Reverse (1st/2nd/3rd)
km/h
4.1/6.5/8.5
4.1/6.5/8.5
4.1/6.5/8.5
Forward
km/h
0.8 – 8.5
0.8 – 8.5
0.8 – 8.5
Reverse
km/h
0.8 – 8.5
0.8 – 8.5
0.8 – 8.5
Bare tractor
kPa {kg/cm2}
35.3 {0.36}
23.5 {0.24}
23.5 {0.24}
With power angle tiltdozer + ROPS canopy
kPa {kg/cm2}
43.1 {0.44}
28.4 {0.29}
28.4 {0.29}
With power angle tiltdozer + ROPS cab
kPa {kg/cm2}
45.1 {0.46}
29.4 {0.30}
29.4 {0.30}
Bare tractor
mm
3,055
3,090
3,110
With power angle tiltdozer + ROPS canopy
mm
4,015
3,995
3,975
With power angle tiltdozer + ROPS cab
mm
4,085
4,065
4,045
Bare tractor
mm
1,850
2,250
2,250
Power angle tiltdozer
mm
2,435
3,200 (2,875)
3,200 (2,875)
To tip of exhaust pipe
mm
2,645
2,645
2,665
To top of operator's compartment
mm
2,015
2,015
2,035
With ROPS cab installed (not including antenna)
mm
2,700
2,700
2,720
With ROPS canopy installed
mm
2,700
2,700
2,720
Track gauge
mm
1,450
1,650
1,650
Length of track on ground
mm
2,010
2,185
2,185
Width of track (standard track shoe)
mm
400
600
600
Min. ground clearance
mm
315
315
385
• With power angle tiltdozer + ROPS cab
kg
Travel speed Overall height
Dimensions
Overall width
Overall length
Ground pressure
Performance
Quick shift mode
Variable shift mode
Values in ( ) are for the machines equipped with narrow blade.
01-4
D31/37/39EX, PX-21
GENERAL
SPECIFICATIONS
D37EX-21 400 mm Single shoe
D37PX-21 600 mm Single shoe
5501 and up
D39EX-21
600 mm Swamp shoe
5501 and up
460 mm Single shoe
D39PX-21 635 mm Single shoe
1501 and up
700 mm Swamp shoe
1501 and up
6,030
6,330
6,310
6,950
7,230
7,210
7,410
7,770 (7,720)
7,750 (7,700)
8,480
8,860 (8,800)
8,840 (8,780)
7,750
8,110 (8,060)
8,090 (8,040)
8,820
9,200 (9,140)
9,180 (9,120)
1.8
1.9
1.9
1.9
2.0
2.0
30
30
30
30
30
30
35
35
35
35
35
35
3.4/5.6/8.5
3.4/5.6/8.5
3.4/5.6/8.5
3.4/5.6/8.5
3.4/5.6/8.5
3.4/5.6/8.5
4.1/6.5/8.5
4.1/6.5/8.5
4.1/6.5/8.5
4.1/6.5/8.5
4.1/6.5/8.5
4.1/6.5/8.5
0.8 – 8.5
0.8 – 8.5
0.8 – 8.5
0.8 – 8.5
0.8 – 8.5
0.8 – 8.5
0.8 – 8.5
0.8 – 8.5
0.8 – 8.5
0.8 – 8.5
0.8 – 8.5
0.8 – 8.5
33.3 {0.34}
23.5 {0.24}
22.6 {0.23}
31.4 {0.32}
23.5 {0.24}
21.6 {0.22}
40.2 {0.41}
28.4 {0.29}
28.4 {0.29}
38.2 {0.39}
29.4 {0.30}
26.5 {0.27}
42.2 {0.43}
29.4 {0.30}
29.4 {0.30}
40.2 {0.41}
30.4 {0.31}
27.5 {0.28}
3,090
3,090
3,095
3,235
3,235
3,255
4,055
4,035
4,015
4,240
4,240
4,220
4,085
4,065
4,045
4,240
4,240
4,220
1,850
2,250
2,250
2,110
2,425
2,490
2,720
3,250 (2,875)
3,250 (2,875)
2,740
3,330 (2,980)
3,330 (2,980)
2,645
2,645
2,665
2,720
2,720
2,740
2,015
2,015
2,035
2,090
2,090
2,110
2,700
2,700
2,720
2,770
2,770
2,790
2,700
2,700
2,720
2,770
2,770
2,790
1,450
1,650
1,650
1,650
1,790
1,790
2,240
2,240
2,240
2,360
2,360
2,360
400
600
600
460
635
700
315
315
385
385
385
460
Values in ( ) are for the machines equipped with narrow blade.
D31/37/39EX, PX-21
01-5
GENERAL
SPECIFICATIONS
D31EX-21 Machine model
400 mm Single shoe
Serial No. Model Type No. of cylinders – bore x stroke
50501 and up —
SAA4D102E-2-B
—
4-cycle, water-cooled, in-line vertical type, 4 cylinders, direct injection, with turbocharger, air-cooled after cooler 4 – 102 x 120 3.92 {3,920}
kW {HP} /rpm
56 {75}/2,000
Nm {kgm} /rpm
384 {39.2}/1,300
High idling
rpm
2,200
Low idling
rpm
800
g/kWh {g/HPh}
211 {157}
Starting motor
—
24 V, 5.5 kW
Alternator
—
24 V, 25 A
Battery (*1)
—
12 V, 60 Ah x 2
Radiator core type
—
D-5
—
Variable displacement swash-plate piston type x 2 Fix displacement internal-gear type x 1
Performance
Engine
600 mm Swamp shoe
mm
Rated horsepower Max. torque
Min. fuel consumption ratio
HST pump
Type, number Discharge amount (variable pump) (charge pump)
cm3/rev
Set pressure (variable pump) (charge pump)
MPa {kg/cm2}
Type, number HST motor
Power train system
600 mm Single shoe
l {cc}
Piston displacement
Undercarriage
D31PX-21
Discharge amount (Max.) (Medium) (Min.)
—
63 40 42.2 {430} 3.0 {31} Variable displacement angled piston type (3-stage selection, with parking brake) x 2 93 61 46
cm3/rev
Final drive
—
Planetary gear, 2-stage reduction type, splash type lubrication
Suspension
—
Rigid
Carrier roller
—
Track roller
—
1 on each side 5 on each side
6 on each side
Track shoe • Assembly-type single grouser — • Assembly-type special swamp shoe
Width: 400 mm Q'ty on each side: 38 pieces Pitch: 154.3 mm —
Width: 600 mm Q'ty on each side: 40 pieces Pitch: 154.3 mm
—
—
Width: 600 mm Q'ty on each side: 40 pieces Pitch: 154.3 mm
*1: The battery capacity (Ah) is the 5-hour rate value.
01-6
D31/37/39EX, PX-21
GENERAL
SPECIFICATIONS
D37EX-21
D37PX-21
400 mm Single shoe
600 mm Single shoe
D39EX-21
600 mm Swamp shoe
460 mm Single shoe
5501 and up
D39PX-21 635 mm Single shoe
700 mm Swamp shoe
1501 and up
SAA4D102E-2-B
SAA4D102E-2-B
4-cycle, water-cooled, in-line vertical type, 4 cylinders, direct injection, with turbocharger, air-cooled after cooler
4-cycle, water-cooled, in-line vertical type, 4 cylinders, direct injection, with turbocharger, air-cooled after cooler
4 – 102 x 120
4 – 102 x 120
3.92 {3,920}
3.92 {3,920}
63 {85}/2,000
71 {95}/2,200
412 {42.0}/1,300
431 {44.0}/1,300
2,200
2,400
800
825
211 {157}
211 {157}
24 V, 5.5 kW
24 V, 5.5 kW
24 V, 25 A
24 V, 25 A
12 V, 60 Ah x 2
12 V, 60 Ah x 2
D-5
D-7
Variable displacement swash-plate piston type x 2 Fix displacement internal-gear type x 1
Variable displacement swash-plate piston type x 2 Fix displacement internal-gear type x 1
63 40
63 40
42.2 {430} 3.0 {31}
42.2 {430} 3.0 {31}
Variable displacement angled piston type (3-stage selection, with parking brake) x 2
Variable displacement angled piston type (3-stage selection, with parking brake) x 2
93 61 46
105 68 52
Planetary gear, 2-stage reduction type, splash type lubrication
Planetary gear, 2-stage reduction type, splash type lubrication
Rigid
Rigid
1 on each side
1 on each side
6 on each side
6 on each side
Width: 400 mm Q'ty on each side: 41 pieces Pitch: 154.3 mm
Width: 600 mm Q'ty on each side: 41 pieces Pitch: 154.3 mm
—
—
Width: 600 mm Q'ty on each side: 41 pieces Pitch: 154.3 mm
—
Width: 460 mm Q'ty on each side: 39 pieces Pitch: 171.5 mm —
Width: 635 mm Q'ty on each side: 39 pieces Pitch: 171.5 mm
—
—
Width: 700 mm Q'ty on each side: 39 pieces Pitch: 171.5 mm
*1: The battery capacity (Ah) is the 5-hour rate value.
D31/37/39EX, PX-21
01-7
GENERAL
SPECIFICATIONS
D31EX-21 Machine model
400 mm Single shoe
Tilt cylinder
600 mm Swamp shoe
50501 and up —
Fix displacement external-gear type x 1
Theoretical discharge amount
3
cm /rev
40.2
Max. discharge pressure
MPa {kg/cm2}
20.6 {210}
Type, number
—
3-spool valve x 1
Operating method
—
Hydraulic pilot type
Type
—
Double-acting piston type
Cylinder bore
mm
ø85
Outside diameter of piston rod
mm
ø40
Piston stroke
mm
365
Max. distance between pins
mm
1,009
Min. distance between pins
mm
644
—
Double-acting piston type
Cylinder bore
mm
ø90
Outside diameter of piston rod
mm
ø45
Piston stroke
mm
139
Max. distance between pins
mm
598
Min. distance between pins
mm
459
—
Double-acting piston type
Type Cylinder bore
mm
ø75
Outside diameter of piston rod
mm
ø40
Piston stroke
mm
393
Max. distance between pins
mm
1,083
Min. distance between pins
mm
690
—
Double-acting piston type
—
Cylinder bore
mm
ø90
—
Outside diameter of piston rod
mm
ø45
—
Piston stroke
mm
433.5
—
Max. distance between pins
mm
1,176.5
—
Min. distance between pins
mm
743
—
Type Ripper cylinder
600 mm Single shoe
Type, number
Type
Angle cylinder
Work equipment hydraulic system
Lift cylinder
Main control valve
Hydraulic pump
Serial No.
D31PX-21
Hydraulic tank
—
Box type (externally mounted control valve type)
Hydraulic filter
—
Tank return side
Oil cooler
—
Air-cooled type (SF-3)
01-8
D31/37/39EX, PX-21
GENERAL
SPECIFICATIONS
D37EX-21
D37PX-21
400 mm Single shoe
600 mm Single shoe
600 mm Swamp shoe
D39EX-21 460 mm Single shoe
D39PX-21 635 mm Single shoe
700 mm Swamp shoe
5501 and up
1501 and up
Fix displacement external-gear type x 1
Fix displacement external-gear type x 1
40.2
43.7
20.6 {210}
20.6 {210}
3-spool valve x 1
3-spool valve x 1
Hydraulic pilot type
Hydraulic pilot type
Double-acting piston type
Double-acting piston type
ø85
ø90
ø40
ø45
365
393
1,009
1,109
644
716
Double-acting piston type
Double-acting piston type
ø90
ø90
ø45
ø45
139
145
598
634
459
489
Double-acting piston type
Double-acting piston type
ø75
ø85
ø40
ø45
393
393
1,083
1,109
690
716
Double-acting piston type
—
Double-acting piston type
—
ø90
—
ø90
—
ø45
—
ø45
—
433.5
—
433.5
—
1,176.5
—
1,176.5
—
743
—
743
—
Box type (externally mounted control valve type)
Box type (externally mounted control valve type)
Tank return side
Tank return side
Air-cooled type (SF-3)
Air-cooled type (SF-4)
D31/37/39EX, PX-21
01-9
GENERAL
SPECIFICATIONS
D31EX-21 Machine model
400 mm Single shoe
Serial No. Type
Performance Dimensions
Work equipment
—
Hydraulic cylinder type
mm
860
855
920
Max. lowering depth (from ground)
mm
385
380
315
Max. tilt
mm
330
435 (395)
435 (395)
Max. angle
deg
25
25
25
Blade width
mm
2,435
3,200 (2,875)
3,200 (2,875)
Blade height
mm
845
750 (790)
750 (790)
Blade cutting angle
deg
56
56
58
Tool bar type
Beam length
mm
Number of shanks
Performance
Hydraulic type angle tiltdozer
Max. lifting height (from ground)
Type
Ripper
600 mm Swamp shoe
50501 and up —
Blade support method
D31PX-21 600 mm Single shoe
Digging angle (at on the ground/ at max. digging depth)
520 Standard 3 units (Wearing is possible 5 units)
deg
Adjustment of digging depth
74/37 Rigid for 1 level
Max. digging depth
mm
310
Max. lift
mm
435
Shank interval (at 3 units/at 5 units)
mm
700/350
Values in ( ) are for the machines equipped with narrow blade.
01-10
D31/37/39EX, PX-21
GENERAL
SPECIFICATIONS
D37EX-21
D37PX-21
400 mm Single shoe
600 mm Single shoe
D39EX-21
600 mm Swamp shoe
460 mm Single shoe
D39PX-21 635 mm Single shoe
700 mm Swamp shoe
5501 and up
1501 and up
Hydraulic type angle tiltdozer
Hydraulic type angle tiltdozer
Hydraulic cylinder type
Hydraulic cylinder type
860
855
920
890
890
965
385
380
315
440
440
365
375
445 (395)
445 (395)
395
480 (430)
480 (430)
25
25
25
25
25 (22)
25 (22)
2,720
3,250 (2,875)
3,250 (2,875)
2,740
3,330 (2,980)
3,330 (2,980)
865
830
830
980
910
910
56
56
58
57
57
59
Tool bar type
Tool bar type
520
520
Standard 3 units (Wearing is possible 5 units)
Standard 3 units (Wearing is possible 5 units)
74/37
67/37
Rigid for 1 level
Rigid for 1 level
310
245
435
505
700/350
700/350
Values in ( ) are for the machines equipped with narrow blade.
D31/37/39EX, PX-21
01-11
GENERAL
WEIGHT TABLE
WEIGHT TABLE a This Weight Table is for reference when handling components or when transporting the machine. Unit: kg Machine model
D31EX-21
Serial No.
D31PX-21 50501 and up
Engine, damper assembly (not including water or oil)
485
485
• Engine assembly
400
400
• Damper assembly
27
27
• Engine related parts (engine mount, air cleaner, muffler, etc.)
58
58
Cooling assembly
177
177
• Radiator
71
71
• Oil cooler
33
33
• Charge air cooler
15
15
Fuel tank (not including fuel)
106
106
HST pump
134
134
HST motor (each side)
133
133
Final drive (each side)
162
162
Sprocket (each side)
26
26
Frame assembly
1,765
1,870
• Main frame
1,100
1,150
• Front underguard
8
8
• Rear underguard (including inspection cover)
41
41
• Idler assembly (each side)
93
93
• Recoil spring assembly (each side)
64
64
• Track roller (each side)
27 x 5
27 x 6
• Carrier roller (each side)
16
16
• Single grouser shoe (400 mm)
520 x 2
520 x 2
• Single grouser shoe (460 mm)
—
—
• Single grouser shoe (600 mm)
—
690 x 2
• Single grouser shoe (635 mm)
—
—
• Swamp shoe
(600 mm)
—
680 x 2
• Swamp shoe
(700 mm)
—
—
Hydraulic tank (not including hydraulic oil)
65
65
Hydraulic pump
6
6
• 3-spool valve
16
16
• 4-spool valve (with ripper)
19
—
Track shoe assembly
Control valve
01-12
D31/37/39EX, PX-21
GENERAL
WEIGHT TABLE
Unit: kg D37EX-21
D37PX-21
D39EX-21
5501 and up
D39PX-21 1501 and up
485
485
485
485
400
400
400
400
27
27
27
27
58
58
58
58
177
177
207
207
71
71
96
96
33
33
42
42
15
15
15
15
106
106
106
106
134
134
134
134
133
133
133
133
162
162
162
162
26
26
38
38
1,850
1,890
2,335
2,355
1,130
1,170
1,342
1,362
8
8
8
8
41
41
41
41
93
93
144
144
64
64
102
102
27 x 6
27 x 6
35 x 6
35 x 6
16
16
15
15
560 x 2
560 x 2
—
—
—
—
760 x 2
760 x 2
—
710 x 2
—
—
—
—
—
925 x 2
—
700 x 2
—
—
—
—
—
915 x 2
65
65
65
65
6
6
6
6
16
16
16
16
19
—
19
—
D31/37/39EX, PX-21
01-13
GENERAL
WEIGHT TABLE
Unit: kg Machine model
D31EX-21
Serial No.
D31PX-21 50501 and up
Power angle tiltdozer assembly
945
1,020 (1,005)
• Blade
460
530 (515)
• Dozer frame
380
380
• Tilt cylinder assembly
20
20
• Angle cylinder assembly
22 x 2
22 x 2
Lift cylinder assembly
23 x 2
23 x 2
Ripper
500
—
Ripper cylinder assembly
30
—
ROPS cab assembly
620
620
ROPS canopy assembly
310
310
Operator's seat
60
60
Floor frame assembly
150
150
Radiator guard assembly (including radiator mask)
175
175
Engine hood assembly
40
40
Engine side cover assembly (including left, right, top, bottom)
55
55
Front bracket (engine dividing wall)
42
42
Fender (left)
107
107
Fender (right)
113
113
Values in ( ) are for the machines equipped with narrow blade.
01-14
D31/37/39EX, PX-21
GENERAL
WEIGHT TABLE
Unit: kg D37EX-21
D37PX-21
D39EX-21
5501 and up
D39PX-21 1501 and up
975
1,035 (1,000)
1,120
1,195 (1,140)
490
550 (505)
580
655 (600)
380
380
400
400
20
20
20
20
22 x 2
22 x 2
25 x 2
25 x 2
23 x 2
23 x 2
28 x 2
28 x 2
500
—
500
—
30
—
30
—
620
620
620
620
310
310
310
310
60
60
60
60
150
150
150
150
180
180
190
190
40
40
40
40
55
55
55
55
42
42
42
42
107
107
107
107
113
113
113
113
Values in ( ) are for the machines equipped with narrow blade.
D31/37/39EX, PX-21
01-15
GENERAL
TABLE OF FUEL, COOLANT AND LUBRICANTS
TABLE OF FUEL, COOLANT AND LUBRICANTS RESERVOIR
KIND OF FLUID
AMBIENT TEMPERATURE 22 30
4 20
14 10
32 0
50 10
68 20
CAPACITY ( ) 86 104 30 40
Specified
Refill
14
12.5
0.16
0.16
97
47
3.5
3.5
SAE30 SAE10W Engine oil pan SAE10W-30 SAE15W-40 Idler (each)
SAE30 Engine oil SAE10W SAE10W-30
Hydraulic system
SAE15W-40 Final drive case (each) Fuel tank
SAE30 ASTM D975 No.2
Diesel fuel
165
ASTM D975 No.1
Grease fitting
Cooling system (including sub-tank)
01-16
Grease
Coolant
NLGI No.2
Add antifreeze
D31, 37: 27 D39: 32
D31/37/39EX, PX-21
GENERAL
TABLE OF FUEL, COOLANT AND LUBRICANTS
NOTICE Use only diesel fuel. The engine mounted on this machine employs electronic control and a high-pressure fuel injection device to obtain good fuel consumption and good exhaust gas characteristics. For this reason, it requires high precision for the parts and good lubrication. If kerosene or other fuel with low lubricating ability is used, there will be a big drop in durability. REMARK • When fuel sulphur content is less than 0.5%, change oil in the oil pan according to the periodic maintenance hours described in this manual. • Change oil according to the following table if fuel sulphur content is above 0.5%. • When staring the engine with an atmospheric temperature of lower than 0°C (32°F), be sure to use engine oil of SAE10W, SAE10W-30 and SAE15W-40, even though the atmospheric temperature goes up to 10°C (50°F) more or less during the day. • Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half. • There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to add single grade oil that matches the temperature range in the table. • We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applications. Specified capacity: Total amount of oil including oil for components and oil in piping. Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance. ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers API: American Petroleum Institute
Fuel sulphur content
Change interval of oil in engine oil pan
0.5 to 1.0%
1/2 of regular interval
Above 1.0%
1/4 of regular interval
D31/37/39EX, PX-21
01-17
10 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Cooling system ........................................ 10Engine control.......................................... 10Power train .............................................. 10Power train system .................................. 10Damper .................................................... 10HST hydraulic equipment arrangement diagram......................... 10Steering, brake control ............................ 10Solenoid valve ......................................... 10Towing valve ............................................ 10Final drive ................................................ 10HST pump ............................................... 10Safety-suction valve ................................ 10Charge safety valve ................................. 10Charge pump ........................................... 10Towing valve ............................................ 10HST motor ............................................... 10Electric lever (for steering)....................... 10Frame assembly ...................................... 10Track frame, recoil spring ........................ 10Idler.......................................................... 10Track roller ............................................... 10Carrier roller............................................. 10Sprocket .................................................. 10-
D31/37/39EX, PX-21
2 3 4 5 6 7 8 10 12 13 16 24 28 30 31 32 44 47 48 50 54 58 60
Track shoe................................................10- 64 Arrangement of hydraulic equipment for work equipment .............................10- 69 Work equipment control ...........................10- 70 Hydraulic tank, filter..................................10- 72 PPC lock valve .........................................10- 73 Accumulator .............................................10- 74 Hydraulic pump ........................................10- 75 Work equipment cylinder..........................10- 76 Control valve ............................................10- 80 CLSS ........................................................10- 88 PPC valve.................................................10- 98 Work equipment .......................................10-108 Cutting edge, end bit ................................10- 112 Ripper.......................................................10- 113 Cab related...............................................10- 114 Engine control ..........................................10- 116 HST control system ..................................10- 117 Gear shift control system..........................10- 118 Parking brake control system ...................10-122 Component equipment of system.............10-124 Monitor system .........................................10-128 Monitor panel............................................10-130 Sensors ....................................................10-134
10-1
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
COOLING SYSTEM
COOLING SYSTEM a The diagram shows D31EX/PX-21, D37EX/PX-21.
1. 2. 3. 4. 5. 6. 7.
Radiator Radiator cap Oil cooler After cooler Shroud Fan Drain valve
8. 9. 10. 11. 12. 13. 14.
After cooler outlet port Radiator inlet port hose Reservoir tank After cooler inlet port Radiator outlet port hose Oil cooler inlet port hose Oil cooler outlet port tube
Specifications Item
Unit
Radiator
Oil cooler
After cooler
D31/D37
D39
D31/D37
D39
D31/D37/D39
Core type
—
D-5
D-7
SF-3
SF-4
AL-CFT
Fin pitch
mm
3.0
3.0
3.0
3.0
6.0/2
Total heat dissipation area
m2
34.05
46.87
12.35
16.46
11.44
Pressure valve cracking pressure
kPa {kg/cm2}
88.3 ± 14.7 {0.9 ± 0.15}
88.3 ± 14.7 {0.9 ± 0.15}
—
—
—
Vacuum valve cracking pressure
kPa {kg/cm2}
0 – 4.9 {0 – 0.05}
0 – 4.9 {0 – 0.05}
—
—
—
10-2
D31/37/39EX, PX-21
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
ENGINE CONTROL
ENGINE CONTROL
1. 2. 3. 4. 5. 6. 7.
Decelerator pedal Clutch Fuel control lever Fuel control lever potentiometer Fuel control cable Decelerator cable Governor lever
D31/37/39EX, PX-21
Outline • The control of the engine speed is carried out with fuel control lever (3) or decelerator pedal (1).
10-3
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
POWER TRAIN
POWER TRAIN
Outline • The power generated by engine (1) has its torsional vibration reduced by damper (2), and is then transmitted to the input shaft of the HST pump. • HST pump (3) consists of swash plate type piston pumps for the left travel and right travel joined in tandem. The hydraulic power passes from each pump through high-pressure hoses (4) and is transmitted to left and right HST motors (5). • HST pump (3) changes the discharge direction and discharge amount continuously in accordance with the movement of the swash plate of each pump to match the movement of the steering, direction, and speed lever. This changes the direction of rotation and speed of the left and right HST motors and controls the forward and reverse travel and turning of the machine. • The hydraulic power transmitted to HST motor (5) is output from the motor output shaft as mechanical power, and is transmitted to final drive (6). • Final drive (6) is a 2-stage planetary gear mechanism. It reduces the speed and rotates sprocket (7) to drive track shoe (8).
10-4
D31/37/39EX, PX-21
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
POWER TRAIN SYSTEM
POWER TRAIN SYSTEM
1. 2. 3. 4. 5.
Engine Damper HST pump Charge pump High-pressure hose
D31/37/39EX, PX-21
6. 7. 8. 9.
HST motor Final drive Sprocket Track shoe
10-5
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
DAMPER
DAMPER
Unit: mm No.
Check item
1
Distance between HST pump mounting surface and tip of boss
2
Wear of inner teeth of coupling (resin)
3. 4. 5. 6. 7.
Coupling Boss HST pump input shaft Cover Flywheel
10-6
Criteria
Remedy
Standard size
Repair limit
62.0
±0.8 Repair limit: 1.0
Adjust
Replace
Outline • The damper reduces the torsional vibration caused by variations in the engine torque, and acts to protect the engine and downstream drive system from the torsional vibration. • The power from the engine is transmitted from flywheel (7) to coupling (3). Coupling (3) absorbs the torsional vibration and transmits the power through boss (4) to the HST pump.
D31/37/39EX, PX-21
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
HST HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAM
HST HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAM a HST: Abbreviation for HydroStatic Transmission
1. 2. 3. 4. 5. 6.
HST pump R.H. HST motor HST charge filter L.H. HST motor 4-spool solenoid valve Towing valve
D31/37/39EX, PX-21
10-7
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
STEERING, BRAKE CONTROL
STEERING, BRAKE CONTROL a PCCS: Abbreviation for Palm Command Control System
10-8
D31/37/39EX, PX-21
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
1. Parking brake lever 2. Joystick (PCCS lever) 3. Electric lever 4. Parking brake limit switch 1 5. Parking brake limit switch 2 6. HST controller 7. HST pump 8. Center brake limit switch 9. Brake pedal potentiometer 10. Brake pedal
D31/37/39EX, PX-21
STEERING, BRAKE CONTROL
Outline • Electric lever (3) sends electric signals to HST controller (6) according to the stroke of joystick (PCCS lever) (2). Upon receiving these signals, HST controller (6) sends signals to the EPC valve of HST pump (7) to change the flow in HST pump (7) and control the HST motor. • If the joystick (PCCS lever)(2) is leaned to the left a little while it is leaned to the forward position, the machine turns to the left gradually. If it is leaned to the left stroke end, the machine makes a counter-rotation. • Brake pedal potentiometer (9) sends electric signals to HST controller (6) according to the stroke of brake pedal (10). Upon receiving these signals, HST controller (6) sends signals to the EPC valve of HST pump (7) to decelerate the right and left HST motors simultaneously. • If brake pedal (10) is pressed fully while parking brake lever (1) is in the FREE position, the right and left HST hydraulic brakes operate simultaneously. At the same time, the signal of center brake limit switch (8) is sent to the slow brake solenoid valve and parking brake solenoid valve. As a result, the machine stops, and then the parking brakes built in the right and left HST motors operate. • Parking brake limit switch 1 (4) is connected to parking brake lever (1) and it sends electric signals to HST controller (6). Upon receiving these signals, HST controller (6) sends signals to the parking brake solenoid valve to operate the parking brakes built in the right and left HST motors.
10-9
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
SOLENOID VALVE
SOLENOID VALVE 4-spool solenoid valve
P : From HST pump CPA T : To hydraulic tank A1 : To towing valve A2 : To left-and-right HST motor PCMID A3 : To left-and-right HST motor PCMIN A4 : Plug A5 : To PPC lock valve
10-10
1. 2. 3. 4.
Parking brake solenoid valve Slow brake solenoid valve 3rd selector solenoid valve 2nd selector solenoid valve
Solenoid valve 5. Coil (ON-OFF type) 6. Push pin 7. Sleeve 8. Valve spool 9. Return spring 10. Block
D31/37/39EX, PX-21
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
SOLENOID VALVE
Outline • Block (10) has 4 solenoid valves. • Parking brake solenoid valve (1) transmits a signal generated by the potentiometer which operates when the brake pedal is pressed or a signal of the limit switch connected to the parking brake lever through the HST controller to drain the changeover oil and operate the parking brakes built in the HST motors. • Upon receiving a signal generated by the limit switch which operates when the brake pedal is pressed fully or a signal from the limit switch connected to the parking brake lever, slow brake solenoid valve (2) drains the changeover oil slowly through the orifice in it to operate the parking brakes built in the HST motors. • 3rd travel speed selector solenoid valve (3) transmits the shift switch signals of the steering/ directional/gear shift lever through the HST controller to output the changeover oil pressure and change the HST motor capacity for the 3rd travel speed. • 2nd travel speed selector solenoid valve (4) transmits the shift switch signals of the steering/ directional/gear shift lever through the HST controller to output the changeover oil pressure and change the HST motor capacity for the 2nd travel speed. Operation When solenoid is "de-energized" (When circuit is disconnected) • While the signal current is not flowing in coil (1) from outside, coil (1) is de-energized. • Accordingly, spool (2) is pushed back to the left by spring (3). • As a result, ports P and A are disconnected and the pilot pressure does not flow from port A to the actuator. At the same time, port T is opened and the oil from the actuator flows in the hydraulic tank. When solenoid is "energized" (When circuit is connected) • If the signal current flows in coil (1) from outside, coil (1) is energized. • Accordingly, spool (2) is pushed to the right by push pin (4). • As a result, ports P and A are connected and the pilot pressure flows from port A to the actuator. At the same time, port T is closed and the oil from the actuator does not flow in the hydraulic tank.
D31/37/39EX, PX-21
10-11
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
TOWING VALVE
TOWING VALVE 1. 2. 3. 4. 5.
Lever End cap Ball Seat Body
Outline • The towing valve is installed between the parking brake solenoid valve and HST motor. When the parking brake cannot be released because of an engine trouble, etc., the parking brake can be released by setting lever (1) of this valve in the "Close" position and applying parking brake release pressure from outside. a For the procedure of releasing the parking brake, see TESTING AND ADJUSTING, Procedure for releasing parking brake.
10-12
D31/37/39EX, PX-21
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
FINAL DRIVE
FINAL DRIVE a The diagram shows D31EX/PX-21, D37EX/PX-21.
1. Oil level plug 2. Drain plug Outline • The final drive is a planetary gear, 2-stage reduction type. It provides splash lubrication when the gear rotates. It is also possible to remove or install the final drive as a single unit. • A floating seal is installed to the rotating and sliding portion of the sprocket to prevent the entry of sand or soil from outside and to prevent leakage of lubricating oil. Specifications Reduction ratio: – ((14 + 88) / 14) x ((20 + 88) / 20) + 1 = –38.343
D31/37/39EX, PX-21
10-13
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
3. 4. 5. 6. 7. 8.
No. 1 sun gear (No. of teeth: 14) No. 2 sun gear (No. of teeth: 20) No. 1 planetary carrier Cover Sprocket No. 2 planetary carrier
9. 10. 11. 12. 13. 14.
FINAL DRIVE
Floating seal HST motor Hub No. 2 planetary pinion (No. of teeth: 34) Ring gear (No. of teeth: 88) No. 1 planetary pinion (No. of teeth: 37) Unit: mm
No.
Check item
Criteria
Remedy
Standard clearance
Clearance limit
0.13 – 0.35
1.00
Backlash of No. 1 planetary pinion and ring gear
0.17 – 0.54
1.10
17
Backlash of No. 1 planetary carrier and No. 2 sun gear
0.27 – 0.46
1.00
18
Backlash of No. 2 sun gear and No. 2 planetary pinion
0.14 – 0.38
1.00
19
Backlash of No. 2 planetary pinion and ring gear
0.18 – 0.54
1.10
15
Backlash of No. 1 sun gear and No. 1 planetary pinion
16
10-14
Replace
D31/37/39EX, PX-21
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
FINAL DRIVE
Path of power transmission
•
•
•
The power from the HST motor goes from No. 1 sun gear (1) through No. 1 planetary pinion (2), is reduced and rotates in the opposite direction from the rotation of the HST motor, and is then transmitted to ring gear (6). When this happens, No. 1 planetary pinion (2) forms one unit with No. 1 planetary carrier (3), and the power from No. 1 planetary carrier (3) is transmitted to No. 2 sun gear (4). The power transmitted to No. 2 sun gear (4) passes through No. 2 planetary pinion (5), has its speed reduced, and is transmitted to ring gear (6). The rotating power undergoes two-stage reduction, is transmitted to ring gear (6), passes through hub (7), and is transmitted to sprocket (8).
D31/37/39EX, PX-21
10-15
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
HST PUMP
HST PUMP a HST: Abbreviation for HydoroStatic Transmission
Type: HPV63 + 63 Structure • This pump consists of a variable displacement swash plate tandem piston pump, servo valve, EPC valve, safety valve with suction, charge safety valve and charge pump.
10-16
D31/37/39EX, PX-21
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
1. 2. 3. 4. 5. 6.
HST PUMP
EPC valve Piston pump Servo valve Safety valve with suction Charge safety vavle Charge pump
D31/37/39EX, PX-21
10-17
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
1. 2. 3. 4. 5. 6. 7. 8.
Shaft Cradle bearing Rocker cam Case Servo piston Slider Cylinder block Valve plate
Outline • The rotation and torque transmitted to the pump shaft is converted into hydraulic energy, and pressurized oil is discharged according to the load. • It is possible to change the discharge amount by changing the swash plate angle (normal io 0 io reverse discharge). Structure • Cylinder block (7) is supported to shaft (1) by spline (12). Shaft (1) is supported by front and rear bearings (14) and (10). • The tip of piston (11) is a concave ball, and shoe (13) is caulked to it to form one unit. Piston (11) and shoe (13) form a spherical bearing.
10-18 (4)
9. 10. 11. 12. 13. 14. 15.
HST PUMP
End cap Bearing Piston Spline Shoe Bearing Charge pump
•
•
•
Rocker cam (3) has flat surface A, and shoe (13) is always pressed against this surface while sliding in a circular movement. Rocker cam (3) positions cradle bearing (2) between case (4) and cylindrical surface B, and rocks. Piston (11) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7). Cylinder block (7) seals the pressure oil to valve plate (8) and carries out relative rotation. This surface is designed so that the oil pressure balance is maintained at a suitable level. The oil inside each cylinder chamber of cylinder block (7) is sucked in and discharged through valve plate (8).
D31/37/39EX, PX-21
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
HST PUMP
Operation 1. Operation of pump •
•
•
•
•
•
•
Cylinder block (9) rotates together with shaft (1), and shoe (7) slides on flat surface A. When this happens, angle between center line X of rocker cam (4) and the axial direction of cylinder block (9) changes. (Angle is called the swash plate angle.) Center line X of rocker cam (4) maintains swash plate angle in relation to the axial direction of cylinder block (9), and flat surface A moves as a cam in relation to shoe (7). In this way, piston (8) slides on the inside of cylinder block (9), so a difference between volumes E and F is created inside cylinder block (9). The suction and discharge is carried out by an amount equal to this difference F – E. In other words, when cylinder block (9) rotates and the volume of chamber F becomes smaller, the oil is discharged during that stroke. On the other hand, the volume of chamber E becomes larger, and as the volume becomes larger, the oil is sucked in. If center line X of rocker cam (4) is in line with the axial direction of cylinder block (9) (swash plate angle = 0), the difference between volu mes E' and F ' i nsi de cy lin der bl ock ( 7) becomes 0, so the pump does not carry out any suction or discharge of oil.
Piston (8) slides on the inside of cylinder block (9), so a difference between volumes E" and F" is created inside cylinder block (9). The suction and discharge is carried out by an amount equal to this difference E" – F". In other words, when cylinder block (9) rotates a nd the v olum e of c hamber E" bec omes smaller, the oil is discharged during that stroke. On the other hand, the volume of chamber F" becomes larger, and the oil is sucked in during that stroke. When the angle of the swash plate is reversed, the suction and discharge of ports PA and PB are reversed.
D31/37/39EX, PX-21
10-19
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
HST PUMP
2. Control of discharge amount •
•
•
•
If swash plate angle becomes larger, the difference between volumes E and F becomes larger and discharge amount Q increases. Swash plate angle is changed by servo piston (5). Servo spool (7) moves according to the command of the EPC valve. Servo piston (5) is reciprocated by the command pressure output from servo spool (7). This straight line movement is transmitted through slider (6) to rocker cam (4). Rocker cam (4), which is supported by the cylindrical surface to cradle bearing (3), then rocks on the cylindrical surface. For the pump, swash plate angle is a maximum of ± 15.3°.
10-20
D31/37/39EX, PX-21
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
HST PUMP
3. Operation of servo valve
10-22
D31/37/39EX, PX-21
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
HST PUMP
(1) When lever is operated 1) Operation of servo spool • The command current from the pump controller flows in the EPC valve solenoids (ESA and ESB). • This command current works on the EPC valve to output signal pressure. The signal pressure is applied through port SA (SB) to chamber sa (sb) and used to change the pressing force on servo spool (1). • The servo spool (1) stops at a point where the pressing force on servo spool (1) is balanced with the force of spring (3). • The strength of the command current is decided by the software of the controller on the basis of the stroke of the steering lever, pump pressure, etc. 2) Operation of servo piston • If servo spool (1) moves to the left, port CP is connected to port A and pressure is applied to chamber a. At the same time, port B is connected to port T and the oil in chamber b is drained. As a result, servo piston (2) moves to the left. • If servo piston (2) moves to the left and port CP is disconnected from port A, servo piston (2) stops. • In short, servo spool (1) and servo piston (2) move by the same distance. • Similarly, if servo spool (1) moves to the right, port CP is connected to port B and pressure is applied to chamber b. At the same time, port A is connected to port T and the oil in chamber a is drained. As a result, servo piston (2) moves to the right until port CP is disconnected from port B. (2) When lever is in neutral • If oil does not flow from the EPC valve, servo spool (1) does not move. Servo piston (2) is kept at the neutral position by the force of spring (4) and the main pump is kept in neutral.
D31/37/39EX, PX-21
10-23
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
SAFETY-SUCTION VALVE
SAFETY-SUCTION VALVE
1. Charge pump 2. Charge safety valve 3. Safety-suction valve 3A. Valve 3B. Rod
10-24
3C. Sleeve 3D. Spring 3E. Spring 3F. Plug
D31/37/39EX, PX-21
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
SAFETY-SUCTION VALVE
1. When it is high-pressure relief valve Function • It restricts the maximum pressure inside the HST circuit to protect the circuit. Operation (valve at piston pump discharge side) • Port A is connected to the pump circuit and port B is connected to the charge circuit. The pressure oil passes through drill hole a in piston (3A) and also fills port C. • The oil at high-pressure port A passes through passage groove b in the body and also fills port D. • Poppet (3A) is in tight contact with valve seat (3C). • If abnormal pressure is generated in the circuit and the oil pressure at ports A and D reaches the pressure set by spring (3D), poppet (3A) is pushed to the right, and the oil at port A is relieved to port B, so the oil pressure at port A goes down.
2. When it is safety-suction valve Function • This ensures the oil flow in in the HST closed circuit. It prevents the charge oil flow from flowing to the pump high-pressure side (discharge side). Operation (1) When HST pump discharge amount is 0 • •
The HST closed circuit is sealed, so the charge pressure oil does not flow into the HST circuit. Therefore, the charge pressure oil from charge pump (1) all passes through charge safety valve (2) and is drained to the inside of the case.
D31/37/39EX, PX-21
10-25
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
SAFETY-SUCTION VALVE
(2) When HST pump discharge amount is being discharged from port PA 1) Valve at piston pump discharge side • • • •
If pressure oil is being discharged from port PA of HST pump (4), port PA becomes the highpressure side. This pressure oil at port PA passes through passage b in the body and flows into port D. When this happens, sleeve (3C) is pushed fully to the left because of the relationship of the difference in area (A1>A2). Therefore, the pressure oil from charge pump (1) is prevented from flowing in.
3. Valve at piston pump suction side Operation • Port PB becomes the suction side, so it is at low-pressure. Sleeve (3C) is pushed to the right by the charge pressure oil from the relationship of the difference in area (A1MB, the shuttle valve moves to the right, MA is selected as the high pressure, and is taken to the 3rd speed spool. MB is selected as the low pressure and is taken to the charge relief valve. • When MA (Right)
Max. 1 V
Neutral
5 – 11 V
< (Left)
Max. 1 V
Between CN-ST2 (6) and CN-ST1 (10)
20-640 (1)
D31/37/39EX, PX-21
TROUBLESHOOTING
E-20
Circuit diagram related to information switch
D31/37/39EX, PX-21
20-641 (1)
TROUBLESHOOTING
E-21
E-21 System is not set in service mode or is not set out of service mode Trouble
• System is not set in service mode or is not set out of service mode.
Related information Cause
Standard value in normal state/Remarks on troubleshooting
1
Defective buzzer cancel switch system
Since the buzzer cancel switch system may be defective, check its operation. (If it does not operate normally, carry out troubleshooting for “Buzzer cancel switch does not function”.)
2
Defective information switch system
Since the information switch system may be defective, check its operation. (If it does not operate normally, carry out troubleshooting for “Information switch does not function”.)
3
Defective fuse (FB2-1)
If the fuse is broken, the circuit probably has a grounding fault, etc. (See Cause 6.)
4
Defective service switch (Internal disconnection or short circuit)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch. CN-S24
Service switch
Resistance
Between (1) and (2) Between (4) and (5)
OFF (Upper position)
Min. 1 Mz
ON (Lower position)
Max. 1 z
Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
5
Disconnection in wiring harness (Disconnection in wiring harness or defective contact in connector)
Wiring harness between FB2 (6) and CN-S24 (1)
Resistance
Max. 1 z
Wiring harness between CN-S03 (female) (16) and CN-S24 (2)
Resistance
Max. 1 z
Wiring harness between CN-ST1 (female) (10) and CN-S24 (4)
Resistance
Max. 1 z
Wiring harness between CN-ST1 (female) (6) and CNS24 (5)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
6
Short circuit with chassis ground in wiring harness (Contact with ground circuit)
Between FB2 (6) – CN-S34 (1) or CN-S03 (female) (5) or (6) or another related circuit wiring harness and chassis ground
Resistance
Min. 1 Mz
Between CN-S03 (female) (16) – CN-S24 (2) wiring harness and chassis ground
Resistance
Min. 1 Mz
Between CN-ST1 (female) (6) – CN-S24 (5) wiring harness and chassis ground
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 7
Defective monitor panel
CN-S03
Service switch
Voltage
Between (16) and chassis ground
OFF (Upper position)
Max. 1 V
ON (Lower position)
20 – 30 V
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 8
Defective HST controller
CN-ST1 Between (6) and (10)
20-642 (1)
Service switch
Voltage
OFF (Upper position)
5 - 11 V
ON (Lower position)
Max. 1 V
D31/37/39EX, PX-21
TROUBLESHOOTING
E-21
Circuit diagram related to service switch
D31/37/39EX, PX-21
20-643 (1)
TROUBLESHOOTING
E-23
E-23 Headlamp or rear lamp does not light up Trouble
• Headlamp or rear lamp does not light up.
Related information
• Note that the connector Nos. of the headlamps and rear lamps of the canopy specification are different from those of the cab specification. Cause
Standard value in normal state/Remarks on troubleshooting
1
Defective left headlamp (Bad contact or breakage of bulb)
If only the left headlamp does not light up, it may have a bad contact or a broken bulb. Check it directly.
2
Defective right headlamp (Bad contact or breakage of bulb)
If only the right headlamp does not light up, it may have a bad contact or a broken bulb. Check it directly.
3
Defective rear (Bad contact or breakage of bulb)
If only the rear lamp does not light up, it may have a bad contact or a broken bulb. Check it directly.
4
Defective fuse (FB1-1)
If the fuse is broken, the circuit probably has a grounding fault, etc. (See Cause 8.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
5
Defective lamp switch (Internal disconnection)
CN-FWL (male)
Possible causes and standard value in normal state
Between (2) and (3)
6
Defective lamp relay (Internal defect)
Lamp switch
Resistance
Q (OFF)
Min. 1 Mz
| (ON)
Max. 1 z
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Turn the lamp switch on and OFF. If the lamp relay makes an operating sound, it is normal. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
7
Disconnection in wiring harness (Disconnection in wiring harness or defective contact in connector)
Wiring harness between FB1 (6) and CN-FWL (2) or CN-54 (female) (1) or (3)
Resistance
Max. 1 z
Wiring harness between CN-FWL (female) (3) and CN54 (female) (5)
Resistance
Max. 1 z
Wiring harness between CN-54 (female) (6) and chassis ground (CN-T10)
Resistance
Max. 1 z
Wiring harness between CN54 (female) (2) or (4), CN33, and each lamp connector (female) (1)
Resistance
Max. 1 z
Wiring harness between each lamp connector (female) (2), CN33, and chassis ground (CN-T35)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
8
20-646 (1)
Short circuit with chassis ground in wiring harness (Contact with ground circuit)
Between FB1 (6) – CN-FWL (2) or CN54 (female) (1) or (3) wiring harness and chassis ground
Resistance
Min. 1 Mz
Between CN-FWL (female) (3) – CN54 (female) (5) or CN-S03 (female) (8) wiring harness and chassis ground
Resistance
Min. 1 Mz
Between CN-54 (female) (2) or (4) – CN-33 - each lamp connector (female) (1) and chassis ground
Resistance
Min. 1 Mz
D31/37/39EX, PX-21
TROUBLESHOOTING
E-23
Circuit diagram related to lamp and panel night lighting system
D31/37/39EX, PX-21
20-647 (1)
TROUBLESHOOTING
E-24
E-24 Canopy heater does not operate [Canopy specification] Trouble
• Canopy heater does not operate.
Related information
• This troubleshooting is for the case when the blower motor does not rotate. (When the blower motor rotates but air is not heated, hot water may not flow in from the engine. In this case, check the hot water system.) Cause
1
Defective fuse (FB2-3)
Standard value in normal state/Remarks on troubleshooting If the fuse is broken, the circuit probably has a grounding fault, etc. (See Cause 4.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch. CN-HS (male)
2
Defective heater switch (Internal disconnection or short circuit)
Between (4) and (3)
Possible causes and standard value in normal state
Between (4) and (2)
Heater switch
Resistance
OFF
Min. 1 Mz
I
Max. 1 z
II
Max. 1 z
OFF
Min. 1 Mz
I
Min. 1 Mz
II
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
3
Disconnection in wiring harness (Disconnection in wiring harness or defective contact in connector)
Wiring harness between FB2 (8) and CN-HS (female) (4)
Resistance
Max. 1 z
Wiring harness between CN-HS (female) (3) and CN92 (female) (3)
Resistance
Max. 1 z
Wiring harness between CN-HS (female) (2) and CN92 (female) (1)
Resistance
Max. 1 z
Wiring harness between CN92 (female) (4) and chassis ground (CNT10)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
4
5
20-648 (1)
Short circuit with chassis ground in wiring harness (Contact with ground circuit)
Defective heater unit (Internal defect)
Between FB2 (8) – CN-HS (female) (4) wiring harness and chassis ground
Resistance
Min. 1 Mz
Between CN-HS (female) (3) – CN92 (female) (3) wiring harness and chassis ground
Resistance
Min. 1 Mz
Between CN-HS (female) (2) – CN92 (female) (1) wiring harness and chassis ground
Resistance
Min. 1 Mz
If none of causes 1 – 5 is the cause of the trouble, the heater unit may be defective.
D31/37/39EX, PX-21
TROUBLESHOOTING
E-24
Circuit diagram related to canopy heater
D31/37/39EX, PX-21
20-649 (1)
TROUBLESHOOTING
E-25
E-25 Air conditioner does not operate [Cab specification] Trouble
(1) Air does not come out.
Related information Cause 1
Defective fuse (FB3-4)
2
Defective blower main relay (Coil side)
3
Possible causes and standard value in normal state
4
5
6
7
Blower main relay (Contact side)
Defective blower Hi relay (Coil side)
Defective blower Hi relay (Contact side)
Defective blower Mid relay (Coil side)
Defective blower Mid relay (Contact side)
Standard value in normal state/Remarks on troubleshooting If the fuse is broken, the circuit probably has a grounding fault, etc. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch. CN-R1 (male)
Resistance
Between (1) and (2)
240 ± 40 z
a Prepare with starting switch OFF, then turn starting switch and air conditioner switch ON and carry out troubleshooting. CN-R1
Air flow selector switch
Voltage
Between (3) and chassis ground
Lo
20 – 30 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch. CN-R2 (male)
Resistance
Between (1) and (2)
240 ± 40 z
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. When the air flow selector switch is set in the “Hi” position, if the blower motor rotates, the blower “Hi” relay is normal. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch. CN-R3 (male)
Resistance
Between (1) and (2)
240 ± 40 z
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. When the air flow selector switch is set in the “t” position, if the blower motor rotates, the blower “Mid” relay is normal. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
8
9
Defective resistor
Defective blower motor
CN-R (male)
Resistance
Between (2) and (4)
2.0 z ± 7%
Between (3) and (4)
0.8 z ± 7%
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. When the air flow selector switch is set in the “Lo” position, if the blower motor rotates, the blower motor is normal. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Disconnection in wiring harness 10 (Disconnection in wiring harness or defective contact in connector)
20-650 (1)
Wiring harness between FB3 (4) and CN80 (female) (13C)
Resistance
Max. 1 z
Wiring harness between FB3 (4) and CN-R1 (female) (13B)
Resistance
Max. 1 z
Wiring harness between FB3 (4) and CN-R2 (female) (13E)
Resistance
Max. 1 z
D31/37/39EX, PX-21
TROUBLESHOOTING
Possible causes and standard value in normal state
Cause
Disconnection in wiring harness 10 (Disconnection in wiring harness or defective contact in connector)
11 Defective control panel 12
Mistake in checking trouble
D31/37/39EX, PX-21
E-25
Standard value in normal state/Remarks on troubleshooting Wiring harness between FB3 (4) and CN-R3 (female) (13H)
Resistance
Max. 1 z
Wiring harness between FB3 (4) and CN-R1 (female) (6C)
Resistance
Max. 1 z
Wiring harness between CN80 (female) (D0) and CN81 (male) (0A)
Resistance
Max. 1 z
Wiring harness between CN-R1 (female) (11B) and CN-B (female) (11A)
Resistance
Max. 1 z
Wiring harness between CN-R1 (female) (14A) and CN80 (female) (14B)
Resistance
Max. 1 z
Wiring harness between CN-R2 (female) (18A) and CN80 (female) (18B)
Resistance
Max. 1 z
Wiring harness between CN-R2 (female) (0H) and CN81 (male) (0A)
Resistance
Max. 1 z
Wiring harness between CN-R3 (female) (17A) and CN80 (female) (17B)
Resistance
Max. 1 z
Wiring harness between CN-R3 (female) (0B) and CN81 (male) (0A)
Resistance
Max. 1 z
Wiring harness between CN-R (female) (0E) and CN81 (male) (0A)
Resistance
Max. 1 z
Wiring harness between CN-R (female) (12A) and CNR3 (female) (12B)
Resistance
Max. 1 z
Wiring harness between CN-B (female) (10A) and CNR (female) (10C)
Resistance
Max. 1 z
Wiring harness between CN-B (female) (10A) and CNR2 (female) (10B)
Resistance
Max. 1 z
If none of causes 1 – 10 is the cause of the trouble, the control panel may be defective. If the cause is not found out, a mistake may be made in check the trouble. In this case, carry out troubleshooting for “Air is not cooled”.
20-651 (1)
TROUBLESHOOTING
Trouble
E-25
(2) Air is not cooled.
Related information Cause 1
Defective fuse (FB3-4)
Standard value in normal state/Remarks on troubleshooting If the fuse is broken, the circuit probably has a grounding fault, etc. a Prepare with starting switch OFF, then turn starting switch and air conditioner switch ON and carry out troubleshooting.
2
Possible causes and standard value in normal state
3
4
5
6
7
8
9
10
20-652 (1)
Defective pressure switch
Defective compressor clutch relay (Coil side)
Defective compressor clutch relay (Contact side)
Defective condenser relay (Coil side)
Defective condenser relay (Contact side)
Defective thermistor
Defective condenser Hi relay (Coil side)
Defective condenser Hi relay (Contact side)
Defective condenser resistor
CN-P
Air flow selector switch
Voltage
Between (2) and chassis ground
Any position
20 – 30 V
a Prepare with starting switch OFF, then start engine and turn air conditioner switch ON and carry out troubleshooting. CN-P
Air flow selector switch
Voltage
Between (4) and chassis ground
Any position
20 – 30 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch. CN-R4 (male)
Resistance
Between (1) and (2)
240 ± 40 z
a Prepare with starting switch OFF, then turn starting switch and air conditioner switch ON and carry out troubleshooting. CN-R4
Air flow selector switch
Voltage
Between (4) and chassis ground
Any position
20 – 30 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch. CN-R5 (male)
Resistance
Between (1) and (2)
240 ± 40 z
a Prepare with starting switch OFF, then turn starting switch and air conditioner switch ON and carry out troubleshooting. CN-R5
Air flow selector switch
Voltage
Between (3) and chassis ground
Any position
20 – 30 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch. CN-T (male)
Resistance
Between (1) and (2)
Max. 3,500 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch. CN-R6 (male)
Resistance
Between (1) and (2)
240 ± 40 z
a Prepare with starting switch OFF, then turn starting switch and air conditioner switch ON and carry out troubleshooting. When the medium pressure switch of the pressure switch operates, if the condenser motor rotates, the condenser Hi relay is normal. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Condenser resistor
Resistance
Between (1) and (2)
2.8 z ± 5%
D31/37/39EX, PX-21
TROUBLESHOOTING
Cause Defective condenser 11 motor
12
Defective compressor magnetic clutch
13 Defective compressor
E-25
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch and air conditioner switch ON and carry out troubleshooting. When the air conditioner switch is turned ON, if the condenser motor rotates, the condenser motor is normal. The compressor magnetic clutch may be defective. Check it directly. The compressor may be defective. Check it directly.
Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Disconnection in wiring harness (Disconnection 14 in wiring harness or defective contact in connector)
15 Defective control panel
D31/37/39EX, PX-21
Wiring harness between FB3 (4) and CN-R4 (female) (6D)
Resistance
Max. 1 z
Wiring harness between FB3 (4) and CN-R5 (female) (6B)
Resistance
Max. 1 z
Wiring harness between FB3 (4) and CN-R4 (female) (13I)
Resistance
Max. 1 z
Wiring harness between FB3 (4) and CN-R5 (female) (13D)
Resistance
Max. 1 z
Wiring harness between CN80 (female) (15B) and CNT (female) (15A)
Resistance
Max. 1 z
Wiring harness between CN80 (female) (16C) and CNt (female) (16B)
Resistance
Max. 1 z
Wiring harness between CN-P (female) (26B) and CN80 (female) (26A)
Resistance
Max. 1 z
Wiring harness between CN-P (female) (29A) and CNR6 (female) (29B)
Resistance
Max. 1 z
Wiring harness between CN-R4 (female) (27C) and CN-R5 (female) (27B)
Resistance
Max. 1 z
Wiring harness between CN-R4 (female) (27C), CN-R5 (female) (27)) and CN-P (female) (27A)
Resistance
Max. 1 z
Wiring harness between CN-R4 (female) (9B) and CN81 (male) (9A)
Resistance
Max. 1 z
Wiring harness between CN-R5 (female) (28C) and condenser motor (female) (C361)
Resistance
Max. 1 z
Wiring harness between CN-R5 (female) (28C) and CN-P (female) (28A)
Resistance
Max. 1 z
Wiring harness between CN-R6 (female) (0K) and chassis ground (CN-T35)
Resistance
Max. 1 z
Wiring harness between CN-R6 (female) (30B) and condenser resistor (female) (C381)
Resistance
Max. 1 z
Wiring harness between CN-R6 (female) (0I) and chassis ground (CN-T35)
Resistance
Max. 1 z
Wiring harness between condenser resistor (female) (C04) and chassis ground (CN-T35)
Resistance
Max. 1 z
Wiring harness between condenser motor (female) (C38) and condenser resistor (C381)
Resistance
Max. 1 z
If none of causes 1 – 10 is the cause of the trouble, the control panel may be defective.
20-653 (1)
TROUBLESHOOTING
E-25
Circuit diagram related to air conditioner
20-654 (1)
D31/37/39EX, PX-21
TROUBLESHOOTING
E-26
E-26 Windshield wiper and windshield washer do not operate [Cab specification] Trouble
(1) Windshield wiper and windshield washer do not operate.
Related information
• Before carry out troubleshooting, check that the wiper arm and blade are not deformed or sticked. Cause
1
Defective fuse (FB3-5)
Standard value in normal state/Remarks on troubleshooting If the fuse is broken, the circuit probably has a grounding fault, etc. (See cause 5.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
2
Defective front wiper switch (Internal disconnection or short circuit)
CN65 (male) Between (3) and (4) Between (4) and (5)
Front wiper switch
Resistance
OFF
Min. 1 Mz
ON
Max. 1 z
OFF
Max. 1 z
ON
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch. CN68 (female) Between (2) and chassis ground
Possible causes and standard value in normal state
3
Defective front wiper motor (Internal defect)
Between (3) and chassis ground
Front wiper switch
Voltage or resistance 20 – 30 V
ON Max. 1 z
Between (5) and chassis ground
OFF
Max. 1 z
Between (6) and chassis ground
ON
20 – 30 V
If the voltage and resistance are normal but the front wiper does not operate, the front wiper motor is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
4
Disconnection in wiring harness (Disconnection in wiring harness or defective contact in connector)
Wiring harness between FB3 (5) and CN65 (female) (3)
Resistance
Max. 1 z
Wiring harness between FB3 (5) and CN68 (female) (6) (Note: If only this wiring harness is disconnected, the wiper operates but does not return to regular position when it stops.)
Resistance
Max. 1 z
Wiring harness between CN65 (female) (4) and CN68 (female) (2)
Resistance
Max. 1 z
Wiring harness between CN68 (female) (3) and chassis ground (CN-T35)
Resistance
Max. 1 z
Wiring harness between CN65 (female) (5) and CN68 (female) (5) (Note: If only this wiring harness is disconnected, the wiper operates but does not return to regular position when it stops.)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
5
Short circuit with chassis ground in wiring harness (Contact with ground circuit)
D31/37/39EX, PX-21
Between FB3 (5) – CN65 (female) (2) or (3) wiring harness and chassis ground
Resistance
Min. 1 Mz
Between FB3 (5) – CN68 (female) (6) wiring harness and chassis ground
Resistance
Min. 1 Mz
Between CN65 (female) (4) – CN68 (female) wiring harness and chassis ground
Resistance
Min. 1 Mz
Between CN65 (female) (5) – CN68 (female) (5) wiring harness and chassis ground
Resistance
Min. 1 Mz
20-655 (1)
TROUBLESHOOTING
E-26
Trouble
(2) Rear wiper does not operate.
Related information
• Before carry out troubleshooting, check that the wiper arm and blade are not deformed or sticked. Cause
Standard value in normal state/Remarks on troubleshooting
1
Defective fuse (FB3-3)
If the fuse is broken, the circuit probably has a grounding fault, etc. (See cause 4.)
2
Defective wiper motor circuit breaker
If the circuit breaker is turned OFF (If it operates), the circuit probably has a grounding fault, etc. (See cause 4.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
3
Defective rear wiper switch (Internal disconnection or short circuit)
CN64 Between (3) and (4) Between (4) and (5)
Rear wiper switch
Resistance
OFF
Min. 1 Mz
ON
Max. 1 z
OFF
Max. 1 z
ON
Min. 1 Mz
a Prepare with starting switch OFF, then keep starting switch OFF or turn it ON and carry out troubleshooting.
Possible causes and standard value in normal state
CN69 (female) Between (1) and chassis ground 4
Between (2) and chassis ground
Voltage or resistance 20 – 30 V
OFF Max. 1 z
Between (3) and chassis ground
ON
20 – 30 V
Between (4) and chassis ground
OFF
Max. 1 z
If the voltage and resistance are normal but the rear wiper does not operate, the rear wiper motor is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
5
20-656 (1)
Defective rear wiper motor (Internal defect)
Front wiper switch
Disconnection in wiring harness (Disconnection in wiring harness or defective contact in connector)
Wiring harness between FB3 (3) and CN64 (female) (3)
Resistance
Max. 1 z
Wiring harness between FB3 (3) and CN69 (female) (3) (Note: If only this wiring harness is disconnected, the wiper operates but does not return to regular position when it stops.)
Resistance
Max. 1 z
Wiring harness between CN64 (female) (4) and CN66 (female) (1)
Resistance
Max. 1 z
Wiring harness between CN66 (female) (2) and CN69 (female) (1)
Resistance
Max. 1 z
Wiring harness between CN69 (female) (2) and chassis ground (CN-T35)
Resistance
Max. 1 z
Wiring harness between CN64 (female) (5) and CN69 (female) (4) (Note: If only this wiring harness is disconnected, the wiper operates but does not return to regular position when it stops.)
Resistance
Max. 1 z
D31/37/39EX, PX-21
TROUBLESHOOTING
Possible causes and standard value in normal state
Cause
E-26
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
6
Short circuit with chassis ground in wiring harness (Contact with ground circuit)
D31/37/39EX, PX-21
Between FB3 (3) - CN64 (female) (2) or (3) wiring harness and chassis ground
Resistance
Min. 1 Mz
Between FB (3) - CN69 (female) (3) wiring harness and chassis ground
Resistance
Min. 1 Mz
Between CN64 (female) (4) – CN66 (female) (1) wiring harness and chassis ground
Resistance
Min. 1 Mz
Between CN66 (female) (2) – CN69 (female) (1) wiring harness and chassis ground
Resistance
Min. 1 Mz
Between CN64 (female) (5) – CN69 (female) (4) wiring harness and chassis ground
Resistance
Min. 1 Mz
20-657 (1)
TROUBLESHOOTING
E-26
Trouble
(3) Front windshield washer does not operate.
Related information
• Before carry out troubleshooting, check that there is sufficient washing liquid in the tank. Cause
1
Defective fuse (FB3-5)
2
Defective front wiper switch (Internal disconnection or short circuit)
Standard value in normal state/Remarks on troubleshooting If the fuse is broken, the circuit probably has a grounding fault, etc. (See cause 5.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch. CN65 (male) Between (2) and (1)
Front wiper switch
Resistance
OFF
Min. 1 Mz
W/I or W/II
Max. 1 z
a Prepare with starting switch OFF, then keep starting switch OFF or turn it ON and carry out troubleshooting. Possible causes and standard value in normal state
CN63 (female) 3
Between (1) and chassis ground Between (2) and chassis ground
Voltage or resistance 20 – 30 V
W/I or W/II Max. 1 z
If the voltage and resistance are normal but the front washer does not operate, the front washer motor is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
4
5
20-658 (1)
Defective front washer motor (Internal defect)
Front wiper switch
Disconnection in wiring harness (Disconnection in wiring harness or defective contact in connector)
Short circuit with chassis ground in wiring harness (Contact with ground circuit)
Wiring harness between FB3 (5) and CN65 (female) (2)
Resistance
Max. 1 z
Wiring harness between CN65 (female) (1) and CN63 (female) (1)
Resistance
Max. 1 z
Wiring harness between CN63 (female) (2) and chassis ground (CN-T35)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Between FB3 (5) – CN65 (female) (2) or (3) wiring harness and chassis ground
Resistance
Min. 1 Mz
Between CN65 (female) (1) – CN63 (female) (1) wiring harness and chassis ground
Resistance
Min. 1 Mz
D31/37/39EX, PX-21
TROUBLESHOOTING
E-26
Trouble
(4) Rear windshield washer does not operate.
Related information
• Before carry out troubleshooting, check that there is sufficient washing liquid in the tank. Cause
1
Defective fuse (FB3-3)
2
Defective rear wiper switch (Internal disconnection or short circuit)
Standard value in normal state/Remarks on troubleshooting If the fuse is broken, the circuit probably has a grounding fault, etc. (See cause 5.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch. CN64 (male) Between (2) and (1)
Rear wiper switch
Resistance
OFF
Min. 1 Mz
W/I or W/II
Max. 1 z
a Prepare with starting switch OFF, then keep starting switch OFF or turn it ON and carry out troubleshooting. Possible causes and standard value in normal state
CN62 (female) 3
Defective rear washer motor (Internal defect)
Between (1) and chassis ground Between (2) and chassis ground
Rear wiper switch
Voltage or resistance 20 – 30 V
W/I or W/II Max. 1 z
If the voltage and resistance are normal but the rear washer does not operate, the rear washer motor is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
4
5
Disconnection in wiring harness (Disconnection in wiring harness or defective contact in connector)
Short circuit with chassis ground in wiring harness (Contact with ground circuit)
D31/37/39EX, PX-21
Wiring harness between FB3 (3) and CN64 (female) (2)
Resistance
Max. 1 z
Wiring harness between CN64 (female) (1) and CN62 (female) (1)
Resistance
Max. 1 z
Wiring harness between CN62 (female) (2) and chassis ground (CN-T35)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Between FB3 (3) - CN64 (female) (2) or (3) wiring harness and chassis ground
Resistance
Min. 1 Mz
Between CN64 (female) (1) – CN62 (female) (1) wiring harness and chassis ground
Resistance
Min. 1 Mz
20-659 (1)
TROUBLESHOOTING
E-26
Circuit diagram related to wiper and windshield washer
20-660 (1)
D31/37/39EX, PX-21
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) Information in troubleshooting table ............................................................................................................ 20-702 H-1 Right and left travel systems do not operate forward and in reverse (No travel systems operate) ...... 20-703 H-2 Right or left travel system does not operate forward and in reverse (Only right or left travel system does not operate) ............................................................................... 20-704 H-3 Right or left travel system does not operate forward or in reverse (Only 1 system does not operate). 20-704 H-4 Speed or power of travel is low ............................................................................................................ 20-705 H-5 Gear is not shifted ................................................................................................................................ 20-706 H-6 Large shock is made when machine stops traveling............................................................................ 20-707 H-7 Machine deviates largely during travel ................................................................................................. 20-707 H-8 Hydraulic drift of travel is larger............................................................................................................ 20-708 H-9 Engine stalls or engine speed lowers extremely during travel ............................................................. 20-708 H-10 Abnormal sound comes out from around HST pump and motor........................................................ 20-709 H-11 Work equipment dose not operate at all............................................................................................. 20-710 H-12 Speed or power of whole work equipment is low ............................................................................... 20- 711 H-13 Speed or power of lifting blade is low ................................................................................................. 20-712 H-14 Speed or power of tilting blade is low ................................................................................................. 20-712 H-15 Speed or power of angling blade is low.............................................................................................. 20-713 H-16 Time lag in lifting blade is large .......................................................................................................... 20-714 H-17 Hydraulic drift of lifting blade is large.................................................................................................. 20-714 H-18 Hydraulic drift of tilting blade is large.................................................................................................. 20-714 H-19 Abnormal sound comes out from around work equipment pump and control valve........................... 20-715 H-20 HST oil temperature (Hydraulic oil temperature) rises too high ......................................................... 20-716
D31/37/39EX, PX-21
20-701 (1)
TROUBLESHOOTING
INFORMATION IN TROUBLESHOOTING TABLE
INFORMATION IN TROUBLESHOOTING TABLE a The following information is summarized in the troubleshooting table. Before carrying out troubleshooting, understand that information fully. Trouble
Trouble which occurred in the machine
Related information
Information related to the detected trouble or troubleshooting
Possible causes and standard value in normal state
Cause 1 Possible causes of 2 trouble (Given numbers are reference numbers, 3 which do not indicate priority)
• Standard value in normal state to judge possible causes • Remarks on judgment
4
20-702 (3)
Standard value in normal state/Remarks on troubleshooting
D31/37/39EX, PX-21
TROUBLESHOOTING
H-1
H-1 Right and left travel systems do not operate forward and in reverse (No travel systems operate) Trouble
• Right and left travel systems do not operate forward and in reverse (No travel systems operate).
Related information
• Check that the oil level in the hydraulic tank is normal before carrying out troubleshooting. Cause
Standard value in normal state/Remarks on troubleshooting
1
Defect in rear damper
The rear damper may have a defect in it. Check it directly.
2
Defect in charge pump
The charge pump may have a defect in it. Check it directly.
3
Clogging of charge filter
The charge filter may be clogged. Check it directly. Clogging of the charge filter can be checked in the monitoring mode (40910-S/T SW1, 4th from left). a Prepare with engine stopped, then run engine at high idling and carry out troubleshooting.
Possible causes and standard value in normal state
4
Defective adjustment or malfunction of HST pump (charge safety valve)
Monitor panel (Adjustment mode) 3016-STALL CHECK (Stall pressure test mode)
PCCS lever
HST charge circuit pressure
Neutral
3.04 ± 0.29 MPa {31 ± 3 kg/cm2}
Forward or reverse
2.84 ± 0.49 MPa {29 ± 5 kg/cm2}
If the oil pressure does not become normal after the adjustment, the charge safety valve of the HST pump may have malfunction or defect in it. Check the charge safety valve directly. a Prepare with engine stopped, then run engine at high idling and carry out troubleshooting.
5
Defective adjustment or malfunction of HST motor (charge relief valve)
Monitor panel (Adjustment mode) 3016-STALL CHECK (Stall pressure test mode)
PCCS lever
HST charge circuit pressure
Neutral
3.04 ± 0.29 MPa {31 ± 3 kg/cm2}
Forward or reverse
2.84 ± 0.49 MPa {29 ± 5 kg/cm2}
If the oil pressure does not become normal after the adjustment, the charge relief valve of the HST motor may have malfunction or defect in it. Check the charge relief valve directly. a Prepare with engine stopped, then run engine at high idling and carry out troubleshooting.
6
Malfunction of parking brake solenoid valve or slow brake solenoid valve
Parking brake lever and brake pedal
Parking brake solenoid valve output pressure
Slow brake solenoid valve output pressure
Lever: Free position Pedal: Released
30.4 ± 0.49 MPa {31 ± 5 kg/cm2}
30.4 ± 0.49 MPa {31 ± 5 kg/cm2}
Lever: Lock position Pedal: Pressed fully
0 MPa {0 kg/cm2}
0 MPa {0 kg/cm2}
7
Wrong operation of parkThe parking brake bypass valve (tow valve) may be operated (changed over) ing brake bypass valve wrongly. Check it directly. (tow valve)
8
Defect in HST pump (pump unit)
D31/37/39EX, PX-21
The pump unit of the HST pump may have a defect in it. Check it directly.
20-703 (1)
TROUBLESHOOTING
H-2, H-3
H-2 Right or left travel system does not operate forward and in reverse (Only right or left travel system does not operate) • Right or left travel system does not operate forward and in reverse (Only right or left travel system does not operate).
Trouble Related information
Possible causes and standard value in normal state
Cause
Standard value in normal state/Remarks on troubleshooting
1
Malfunction of HST pump (servo valve)
The servo valve of the HST pump (on 1 side) may be malfunctioning. Check it directly.
2
Wrong operation of HST pump (towed valve)
The towed valve of the HST pump (on 1 side) may be operated (opened) wrongly. Check it directly.
3
Defect in HST pump (pump unit)
The pump unit of the HST pump (on 1 side) may have a defect in it. Check it directly.
4
Defect in HST pump (parking brake)
The parking brake of the HST motor (on 1 side) may have a defect in it. Check it directly.
5
Defect in HST motor (motor unit)
The motor unit of the HST motor (on 1 side) may have a defect in it. Check it directly.
6
Defect in final drive
The final drive (on 1 side) may have a defect in it. Check it directly.
H-3 Right or left travel system does not operate forward or in reverse (Only 1 system does not operate) Trouble
• Right or left travel system does not operate forward or in reverse (Only 1 system does not operate).
Related information
• If this trouble occurs just after the initial adjustment of the pump, the pump may be adjusted wrongly. In this case, perform the initial adjustment of the pump again. (During idle travel: 3001-PUMP ADJST F, 3002-PUMP ADJST R) (During actual travel: 3003-PU F-UP MPA, 3004-PU R-UP MAP, 3005-PU FHF MAP, 3006-PU R-HF MAP) Cause
Standard value in normal state/Remarks on troubleshooting
Possible causes and standard value in normal state
a Prepare with starting switch ON, then run engine at high idling and carry out troubleshooting.
1
Monitor panel (Adjustment mode) 3016-STALL CHECK (Stall pressure test mode)
PCCS lever
HST main circuit pressure
Forward
39.2 – 45.1 MPa {400 – 460 kg/cm2}
Reverse
39.2 – 45.1 MPa {400 – 460 kg/cm2}
a Prepare with engine stopped, then run engine at high idling and carry out troubleshooting. 2
Malfunction of HST pump (EPC valve)
PCCS lever
EPC valve output pressure
F1 (Travel)
Min. 1.0 MPa {Min. 10 kg/cm 2}
N (Neutral)
0 MPa {0 kg/cm2}
R1 (Travel)
Min. 1.0 MPa {Min. 10 kg/cm2}
3
Malfunction of HST pump (servo valve)
The servo valve of the HST pump (on 1 side) may be malfunctioning. Check it directly.
4
Defect in HST pump (pump unit)
The pump unit of the HST pump (on 1 side) may have a defect in it. Check it directly.
20-704 (1)
Malfunction of HST pump (safety-suction valve)
D31/37/39EX, PX-21
TROUBLESHOOTING
H-4
H-4 Speed or power of travel is low Trouble
• Speed or power of travel is low.
Related information
• If this trouble occurs just after the initial adjustment of the pump, the pump may be adjusted wrongly. In this case, perform the initial adjustment of the pump again. (During idle travel: 3001-PUMP ADJST F, 3002-PUMP ADJST R) (During actual travel: 3003-PU F-UP MPA, 3004-PU R-UP MAP, 3005-PU FHF MAP, 3006-PU R-HF MAP) Cause
Standard value in normal state/Remarks on troubleshooting
1
Defect in charge pump
The charge pump may have a defect in it. Check it directly.
2
Clogging of charge filter
The charge filter may be clogged. Check it directly. Clogging of the charge filter can be checked in the monitoring mode (40910-S/T SW1, 4th from left). a Prepare with engine stopped, then run engine at high idling and carry out troubleshooting.
Possible causes and standard value in normal state
3
Defective adjustment or malfunction of HST pump (charge safety valve)
Monitor panel (Adjustment mode) 3016-STALL CHECK (Stall pressure test mode)
PCCS lever
HST charge circuit pressure
Neutral
3.04 ± 0.29 MPa {31 ± 3 kg/cm2}
Forward or reverse
2.84 ± 0.49 MPa {29 ± 5 kg/cm2}
If the oil pressure does not become normal after the adjustment, the charge safety valve of the HST pump may have malfunction or defect in it. Check the charge safety valve directly. a Prepare with engine stopped, then run engine at high idling and carry out troubleshooting.
4
Defective adjustment or malfunction of HST motor (charge relief valve)
Monitor panel (Adjustment mode) 3016-STALL CHECK (Stall pressure test mode)
PCCS lever
HST charge circuit pressure
Neutral
3.04 ± 0.29 MPa {31 ± 3 kg/cm2}
Forward or reverse
2.84 ± 0.49 MPa {29 ± 5 kg/cm2}
If the oil pressure does not become normal after the adjustment, the charge relief valve of the HST motor may have malfunction or defect in it. Check the charge relief valve directly. a Prepare with starting switch ON, then run engine at high idling and carry out troubleshooting.
5
Malfunction of safety-suction valve
Monitor panel (Adjustment mode) 3016-STALL CHECK (Stall pressure test mode)
D31/37/39EX, PX-21
PCCS lever
HST relief pressure
Forward
39.2 – 45.1 MPa {400 – 460 kg/cm2}
Reverse
39.2 – 45.1 MPa {400 – 460 kg/cm2}
20-705 (1)
TROUBLESHOOTING
H-5
H-5 Gear is not shifted (1) Gear is not shifted to 2nd in quick shift mode. Gear is not shifted to medium speed range in variable shift mode.
Trouble Related information Possible causes and standard value in normal state
Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idling and carry out troubleshooting.
1
Malfunction of 2nd travel speed selection solenoid valve
Shift mode
PCCS lever
Solenoid valve output pressure
N1 (Neutral + 1st)
0 MPa {0 kg/cm2}
F2, R2 (Travel + 2nd)
30.9 ± 0.49 MPa {31 ± 5 kg/cm2}
Quick shift
2
Malfunction of HST motor
If the machine deviates during travel, the HST motor may be malfunctioning. Check the HST motor directly.
(2) Gear is not shifted to 3rd in quick shift mode. Gear is not shifted to high speed range in variable shift mode.
Trouble Related information Possible causes and standard value in normal state
Cause
a Prepare with engine stopped, then run engine at high idling and carry out troubleshooting.
1
Malfunction of 3rd travel speed selection solenoid valve
Shift mode
PCCS lever
Solenoid valve output pressure
N1 (Neutral + 1st)
0 MPa {0 kg/cm2}
F3, R3 (Travel + 3rd)
30.9 ± 0.49 MPa {31 ± 5 kg/cm2}
Quick shift
2
20-706 (1)
Standard value in normal state/Remarks on troubleshooting
Malfunction of HST motor
If the machine deviates during travel, the HST motor may be malfunctioning. Check the HST motor directly.
D31/37/39EX, PX-21
TROUBLESHOOTING
H-6, H-7
H-6 Large shock is made when machine stops traveling Trouble
• Large shock is made when machine stops traveling.
Related information Possible causes and standard value in normal state
Cause 1
Defective air bleeding from HST pump
2
Low HST oil temperature
3
Defective initial adjustment of pump
Standard value in normal state/Remarks on troubleshooting Air may be left in the servo valve of the HST pump. Bleed air again. Warm up the engine (to the green range of the HST oil thermometer). HST oil thermometer
Green range
The initial adjustment of the pump may be defective. Adjust the pump again.
H-7 Machine deviates largely during travel Trouble
• Machine deviates largely during travel.
Related information
Possible causes and standard value in normal state
Cause
Standard value in normal state/Remarks on troubleshooting
1
Malfunction of HST pump (servo valve)
The servo valve of the HST pump (on 1 side) may be malfunctioning. Check it directly.
2
Wrong operation of HST pump (towed valve)
The towed valve of the HST pump (on 1 side) may be operated (opened) wrongly. Check it directly.
3
Defect in HST pump (pump unit)
The pump unit of the HST pump (on 1 side) may have a defect in it. Check it directly.
4
Defect in HST pump (parking brake)
The parking brake of the HST motor (on 1 side) may have a defect in it. Check it directly.
5
Malfunction of HST motor (charge relief valve)
The charge relief valve of the HST motor (on 1 side) may be malfunctioning. Check it directly.
6
Defect in HST motor (motor unit)
The motor unit of the HST motor (on 1 side) may have a defect in it. Check it directly.
7
Defective HST motor (speed sensor)
If error code [DLM1KB], [DLM1MA], [DLM2KB], or [DLM2MA] is displayed, carry out troubleshooting for it.
8
Defective air bleeding from HST pump
Air may be left in the servo valve of the HST pump. Bleed air again.
D31/37/39EX, PX-21
20-707 (1)
TROUBLESHOOTING
H-8, H-9
H-8 Hydraulic drift of travel is larger Trouble
• Hydraulic drift of travel is large.
Related information Cause
Standard value in normal state/Remarks on troubleshooting
Possible causes and standard value in normal state
a Prepare with starting switch ON, then run engine at high idling and carry out troubleshooting. 1
Malfunction of HST pump (safety-suction valve)
Monitor panel Stall pressure test mode [3016]
PCCS lever
HST relief pressure
Forward
39.2 – 45.1 MPa {400 – 460 kg/cm2}
Reverse
39.2 – 45.1 MPa {400 – 460 kg/cm2}
2
Wrong operation of HST pump (towed valve)
The towed valves of the HST pumps (on both sides) may be operated (opened) wrongly. Check it directly.
3
Defect in HST pump (pump unit)
Oil may be leaking in the pump unit of the HST pump (on both sides). Check the pump unit directly.
4
Malfunction of HST pump (servo valve)
The neutral positions of the servo valves of the HST motors (on both sides) may be adjusted wrongly. Check them directly.
5
Leakage in HST motor (motor unit)
Oil may be leaking in the motor units of the HST motors (on both sides). Check the motor units directly.
H-9 Engine stalls or engine speed lowers extremely during travel Trouble
• Engine stalls or engine speed lowers extremely during travel.
Related information
Possible causes and standard value in normal state
Cause
a Prepare with engine stopped, then run engine at high idling and carry out troubleshooting. 1
Malfunction of HST pump (EPC valve)
PCCS lever
EPC valve output pressure
F1 (Travel)
Min. 1.0 MPa {Min. 10 kg/cm2}
N (Neutral)
0 MPa {0 kg/cm2}
R1 (Travel)
Min. 1.0 MPa {Min. 10 kg/cm2}
2
Malfunction of HST pump (servo valve)
The servo valve of the HST pump (on 1 side) may be malfunctioning. Check it directly.
3
Defect in HST pump (pump unit)
The pump unit of the HST pump (on 1 side) may have a defect in it. Check it directly.
20-708 (1)
Standard value in normal state/Remarks on troubleshooting
D31/37/39EX, PX-21
TROUBLESHOOTING
H-10
H-10 Abnormal sound comes out from around HST pump and motor Trouble
• Abnormal sound comes out from around HST pump and motor.
Related information
• Check that the oil level in the hydraulic tank is normal before carrying out troubleshooting. Cause
Standard value in normal state/Remarks on troubleshooting
1
Low oil level in hydraulic tank or use of improper oil
The oil level in the hydraulic tank may be low or improper oil may be used. Check the oil directly.
2
Clogging of charge pump suction strainer
The charge pump suction strainer may be clogged. Check it directly.
3
Loosening of charge pump suction piping
The charge pump suction piping may be loosened. Check it directly.
4
Defect in charge pump
The charge pump may have a defect in it. Check it directly.
5
Clogging of charge filter
The charge filter may be clogged. Check it directly.
Possible causes and standard value in normal state
a Prepare with engine stopped, then run engine at high idling and carry out troubleshooting.
6
Defective adjustment or malfunction of HST pump (charge safety valve)
Monitor panel (Adjustment mode) 3016-STALL CHECK (Stall pressure test mode)
PCCS lever
HST charge circuit pressure
Neutral
3.04 ± 0.29 MPa {31 ± 3 kg/cm2}
Forward or reverse
2.84 ± 0.49 MPa {29 ± 5 kg/cm2}
If the oil pressure does not become normal after the adjustment, the charge safety valve of the HST pump may have malfunction or defect in it. Check the charge safety valve directly. a Prepare with engine stopped, then run engine at high idling and carry out troubleshooting.
7
Defective adjustment or malfunction of HST motor (charge relief valve)
Monitor panel (Adjustment mode) 3016-STALL CHECK (Stall pressure test mode)
PCCS lever
HST charge circuit pressure
Neutral
3.04 ± 0.29 MPa {31 ± 3 kg/cm2}
Forward or reverse
2.84 ± 0.49 MPa {29 ± 5 kg/cm2}
If the oil pressure does not become normal after the adjustment, the charge relief valve of the HST motor may have malfunction or defect in it. Check the charge relief valve directly. 8
Defect in HST pump (pump unit)
The pump unit of the HST pump may have a defect in it. Check it directly.
9
Loosening of piping between HST pump and HST motor
The piping between the HST pump and HST motor may be loosened. Check it directly.
10
Defect in HST motor (motor unit)
The motor unit of the HST motor may have a defect in it. Check it directly. Troubleshooting cannot be carried out since the defect is in the motor unit.
11
Defective air bleeding from HST pump
Air may be left in the servo valve of the HST pump. Bleed air again.
D31/37/39EX, PX-21
20-709 (1)
TROUBLESHOOTING
H-11
H-11 Work equipment dose not operate at all Trouble
• Work equipment dose not operate at all.
Related information
• Check that the oil level in the hydraulic tank is normal before carrying out troubleshooting. Cause
Standard value in normal state/Remarks on troubleshooting
1
Defect in rear damper
The rear damper may have a defect in it. Check it directly.
2
Defect in charge pump
The charge pump may have a defect in it. Check it directly.
3
Clogging of charge filter
The charge filter may be clogged. Check it directly. a Prepare with engine stopped, then run engine at high idling and carry out troubleshooting.
Possible causes and standard value in normal state
4
Defective adjustment or malfunction of HST pump (charge relief valve)
PCCS lever and blade control lever
HST charge circuit pressure
All levers in neutral
2.84 ± 0.49 MPa {29 ± 5 kg/cm2}
If the oil pressure does not become normal after adjustment, the HST charge relief valve may have a malfunction or a defect in it. Check the HST charge relief valve directly.
5
Malfunction of work equipment PPC lock valve
The work equipment PPC lock valve may be malfunctioning. Check it directly.
6
Defect in front PTO
The front PTO may have a defect in it. Check it directly.
7
Defect in work equipment pump
The work equipment pump may have a defect in it. Check it directly.
8
Malfunction of control valve (unload valve)
The unload valve of the control valve may be malfunctioning. Check it directly. a Prepare with engine stopped, then run engine at high idling and carry out troubleshooting.
9
Defective adjustment or malfunction of control valve (main relief valve)
Blade control lever
Work equipment pump relief pressure
Relieve blade circuit (by lifting, tilting, or angling).
17.6 MPa {180 kg/cm2}
If the oil pressure does not become normal after adjustment, the main relief valve may have a malfunction or a defect in it. Check the main relief valve directly.
20-710 (1)
D31/37/39EX, PX-21
TROUBLESHOOTING
H-12
H-12 Speed or power of whole work equipment is low Trouble
• Speed or power of whole work equipment is low.
Related information
• Check that the oil level in the hydraulic tank is normal before carrying out troubleshooting. Cause
Standard value in normal state/Remarks on troubleshooting
1
Defect in charge pump
The charge pump may have a defect in it. Check it directly.
2
Clogging of charge filter
The charge filter may be clogged. Check it directly.
Possible causes and standard value in normal state
a Prepare with engine stopped, then run engine at high idling and carry out troubleshooting. 3
Defective adjustment or malfunction of HST pump (charge relief valve)
PCCS lever and blade control lever
HST charge circuit pressure
All levers in neutral
2.84 ± 0.49 MPa {29 ± 5 kg/cm2}
If the oil pressure does not become normal after adjustment, the HST charge relief valve may have a malfunction or a defect in it. Check the HST charge relief valve directly.
4
Defect in work equipment pump
The work equipment pump may have a defect in it. Check it directly.
5
Malfunction of control valve (unload valve)
The unload valve of the control valve may be malfunctioning. Check it directly. a Prepare with engine stopped, then run engine at high idling and carry out troubleshooting.
6
Defective adjustment or malfunction of control valve (main relief valve)
Blade control lever
Work equipment pump relief pressure
Relief of blade circuit (by lifting, tilting, or angling)
17.6 MPa {180 kg/cm2}
If the oil pressure does not become normal after adjustment, the main relief valve may have a malfunction or a defect in it. Check the main relief valve directly.
D31/37/39EX, PX-21
20-711 (1)
TROUBLESHOOTING
H-13, H-14
H-13 Speed or power of lifting blade is low Trouble
• Speed or power of lifting blade is low.
Related information
• Check that the blade has not been modified before carrying out troubleshooting. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idling and carry out troubleshooting.
Possible causes and standard value in normal state
1
Malfunction of boom PPC valve (lift)
Blade control lever
PPC valve output pressure
Raising stroke end
Min. 1.65 MPa {Min. 16.8 kg/cm2}
Lowering position
Min. 1.37 MPa {Min. 14.0 kg/cm2}
Floating stroke end
Min. 2.01 MPa {Min. 21.0 kg/cm2}
2
Malfunction of blade lift control valve (spool)
The spool of the blade lift control valve may be malfunctioning. Check it directly.
3
Malfunction of blade lift control valve (pressure compensation valve)
The pressure compensation valve of the blade lift control valve may be malfunctioning. Check it directly.
4
Malfunction of blade lift control valve (suction valve)
The suction valve of the blade lift control valve may be malfunctioning. Check it directly.
5
Defect in blade lift cylinder
a Prepare with engine stopped, then run engine at high idling and carry out troubleshooting. Blade lift cylinder
Leakage from cylinder
Relief by raising
6.5 cc/min
H-14 Speed or power of tilting blade is low Trouble
• Speed or power of tilting blade is low.
Related information
• Check that the blade has not been modified before carrying out troubleshooting. Cause
Standard value in normal state/Remarks on troubleshooting
Possible causes and standard value in normal state
a Prepare with engine stopped, then run engine at high idling and carry out troubleshooting. 1
Blade control lever
PPC valve output pressure
Left tilting stroke end
Min. 1.72 MPa {Min. 17.5 kg/cm2}
Right tilting stroke end
Min. 1.72 MPa {Min. 17.5 kg/cm2}
2
Malfunction of blade lift control valve (spool)
The spool of the blade lift control valve may be malfunctioning. Check it directly.
3
Malfunction of blade tilt control valve (pressure compensation valve)
The pressure compensation valve of the blade tilt control valve may be malfunctioning. Check it directly.
4
20-712 (1)
Malfunction of boom PPC valve (tilt)
Defect in blade tilt cylinder
a Prepare with engine stopped, then run engine at high idling and carry out troubleshooting. Blade tilt cylinder
Leakage from cylinder
Relief by tilting left
6.5 cc/min
D31/37/39EX, PX-21
TROUBLESHOOTING
H-15
H-15 Speed or power of angling blade is low Trouble
• Speed or power of angling blade is low.
Related information
• Check that the blade has not been modified before carrying out troubleshooting. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idling and carry out troubleshooting.
Possible causes and standard value in normal state
1
Malfunction of boom PPC valve (angle)
Blade control lever
PPC valve output pressure
Left angling stroke end
Min. 1.96 MPa {Min. 20.0 kg/cm2}
Right angling stroke end
Min. 1.96 MPa {Min. 20.0 kg/cm2}
2
Malfunction of blade angle control valve (spool)
The spool of the blade angle control valve may be malfunctioning. Check it directly.
3
Malfunction of blade angle control valve (pressure compensation valve)
The pressure compensation valve of the blade angle control valve may be malfunctioning. Check it directly.
4
Malfunction of blade angle control valve (safety valve)
The safety valve of the blade angle control valve may be malfunctioning. Check it directly.
5
Malfunction of blade angle control valve (suction valve)
The suction valve of the blade angle control valve may be malfunctioning. Check it directly.
6
Defect in blade angle cylinder
D31/37/39EX, PX-21
a Prepare with engine stopped, then run engine at high idling and carry out troubleshooting. Blade angle cylinder
Leakage from cylinder
Relief by right or left angling
6.0 cc/min
20-713 (1)
TROUBLESHOOTING
H-16, H-17, H-18
H-16 Time lag in lifting blade is large Trouble
• Time lag in lifting blade is large.
Related information Possible causes and standard value in normal state
Cause 1
Malfunction of blade lift control valve (suction valve)
Standard value in normal state/Remarks on troubleshooting The suction valve of the blade lift control valve may be malfunctioning. Check it directly.
H-17 Hydraulic drift of lifting blade is large Trouble
• Hydraulic drift of lifting blade is large
Related information
• Check that the blade has not been modified before carrying out troubleshooting. Cause
Possible causes and standard value in normal state
1
2
Defective seal of blade lift control valve (spool) Defective seal of blade lift cylinder
Standard value in normal state/Remarks on troubleshooting The seal of the blade lift control valve may be defective. Check it directly. a Prepare with engine stopped, then run engine at high idling and carry out troubleshooting. Blade lift cylinder
Leakage from cylinder
Relief by raising
6.5 cc/min
H-18 Hydraulic drift of tilting blade is large Trouble
• Hydraulic drift of tilting blade is large
Related information
• Check that the blade has not been modified before carrying out troubleshooting. Cause
Possible causes and standard value in normal state
20-714 (1)
1
Defective seal of blade tilt control valve (spool)
2
Defective seal of blade tilt cylinder
Standard value in normal state/Remarks on troubleshooting The seal of the blade tilt control valve may be defective. Check it directly. a Prepare with engine stopped, then run engine at high idling and carry out troubleshooting. Blade tilt cylinder
Leakage from cylinder
Relief by tilting left
6.5 cc/min
D31/37/39EX, PX-21
TROUBLESHOOTING
H-19
H-19 Abnormal sound comes out from around work equipment pump and control valve Trouble
• Abnormal sound comes out from around work equipment pump and control valve.
Related information
• Check that the oil level in the hydraulic tank is normal before carrying out troubleshooting.
Possible causes and standard value in normal state
Cause
Standard value in normal state/Remarks on troubleshooting
1
Low oil level in hydraulic tank or use of improper oil
The oil level in the hydraulic tank may be low or improper oil may be used. Check the oil directly.
2
Clogging of work equipment pump suction strainer
The work equipment pump suction strainer may be clogged. Check it directly.
3
Looseness of work The work equipment suction piping may be loosened. Check it directly. equipment suction piping a Prepare with engine stopped, then run engine at high idling and carry out troubleshooting.
4
Defective adjustment or malfunction of control valve (main relief valve)
Blade control lever
Work equipment pump relief pressure
Relief of blade circuit (by lifting, tilting, or angling)
17.6 MPa {180 kg/cm2}
If the oil pressure does not become normal after adjustment, the main relief valve may have a malfunction or a defect in it. Check the main relief valve directly. 5
Defect in work equipment pump (pump unit)
The pump unit of the work equipment pump may have a defect in it. Check it directly.
6
Loosening of piping between HST pump and HST motor
The piping between the HST pump and HST motor may be loosened. Check it directly.
D31/37/39EX, PX-21
20-715 (1)
TROUBLESHOOTING
H-20
H-20 HST oil temperature (Hydraulic oil temperature) rises too high Trouble
• HST oil temperature (Hydraulic oil temperature) rises too high
Related information
• Check that the oil level in the hydraulic tank is normal before carrying out troubleshooting.
Possible causes and standard value in normal state
Cause
Standard value in normal state/Remarks on troubleshooting
1
Low oil level in hydraulic tank or use of improper oil
The oil level in the hydraulic tank may be low or improper oil may be used. Check the oil directly.
2
Clogging of hydraulic oil cooler
The fins and cores of the hydraulic oil cooler may be clogged. Check them directly.
3
Malfunction of HST motor (charge relief valve)
The charge relief valve of the HST motor may be malfunctioning. Check it directly. a Prepare with starting switch ON, then run engine at high idling and carry out troubleshooting.
4
5
Malfunction of HST pump (safety-suction valve)
Defect in HST pump (pump unit)
Monitor panel Stall pressure test mode [3016]
PCCS lever
HST relief pressure
Forward
39.2 – 45.1 MPa {400 – 460 kg/cm2}
Reverse
39.2 – 45.1 MPa {400 – 460 kg/cm2}
The pump unit of the HST pump may have a defect in it. Check it directly. a Prepare with engine stopped, then run engine at high idling and carry out troubleshooting.
6
Defective adjustment or malfunction of control valve (main relief valve)
Blade control lever
Work equipment pump relief pressure
Relief of blade circuit (by lifting, tilting, or angling)
17.6 MPa {180kg/cm2}
If the oil pressure does not become normal after adjustment, the main relief valve may have a malfunction or a defect in it. Check the main relief valve directly. 7
20-716 (1)
Defect in work equipment pump (pump unit)
The pump unit of the work equipment pump may have a defect in it. Check it directly.
D31/37/39EX, PX-21
TROUBLESHOOTING OF ENGINE (S MODE) Method of using troubleshooting charts ...................................................................................................... 20-802 S-1 Starting performance is poor (Starting always takes time) ................................................................... 20-806 S-2 Engine does not start............................................................................................................................ 20-807 S-3 Engine does not pick up smoothly (Follow-up is poor) ......................................................................... 20-810 S-4 Engine stops during operations .............................................................................................................20-811 S-5 Engine does not rotate smoothly (Hunting) .......................................................................................... 20-812 S-6 Engine lacks output (or lacks power) ................................................................................................... 20-813 S-7 Exhaust smoke is black (Incomplete combustion) ............................................................................... 20-814 S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................................... 20-815 S-9 Oil becomes contaminated quickly ....................................................................................................... 20-816 S-10 Fuel consumption is excessive........................................................................................................... 20-817 S-11 Oil is in cooling water, or water spurts back, or water level goes down.............................................. 20-818 S-12 Oil pressure caution lamp lights up (Drop in oil pressure).................................................................. 20-819 S-13 Oil level rises (Water, fuel in oil) ......................................................................................................... 20-820 S-14 Water temperature becomes too high (Overheating) ......................................................................... 20-821 S-15 Abnormal noise is made..................................................................................................................... 20-822 S-16 Vibration is excessive ......................................................................................................................... 20-823
D31/37/39EX, PX-21
20-801 (1)
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS This troubleshooting chart is divided into three sections: questions, check items, and troubleshooting. The questions and check items are used to pinpoint high probability causes that can be located from the failure symptoms or simple inspection without using troubleshooting tools. Next, troubleshooting tools or direct inspection are used to check the high probability causes to make final confirmation. [Questions] Sections (A) + (B) in the chart on the right corresponds to the items where answers can be obtained from the user. The items in (B) are items that can be obtained from the user, depending on the user's level.
Causes
[Check items] The serviceman carries out simple inspection to narrow down the causes. The items under (C) in the chart on the right correspond to this. The serviceman narrows down the causes from information (A) that he has obtained from the user and the results of (C) that he has obtained from his own inspection.
(A)
(B) (C)
(a) (b) (c) (d) (e)
Check items
[Troubleshooting] Troubleshooting is carried out in the order of probability, starting with the causes that have been marked as having the highest probability form information gained from [Questions] and [Check items].
Questions
(b) (2) (3)
Troubleshooting
i
20-802 (1)
ii iii
D31/37/39EX, PX-21
METHOD OF USING TROUBLESHOOTING CHARTS
njec tion)
Causes
Seiz
The basic method of using the troubleshooting chart is as follows. Items listed for [Questions] and [Check items] that have a relationship with the Cause items are marked with Q, and of these, causes that have a high probability are marked with w. Check each of the [Questions] are [Check items] in turn, and marked the Q or w in the chart for items where the problem appeared. The vertical column (Causes) that has the highest number of points is the most probable cause, so start troubleshooting for that item to make final confirmation of the cause. 1. For [Confirm Section, ask repair history] in the [Questions] Section, ask the user, and mark the Cause column with E to use as reference for locating the cause of the failure. However, do not use this when marking calculations to narrow down the causes. 2. Use the E in the Cause column as reference for [Degree of use (Operated for long period)] in the [Questions] section as reference. As a rule, do not use it when calculating be included if necessary to determine the order for troubleshooting.
ed t urbo Clog char ger, ged air c inter Wor lean fere n pis nce er e leme ton ring Clog nt , cyl ged inde , se r line Imp ized rope r injec r inje t i o n no Defe ction zzle ctive timin injec g tion pum p (e xces sive i
TROUBLESHOOTING
D31/37/39EX, PX-21
1
Confirm recent repair history
2
Degree of use
Operated for long period
20-803 (1)
TROUBLESHOOTING
•
METHOD OF USING TROUBLESHOOTING CHARTS
Example of troubleshooting when exhaust gas is black Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became weaker], and [Dust indicator is red]. If we look from these three symptoms to find the causes, we find that there is a relationship with five causes. Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
S-7 Exhaust gas is black (incomplete combustion) General causes why exhaust gas is black • Insufficient intake of air • Improper condition of fuel injection • Excessive injection of fuel
Seiz
Legend : Possible causes (judging from Questions and check items) : Most probable causes (judging from Questions and Check items) : Possible causes due to length of use (used for a long period) : Items to confirm the cause.
ed t urbo Clog char ger, ged air c inter Wor lean fere n pis nce er e leme ton ring Clog nt , c ged ylind , seiz er Imp ed rope r inje injectio nn Defe ction ctive timin ozzle injec g Imp tion rope pum r va p (e lve c Crus xces lear hed sive ance , clo injec gge Lea tion) dm kage uffle of a r ir be Defe twee ctive n tu cont Defe rboc act o ctive harg f valv er a injec e, va nd h tion lve s ead pum eat p (ra ck, p lung er s eize d)
Causes
Confirm recent repair history Degree of use
Operated for long period Suddenly became black
Questions
Color of exhaust gas
Gradually became black Blue under light load
Engine oil must be added more frequently Power was lost
Suddenly Gradually
Non-specified fuel has been used Noise of interference is heard from around turbocharger Dust indicator is red Blow-by gas is excessive
Check items
Engine pickup is poor and combustion is irregular When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Match marks on fuel injection pump are out of alignment Seal on injection pump has come off Clanging sound is heard from around cylinder head Exhaust noise is abnormal Muffler is crushed Leakage of air between turbocharger and head, loose clamp When turbocharger is rotated by hand, it is found to be heavy When air cleaner is inspected directly, it is found to be clogged
Troubleshooting
When compression pressure is measured, it is found to be low Speed of some cylinders does not change when operating on reduced cylinders When check is made using delivery method, injection timing is found to be incorrect Injection pump test shows that injection amount is incorrect When valve clearance is checked directly it is found to be outside standard value When muffler is removed, exhaust gas color returns to normal
20-804 (1)
Replace
Replace
Repair
Replace
Adjust
Adjust
Adjust
Replace
Replace
Clean
Remedy
Replace
When control rack is pushed, it is found to be heavy or does not return
D31/37/39EX, PX-21
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHARTS
Five causes Step 1 Clarify the relationship between the three symptoms in the [Questions] and [Check items] section and the five Causes items in the vertical column.
Three symptoms
Step 2 Add up the total of and marks where the horizontal lines for the three symptoms and the vertical columns for the causes intersect. (1) Clogged air cleaner element: (2) Air leakage between turbocharger and head: (3) Clogged, seized injection nozzle: (4) Defective contact of valve, valve seat: (5) Worn piston ring, cylinder:
Step 3 The calculation in Step 2 shows that the closest relationship is with [Clogged air cleaner element]. Follow this column down to the troubleshooting area and carry out the troubleshooting item marked . The Remedy is given as [Clean], so carry out cleaning, and the exhaust gas color should return to normal.
D31/37/39EX, PX-21
20-805 (1)
TROUBLESHOOTING
S-1
S-1
Starting performance is poor (Starting always takes time) General causes why exhaust smoke comes out but engine takes time to start • Defective electrical system • Insufficient supply of fuel • Insufficient intake of air • Improper selection of fuel (At ambient temperature of –10°C or below, ASTM D975 No. 2 diesel fuel is used) a Battery charging rate
•
1.28
1.26 1.24 1.23 1.22
0°C –10°C
1.29 1.30
1.27 1.25 1.24 1.23 1.28 1.26 1.25 1.24
The specific gravity should exceed the value for the charging rate of 70% in the above table. In cold areas the specific gravity must exceed the value for the charging rate of 75% in the above table.
Wor
•
20°C
Causes n pis ton r Defe ing, cylin ctive der cont Clog act o ged f valv air c e, va Clog lean lve s er ele ged eat fuel men Clog filter t , stra ged feed in e r Defe pum ctive p str aine intak Defe r e air ctive heat r egula er Defe tor ctive alter Defe nato ctive r or de Defe terio ctive rated fuel batte Defe injec ry tive tion fuel nozz injec Defe le tion tive timin fuel Leak injec g age, tion p c ump lo ggin Clog (rack g, air ged , plu air b in fu nger reath Defe el pip stuc ctive er ho ing k) feed le in Defe fuel pum ctive tank p boos t com pens ator canc el
Charging rate Ambient 100% 90% 80% 75% 70% temperature
Questions
Confirm recent repair history Degree of use of machine
Operated for long period
Ease of starting
Gradually became worse Starts when warm
Preheating monitor does not light up Engine oil must be added more frequently Replacement of filters has not been carried out according to operation Manual Non-specified fuel has being used Air cleaner clogging monitor lights up Battery charge monitor is ON Starting motor cranks engine slowly When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
Check items
Engine does not pick up smoothly, and combustion is irregular Blow-by gas is excessive Timing lock on fuel injection pump does not match Mud is stuck to fuel tank cap When engine is cranked with starting motor, 1) Little fuel comes out even when fuel injection pump piping sleeve nut is loosened 2) Little fuel comes out even when fuel filter air bleed plug is loosened Leakage from fuel piping There is hunting from engine (rotation is irregular) When compression pressure is measured, it is found to be low When air cleaner element is inspected directly, it is found to be clogged
Troubleshooting
When fuel filter, strainer are inspected directly, they are found to be clogged When feed pump strainer is inspected directly, it is found to be clogged Heater mount does not become warm Is voltage 20 26 V between alternator terminal B and terminal E with engine at low idling?
Yes No
Either specific gravity of electrolyte or voltage of battery is low Speed does not change when operation of certain cylinders is stopped When control rack is pushed, it is found to be heavy or does not return (check after removing fuel injection pump)
Replace
Replace
Clean
Correct
Replace
Adjust (*1)
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Correct
Remedy
Replace
When fuel tank cap is inspected directly, it is found to be clogged
*1. Use a test stand when adjusting.
20-806 (1)
D31/37/39EX, PX-21
TROUBLESHOOTING
S-2
S-2
Engine does not start (1) Engine does not turn General causes why engine does not turn • Seizure inside engine a For seizure inside the engine, carry out the troubleshooting for S-4 Engine stops during operation. • Hydraulic pump system error • Defective electrical system
Questions
Defe
ctive wirin Defe g of ctive star or d ting Defe eter circu iora ctive it t e s d ba tarti Brok ttery ng m en r otor ing g Defe ear ctive safe Defe ty re ctive lay b atte Defe r y re ctive lay batt Defe ery ctive term inal star ting conn swit ectio ch n
Causes
Confirm recent repair history Degree of use of machine
Operated for long period
Horn does not sound Condition of horn when starting switch is turned ON Horn volume is low Speed of rotation is low When starting switch is turned to START, pinion moves out, but
Makes grating noise Soon disengages pinion again
D31/37/39EX, PX-21
Replace
Replace
Remedy
Replace
For the following conditions 1) - 4), turn the starting switch OFF, connect the cord, and carry out troubleshooting 1) When terminal B and terminal C of starting switch are connected, engine starts 2) When terminal B and terminal C of starting motor are connected, engine starts 3) When terminal B and terminal C of safety relay are connected, engine starts 4) There is no 24V between battery relay terminal BR and terminal E When ring gear is inspected directly, tooth surface is found to be chipped
Replace
Troubleshooting
Specific gravity of electrolyte, voltage of battery is low
Replace
When battery is checked, battery electrolyte is found to be low
Replace
Battery terminal is loose
Troubleshooting of defective wiring in starting circuit
When starting switch is turned to ON, there is no clicking sound
Replace
Check items
Makes rattling noise and does not turn When starting switch is turned to START, pinion does not move out
20-807 (1)
TROUBLESHOOTING
S-2
(2) Engine turns but no exhaust smoke comes out (Fuel is not being injected)
Type of fuel
Selection of fuel according to ambient temperature –22 –30
–4 –14 –20 –10
32 0
50 10
68 20
86 30
104°F 140°C
ASTM D975 No.2 Diesel oil
Questions
ASTM D975A No.1
Causes
Brok en in jecti Defe on p ctive ump injec drive Seiz tion shaf ed, pum t, ke brok p (ra y en f Clog ck, p eed ged lung p ump fuel er s Clog filter pisto eize ged , str d) n feed a i n e Insu r p u m fficie p s train nt fu Clog er el in ged tank , lea Clog king ged fuel air b pipin Imp reat g rope h er h r fue ole i l use n fu d el ta nk
General causes why engine turns but not exhaust smoke comes out • Supply of fuel impossible • Supply of fuel extremely small • Improper selection of fuel (particularly in winter)
Confirm recent repair history Operated for long period Degree of use of machine Exhaust smoke suddenly stops coming out (when starting again) Replacement of filters has not been carried out according to Operation Manual Fuel tank is found to be empty There is leakage from fuel piping Mud is stuck to fuel tank cap
Check items
When fuel filter is drained, fuel does not come out When engine is cranked with starting motor, 1) No fuel comes out even when fuel filter air bleed plug is loosened 2) No fuel spurts out even when fuel injection pump piping sleeve nut is loosened Rust and water are found when fuel tank is drained
20-808 (1)
Replace
Correct
Correct
Add
Clean
Clean
Replace
Remedy
Replace
When control rack is pushed, it is found to be heavy, or does not return Inspect feed pump directly When fuel filter, strainer are inspected directly, they are found to be clogged When feed pump strainer is inspected directly, it is found to be clogged When fuel cap is inspected directly, it is found to be clogged Replace
Troubleshooting
Inspect injection pump directly
D31/37/39EX, PX-21
TROUBLESHOOTING
S-2
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected)
ctive , bro Defe ken ctive valv e sy injec Wor stem tion n pis pum (valv ton p (ra e, ro ring Clog ck, p cker , cyl ged lung leve i n fuel der er s r, et Clog l f i i n t l uck) t c.) e e ged r r, st rain feed er Clog p u mp ged stra air c iner Defe lean ctive er e leme i ntak Defe nt e air ctive hea or d t e r Lea eter kage iora , clo ted batt Clog ggin ery g, a ged ir in fuel fuel Clog injec syst ged tion em air b nozz Imp reat le, d rope h efec e r ho r fue tive le in l use spra fuel d y tank cap
Causes
Defe
General causes why exhaust smoke comes out but engine does not start • Lack of rotating force due to defective electrical system • Insufficient supply of fuel • Insufficient intake of air • Improper selection of fuel and oil
Confirm recent repair history
Questions
Degree of use of machine
Operated for long period
Suddenly failed to start When engine is cranked, abnormal noise is heard from around cylinder head Engine oil must be added more frequently Non-specified fuel is being used Replacement of filters has not been carried out according to Operation Manual Rust and water are found when fuel tank is drained Air cleaner clogging monitor lights up Preheating monitor does not light up Starting motor cranks engine slowly Mud is stuck to fuel tank cap
Check items
When fuel lever is placed at FULL position, it does not contact stopper When engine is cranked with starting motor, 1) Little fuel comes out even when injection pump piping sleeve nut is loosened 2) No fuel comes out even when fuel filter air bleed plug is loosened There is leakage from fuel piping When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low When fuel filter is drained, no fuel comes out Remove head cover and check directly
Troubleshooting
When control rack is pushed, it is found to be heavy, or does not return When compression pressure is measured, it is found to be low When fuel filter, strainer are inspected directly, they are found to be clogged When feed pump strainer is inspected directly, it is found to be clogged When air cleaner element is inspected directly, it is found to be clogged Heater mount does not become warm Either specific gravity of electrolyte or voltage of battery is low When feed pump is operated, there is no response, or operation is too heavy Speed does not change when operation of certain cylinders is stopped
D31/37/39EX, PX-21
Replace
Clean
Clean
Correct
Replace
Correct
Clean
Clean
Clean
Replace
Replace
Remedy
Replace
When fuel tank cap is inspected directly, it is found to be clogged
20-809 (1)
TROUBLESHOOTING
Engine does not pick up smoothly (Follow-up is poor)
Clog
Clean
ged air c lean er e ged leme f uel f Clog nt ilter, ged st ra f e iner ed p Clog ump ged st ra fuel iner Seiz injec ed f tion uel in nozz jectio Wor le, d n pis efec n pu ton tive mp Seiz ring plun spra , cyl ed t ger y inde urbo r line char Imp rope ger, r r va inter lve c Clog fere lear ged nce a air b nce reat Clog her ged hole , lea in fu Defe king el ta ctive fuel nk c pipin cont ap act o g f val ve a nd v alve seat
Causes
Clog
General causes why engine does not pick up smoothly • Insufficient intake of air • Insufficient supply of fuel • Improper condition of fuel injection • Improper fuel used
Clean
S-3
S-3
Questions
Confirm recent repair history Operated for long period Degree of use of machine Replacement of filters has not been carried out according to Operation Manual Non-specified fuel is being used Engine oil must be added more frequently Engine pick-up suddenly became poor Rust and water are found when fuel tank is drained Air cleaner clogging monitor lights up Noise of interference is heard from around turbocharger Color of exhaust gas
Blue under light load Black
Check items
Clanging sound is heard from around cylinder head Mud is stuck to fuel tank cap There is leakage from fuel piping High idling speed under no load is normal, but speed suddenly drops when load is applied There is hunting from engine (rotation is irregular) When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
Troubleshooting
Blow-by gas is excessive When air cleaner element is inspected directly, it is found to be clogged When fuel filter, strainer are inspected directly, they are found to be clogged When feed pump strainer is inspected directly, it is found to be clogged Speed does not change when operation of certain cylinders is stopped When control rack is pushed, it is found to be heavy, or does not return When compression pressure is measured, it is found to be low When turbocharger is rotated by hand, it is found to be heavy When valve clearance is checked directly, it is found to be outside standard value When fuel tank cap is inspected directly, it is found to be clogged
20-810 (1)
Replace
Correct
Clean
Adjust
Replace
Replace
Replace
Correct
Remedy
Clean
When feed pump is operated, operation is too light or too heavy
D31/37/39EX, PX-21
TROUBLESHOOTING
S-4
S-4
Engine stops during operations General causes why engine stops during operations • Seized parts inside engine • Insufficient supply of fuel • Overheating a If the engine is overheating and the engine stops, carry out troubleshooting for overheating. (See S-14 Water temperature becomes too high) • Failure in hydraulic pump a If the machine stops because of the failure in hydraulic pump, carry out troubleshooting for H-mode.
Brok en, seiz ed p Brok iston en, seiz , con ed c Brok nect rank en d ing r shaf ynam od t be Brok i c arin valv en, g e s e s yst e ized Brok m ( gea en p valv r t ra ump e, ro in Brok a uxili cker en f ary leve uel p equ r, et Insu u ipme mp c. ) fficie d n r t i v nt fu e sh Clog el in a f t , ged key tank fuel Clog filter ged , st r aine feed r Brok pum en, p str seiz aine Clog ed f r eed ged pum , lea king p pis Clog fuel ton ged pipin air b g Defe reat her ctive hole fuel Failu in fu injec re in el ta t i o n pu nk hydr m aulic p (ra pum ck, p p sy lung stem er s tuck )
Causes
Confirm recent repair history Degree of use of machine Operated for long period
Questions
Abnormal noise was heard and engine stopped suddenly Condition when engine stopped
Engine overheated and stopped Engine stopped slowly There was hunting and engine stopped
Replacement of filters has not been carried out according to Operation Manual Non-specified fuel is being used Fuel level lamp lights up Fuel tank is found to be empty When feed pump is operated, operation is too light or too heavy Engine rotates, but stops when work equipment and travel levers are operated Does not turn at all When it is attempted to turn by hand using barring tool
Turns in opposite direction Moves amount of backlash Carry out troubleshooting for H-mode
Check items
Mud is stuck to fuel tank cap
Shaft does not turn Rust and water are found when fuel tank is drained Metal particles are found when oil is drained Remove oil pan and inspect directly
Troubleshooting
Remove head cover and inspect directly When gear train is inspected, it does not turn Rotates when pump auxiliary equipment is removed When fuel filter, strainer are inspected directly, they are found to be clogged When feed pump strainer is inspected directly, it is found to be clogged Inspect feed pump directly
D31/37/39EX, PX-21
Replace
Clean
Correct
Replace
Clean
Clean
Add
Replace
Replace
Replace
Replace
Replace
Remedy
Replace
When control rack is pushed, it is found to be heavy, or does not return
20-811 (1)
TROUBLESHOOTING
Engine does not rotate smoothly (Hunting) Causes
Defe
General causes why engine does not rotate smoothly • Air in fuel system • Defective governor mechanism • Defective electronical governor mechanism a If hunting stops when governor spring is disconnected, carry out troubleshooting for the troubleshooting for E-mode.
ctive ope Defe ratio ctive n of adju gove Defe stme rnor ctive nt o f go ope Low vern ratio or idlin n of g sp cont Insu eed rol r fficie i a s ck t oo lo nt fu Clog el in w ged tank feed Clog pum ged p st r f uel f aine Clog i lter, r ged st ra , air iner in ci Clog r ged cuit , air betw in ci Clog een rcuit ged fuel betw air b tank reat een and her feed feed hole pum pum in fu p an p el ta d no nk zzle
S-5
S-5
Confirm recent repair history
Questions
Degree of use of machine
Operated for long period Occurs at a certain speed range
Condition of hunting
Occurs at low idling Occurs even when speed is raised Occurs on slopes
Replacement of filters has not been carried out according to Operation Manual Fuel tank is found to be empty Rust, water are found when fuel tank is drained Check items
Leakage from fuel piping When feed pump is operated, 1) No response, light, return is quick 2) No response, light, return is normal Engine speed sometimes rises too far Engine is sometimes difficult to stop
Troubleshooting
Seal on injection pump has come off When governor lever is moved it is found to be stiff When injection pump is tested, governor is found to be improperly adjusted When control rack is pushed, it is found to be heavy, or does not return When fuel tank cap is inspected directly, it is found to be clogged When feed pump strainer is inspected directly, it is found to be clogged
20-812 (1)
Clean
Correct
Correct
Clean
Clean
Add
Adjust
Adjust
Adjust
Remedy
Adjust
When fuel filter, strainer are inspected directly, they are found to be clogged
D31/37/39EX, PX-21
TROUBLESHOOTING
Engine lacks output (or lacks power)
Clog
Seiz
ged air c lean ed t er e urbo leme char Wor nt ger, n pis inter ton ring f Clog eren , cyl ged ce inde fuel r Clog f i l ter, ged st ra feed iner Clog pum ged p st r f u aine el in Seiz r jecti ed f on n uel i ozzl njec Imp e, d rope tion efec pum r va tive lve c p plu Defe spra lear n ctive g y er ance c o ntac Ben t of t go valv vern e an or s Clog d va prin ged g, d lve s , lea e eat fecti k ing f Clog ve a uel p ged djus air b iping t men Defe reat t her ctive hole boo in fu st co el ta mpe nk nsat or d iaph ragm
Causes
Replace
General causes why engine lacks output • Insufficient intake of air • Insufficient supply of fuel • Improper condition of fuel injection • Improper fuel used (if non-specified fuel is used, output drops) • Lack of output due to overheating a If there is overheating and lack of output, carry out troubleshooting for S-14 overheating.
Clean
S-6
S-6
Confirm recent repair history
Questions
Degree of use of machine Power was lost
Operated for long period Suddenly Gradually
Engine oil must be added more frequently Replacement of filters has not been carried out according to Operation Manual Non-specified fuel is being used Air cleaner clogging monitor lights up Color of exhaust gas
Black Blue under light load
Noise of interference is heard from around turbocharger Blow-by gas is excessive Check items
Engine pickup is poor and combustion is irregular High idling speed under no load is normal, but speed suddenly drops when load is applied When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low There is hunting from engine (rotation is irregular) Clanging sound is heard from around cylinder head High idling speed of engine is low Leakage from fuel piping When air cleaner element is inspected directly, it is found to be clogged When turbocharger is rotated by hand, it is found to be heavy When compression pressure is measured, it is found to be low
Troubleshooting
When fuel filter, strainer are inspected directly, they are found to be clogged When feed pump strainer is inspected directly, it is found to be clogged Speed does not change when operation of certain cylinders is stopped When control rack is pushed, it is found to be heavy, or does not return When valve clearance is checked directly, it is found to be outside standard value When fuel dial is placed at FULL position, lever does not contact stopper When feed pump is operated, operation is too light or too heavy
D31/37/39EX, PX-21
Replace
Clean
Correct
Adjust
Replace
Adjust
Replace
Correct
Clean
Clean
Remedy
Replace
When fuel tank cap is inspected directly, it is found to be clogged
20-813 (1)
TROUBLESHOOTING
S-7
S-7
Exhaust smoke is black (Incomplete combustion) General causes why exhaust smoke is black • Insufficient intake of air • Improper condition of fuel injection • Excessive injection of fuel
Seiz ed t urbo Clog char ger, ged air c inter Wor lean fere n pis nce er e leme ton ring Clog nt , cylin ged , sei der Imp zed liner rope f u el in r fue jecti l inje Defe on n ction ctive timin ozzle fuel Imp i g n jecti rope on p r va lve c ump Crus lear (exc hed ance , clo essi gge ve in Lea dm kage jecti u ffler on) of a ir be Defe twee ctive n c t o urbo Defe ntac char t of ctive ger valv injec intak e an tion d em valv pum anifo e se p (ra ld at ck, p lung er s eize d)
Causes
Confirm recent repair history Degree of use of machine
Operated for long period Suddenly became black
Questions
Color of exhaust gas
Gradually became black Blue under light load
Engine oil must be added more frequently Power was lost
Suddenly Gradually
Non-specified fuel is being used Noise of interference is heard from around turbocharger Air cleaner clogging monitor lights up Blow-by gas is excessive
Check items
Engine pickup is poor and combustion is irregular When exhaust manifold is touched immediately after starting engine temperature of some cylinders is low Timing lock on fuel injection pump does not match Seal on injection pump has come off Clanging sound is heard from around cylinder head Exhaust noise is abnormal Muffler is crushed Leakage of air between turbocharger and head, loose clamp When turbocharger is rotated by hand, it is found to be heavy When air cleaner element is inspected directly, it is found to be clogged Troubleshooting
When compression pressure is measured, it is found to be low Speed does not change when operation of certain cylinders is stopped When check is made using delivery method, injection timing is found to be incorrect Injection pump test shows that injection amount is incorrect When valve clearance is checked directly it is found to be outside standard value When muffler is removed, exhaust color returns to normal
20-814 (1)
Replace
Replace
Correct
Replace
Adjust
Adjust
Adjust
Replace
Replace
Clean
Remedy
Replace
When control rack is pushed, it is found to be heavy, or does not return
D31/37/39EX, PX-21
TROUBLESHOOTING
S-8
S-8
Oil consumption is excessive (or exhaust smoke is blue) a Do not run the engine at idling for more than 20 minutes continuously. (Both low and high idling)
Brok en p iston Wor ring n pis ton ring Clog , cyli ged nde brea r line Lea t h e r r or kage brea f r o Lea m t h e o r kage il filt hose er o from r oil Lea oil p cool kage iping er from Lea oil d kage rain f rom plug Brok oil p en o an o il co r cylin Wor oler der n se hea al at d Wor turb ine e n se al at n d Wor blow n, b er e roke nd n re Dus ar s Turb t suc e a ocha l, se ked al su rger Wor in fr om n va r f a c intak e lve ( e sy stem stem , gu ide) , bro ken seal
General causes why oil consumption is excessive • Abnormal combustion of oil • External leakage of oil • Wear of lubrication system
Causes
Confirm recent repair history Questions
Degree of use of machine
Operated for long period
Oil consumption suddenly increased Engine oil must be added more frequently Engine oil becomes contaminated quickly Exhaust smoke is blue under light load Amount of blow-by gas
Excessive None
Area around engine is dirty with oil Check items
There is oil in engine cooling water When exhaust pipe is removed, inside is found to be dirty with oil When turbocharger air supply pipe is removed, inside is found to be dirty with oil Oil level in damper chamber rises Clamps for intake system are loose
Troubleshooting
When compression pressure is measured, it is found to be low When breather element is inspected, it is found to be clogged with dirty oil There is external leakage of oil from engine Pressure-tightness test of oil cooler shows there is leakage Excessive play of turbocharger shaft Inspect rear seal directly When intake manifold is removed, dust is found inside
D31/37/39EX, PX-21
Correct
Correct
Correct
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Clean
Replace
Remedy
Replace
When intake manifold is removed, inside is found to be dirty with oil
20-815 (1)
TROUBLESHOOTING
Oil becomes contaminated quickly General causes why oil becomes contaminated quickly • Entry of exhaust gas due to internal wear • Clogging of lubrication passage • Improper fuel used • Improper oil used • Operation under excessive load
Causes
Wor n pis ton ring Clog , cyl ged inde brea r line Clog ther r , bre ged athe oil fi lter Wor r ho se n va lve, Clog valv ged e gu oil c ide oole Clog r ged t u r boch Defe arge ctive r oil seal Exh drai at tu aust n tu rboc be smo harg ke is e r tur blac bine k end
S-9
S-9
Degree of use of machine
Operated for long period
Engine oil must be added more frequently Non-specified oil is being used Color of exhaust gas
Blue under light load Black
Carry out troubleshooting for S-7 Exhaust smoke is black .
Questions
Confirm recent repair history
Check items
Excessive Amount of blow-by gas
None
When oil filter is inspected, metal particles are found When exhaust pipe is removed, inside is found to be dirty with oil Engine oil temperature rises quickly
When breather element is inspected directly, hose is broken or is found to be clogged with dirty oil When oil filter is inspected directly, it is found to be clogged When oil cooler is inspected directly, it is found to be clogged Turbocharger oil drain tube is clogged
20-816 (1)
Replace
Clean
Clean
Replace
Replace
Remedy
Clean
Excessive play of turbocharger shaft When safety valve is directly inspected, spring is found to be catching or broken Replace
Troubleshooting
When compression pressure is measured, it is found to be low
D31/37/39EX, PX-21
TROUBLESHOOTING
S-10
S-10 Fuel consumption is excessive Causes Defe ctive fuel Defe injec ctive tion pum fuel Defe injec p (e ctive xces tion fuel sive nozz Defe i injec n le ho j ectio ctive tion) lder n f u p spra el in ump Exte jecti y p rnal l u on t nge leak imin r Lea age g kage from o f uel p f fue Defe l ins iping ctive ide h , fue oil s ead l filte Defe eal i cove r ctive nsid r adju e fe ed p stme ump nt o f go (pist vern on) or s prin g
General causes why fuel consumption is excessive • Leakage of fuel • Improper condition of fuel injection • Excessive injection of fuel
Questions
Confirm recent repair history Degree of use of machine Condition of fuel consumption
Operated for long period More than for other machines of same model Gradually increased Suddenly increased Black
Exhaust smoke color
White
Seal on injection pump has come off Check items
There is irregular combustion When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Timing lock on fuel injection pump is misaligned There is external leakage of fuel from engine Engine oil level rises and smells of diesel fuel Engine low idling and high idling speeds are high Injection pump measurement shows that injection amount is excessive Troubleshooting
Speed does not change when operation of certain cylinders is stopped When control rack is pushed, it is found to be heavy, or does not return When check is made using delivery method, fuel injection timing is found to be incorrect Remove head cover and inspect directly Remove feed pump and inspect directly
D31/37/39EX, PX-21
Adjust
Correct
Correct
Correct
Adjust
Replace
Replace
Remedy
Adjust
When engine speed is measured, low idling and high idling speeds are found to be high
20-817 (1)
TROUBLESHOOTING
S-11
S-11 Oil is in cooling water, or water spurts back, or water level goes down General causes why oil in cooling water • Internal leakage in lubrication system • Internal leakage in cooling system
Brok en o il co oler Brok core en c , Oy linde ring Brok r he en h ad, y hea drau Hole d ga lic o s ca sket il co used oler Inte by p rnal itting crac ks in cylin der bloc k
Causes
Questions
Confirm recent repair history Degree of use of machine Oil level
Operated for long period Suddenly increased Gradually increased
Engine oil level has risen, oil is cloudy white Excessive air bubbles inside radiator, spurts back Hydraulic oil, transmission oil is cloudy white When hydraulic oil, transmission oil is drained, water is found Pressure-tightness test of oil cooler shows there is leakage Pressure-tightness test of cylinder head shows there is leakage
20-818 (1)
Replace
Replace
Replace
Remedy
Replace
Remove oil pan and inspect directly Replace
Troubleshooting
Check items
Hard water is being used as cooling water
D31/37/39EX, PX-21
TROUBLESHOOTING
S-12
S-12 Oil pressure caution lamp lights up (Drop in oil pressure) General causes why oil pressure lamp lights up • Leakage, clogging, wear of lubricating system • Defective oil pressure control • Improper oil used (improper viscosity) • Deterioration of oil due to overheating
Causes
a Standards for engine oil selection Selection of oil according to ambient temperature –30
–20 –10
0
10
20
30
ged oil fi Wor lter n be arin g, jo Clog urna ged l stra iner Clog insid ged e oil oil p Brok ipe i pan en s uctio nside o il pa Defe n pip n ctive e br azin oil p Lack g ump of o il in Defe oil p an ctive regu Defe lator ctive valv relie e Lea f val king v e , cru Defe shed ctive hydr aulic oil le Defe vel s pipin ctive enso g oil p r Wat ress er, f ure uel i sens n oil or
Type of fuel
140°C
SAE30CD Engine oil
SAE10WCD SAE10W-30CD
Clog
SAE15W-40CD
Questions
Confirm recent repair history Degree of use of machine Operated for long period Replacement of filters has not been carried out according to Operation Manual Non-specified oil is being used Oil pressure monitor lights up Lights up at low idling Condition when oil pressure lamp lights up
Lights up at low, high idling Lights up on slopes
Check items
Sometimes lights up There is crushing, leakage from hydraulic piping (external) Oil level monitor lights up When oil level in oil pan is inspected, it is found to be low Metal particles are found when oil is drained Metal particles are stuck to oil filter element Oil is cloudy white or smells of diesel oil Carry out troubleshooting for S-13 Oil level rises .
Troubleshooting
When oil filter is inspected, it is found to be clogged Remove oil pan and inspect directly Oil pump rotation is heavy, there is play There is catching of relief valve or regulator valve, spring or valve guide is broken Oil pressure monitor goes OFF when oil level sensor is replaced
D31/37/39EX, PX-21
Replace
Replace
Correct
Adjust
Adjust
Add
Replace
Correct
Clean
Clean
Clean
Remedy
Clean
When oil pressure is measured, it is found to be within standard value
20-819 (1)
TROUBLESHOOTING
S-13
S-13 Oil level rises (Water, fuel in oil) a If there is oil in the cooling water, carry out troubleshooting for “S-11 Oil is in cooling water, or water level goes down”.
Brok en o il co oler Defe core ctive , Onozz ring Brok le ho en c ld e y r sle linde Wor eve r he n, d ad, ama hea ged Defe d gask rear ctive et seal pum Lea s u p rfac auxi kage e l i a o r f fue y eq Defe l f ro uipm ctive mp ent iping part seal Defe insid insid ctive e e he f uel i t h ad c e Hole rmo njec over stat tion s ma p d u e m Crac by p p itting ks in side cylin der bloc k
General causes why oil level rises • Water in oil (milky white) • Fuel in oil (diluted, and smells of diesel fuel) • Entry of oil from other component
Causes
Questions
Confirm recent repair history Degree of use of machine
Operated for long period
There is oil in radiator cooling water Fuel must be added more frequently
Check items
Exhaust smoke is white When engine is first started, drops of water come from muffler Leave radiator cap open. When engine is run at idling, an abnormal number of bubbles appear, or water spurts back Oil level goes down in damper chamber Oil level goes down in hydraulic tank Engine oil smells of diesel fuel Water temperature is low Pressure-tightness test of oil cooler shows there is leakage
Troubleshooting
Pressure-tightness test of cylinder head shows there is leakage When compression pressure is measured, it is found to be low Inspect rear seal directly When pump auxiliary equipment is removed, seal is found to be damaged Remove head cover and inspect directly Remove fuel injection pump and inspect directly Defective contact with thermostat seal valve
20-820 (1)
Replace
Replace
Correct
Replace
Correct
Replace
Correct
Replace
Replace
Remedy
Replace
Remove oil pan and check directly
D31/37/39EX, PX-21
TROUBLESHOOTING
S-14
S-14 Water temperature becomes too high (Overheating) General causes why water temperature becomes too high • Lack of cooling air (deformation, damage of fan) • Drop in heat dissipation efficiency • Defective cooling circulation system • Oil temperature of hydraulic pump system goes excesively high a Carry out troubleshooting for H-mode.
Brok en w ater Clog pum ged p , cru shed Clog ged radia radi tor f ator Defe ins core ctive ther Defe m o ctive stat (doe wate Lack s no r tem t op of co pera en) o ture ling Fan wate gau belt ge r slipp Clog ing, ged worn , bro fan ken Defe pulle o ctive il co y o p ler r e Brok ssur e va en c lve ylind Hole er h s ma ead , d hea e by Hyd d ga pittin raul sket ic pu g mp oil te mpe ratu re to o hig h
Causes
Confirm recent repair history
Questions
Degree of use of machine Condition of overheating
Operated for long period Suddenly overheated Always tends to overheat
Water temperature gauge
Rises quickly Does not go down from red range
Radiator water level sensor lights up Fan belt whines under sudden load Cloudy white oil is floating on cooling water Cooling water flows out from overflow hose
Check items
Excessive air bubbles inside radiator, water spurts back Engine oil level has risen, oil is cloudy white There is play when fan pulley is rotated Radiator shroud, inside of underguard are clogged with dirt or mud When light bulb is held behind radiator, no light passes through Water is leaking because of cracks in hose or loose clamps When belt tension is inspected, it is found to be loose Power train oil temperature enters red range faster than engine water temperature Carry out troubleshooting for H-mode
Troubleshooting
Temperature difference between top and bottom radiator tanks is excessive Temperature difference between top and bottom radiator tanks is slight When water filler port is inspected, core is found to be clogged When function test is carried out on thermostat, it does not open even at cracking temperature When water temperature is measured, it is found to be normal When oil cooler is inspected directly, it is found to be clogged When measurement is made with radiator cap tester, set pressure is found to be low When compression pressure is measured, it is found to be low
D31/37/39EX, PX-21
Replace
Replace
Replace
Replace
Correct
Add
Replace
Replace
Correct
Correct
Remedy
Replace
Remove oil pan and inspect directly
20-821 (1)
TROUBLESHOOTING
S-15
S-15 Abnormal noise is made a Judge if the noise is an internal noise or an external noise.
Exc essi ve w ear Seiz of p ed t iston urbo char Miss ring , cyl ger, ing, inde inter seiz r (lin fere ed b Clog erle nce ushi ged ss e n , g s e ngin Defe ized e) ctive fuel i n f u j ectio el in Defe jecti n no ctive on p zzle fuel ump Defo injec (rac rme tion k, pl d fa pum ung n, fa Defe p (e er s n be ctive x eize c lt int essi a d) d justm ve in erfe Brok renc j en d ent e c tion) e of va ynam Imp lve c ic va rope lear lve s r ge ance yste ar tr Leak m (v ain b age alve ackl of air , roc ash Defe betw ker ct in leve een side r, et t u r boch muf c.) fler a r g er a (divi nd in ding take boa rd o man ut o ifold f po sitio n)
General causes why abnormal noise is made • Abnormality due to defective parts • Abnormal combustion • Air sucked in from intake system
Causes
Questions
Confirm recent repair history Degree of use of machine
Operated for long period
Condition of abnormal noise
Gradually occurred Suddenly occurred
Non-specified fuel is being used Engine oil must be added more frequently Color of exhaust gas
Blue under light load Black
Metal particles are found in oil filter Blow-by gas is excessive Noise of interference is heard from around turbocharger Check items
Engine pickup is poor and combustion is abnormal When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Seal on fuel injection pump has come off Abnormal noise is loud when accelerating engine Clanging sound is heard from around cylinder head Leakage of air between turbocharger and cylinder head, loose clamp Vibrating noise is heard from around muffler When compression pressure is measured, it is found to be low When turbocharger is rotated by hand, it is found to be heavy
Troubleshooting
Remove gear cover and inspect directly Speed does not change when operation of certain cylinders is stopped When control rack is pushed, it is found to be heavy, or does not return Injection pump test shows that injection amount is incorrect Fan is deformed, belt is loose When valve clearance is checked, it is found to be outside standard value Remove cylinder head cover and inspect directly
20-822 (1)
Replace
Replace
Replace
Correct
Replace
Correct
Replace
Correct
Replace
Replace
Replace
Remedy
Replace
When muffler is removed, abnormal noise disappears
D31/37/39EX, PX-21
TROUBLESHOOTING
S-16
S-16 Vibration is excessive
Wor n
General causes why vibration is excessive • Defective parts (abnormal wear, breakage) • Improper alignment • Abnormal combustion
Causes conn ectin Wor g ro n ca d, m mb ain b ushin Loo eari se e g ng ngin em Brok oun en p ting art i bolts nsid Cen , bro e da ter o ken mpe f en cush g r Imp i n e rope ion and r ge h y d ar tr raul Defe ain b ic pu ctive mp ackl dyna Defe misa ash mic ctive ligne valv d fuel e syst injec e m tion ( v a lve, pum rock p (e er le xces ver, sive etc. fuel stuc injec k) tion)
a If there is abnormal noise together with the vibration, carry out troubleshooting also for “S-15 Abnormal noise is made”.
Questions
Confirm recent repair history Degree of use of machine Condition of vibration
Operated for long period Suddenly increased Gradually increased
Non-specified oil is being used Metal particles are found in oil filter Metal particles are found when oil is drained
Check items
Oil pressure is low at low idling Vibration occurs at mid-range speed Vibration follows engine speed Exhaust smoke is black Seal on fuel injection pump has come off Remove oil pan and inspect directly Troubleshooting
Remove side cover and inspect directly Inspect directly for loose engine mounting bolts, broken cushion Inspect inside of damper directly When face runout and radial runout are inspected, they are found to be incorrect Remove front cover and inspect directly Remove fuel head cover and inspect directly
D31/37/39EX, PX-21
Adjust
Replace
Correct
Correct
Replace
Replace
Replace
Remedy
Replace
Fuel injection pump test shows that fuel injection amount is incorrect
20-823 (1)
30 DISASSEMBLY AND ASSEMBLY
How to read this manual ................................. 30- 2 Coating materials list....................................... 30- 4 Special tool list ................................................ 30- 6 Sketches of special tools ................................ 30- 8 Removal and installation of fuel injection pump assembly ......................................... 30- 9 Removal and installation of cylinder head assembly ................................................... 30-13 Removal and installation of engine front seal ........................................ 30-20 Removal and installation of engine rear seal ......................................... 30-23 Removal and installation of radiator guard assembly ................................................... 30-25 Disassembly and assembly of radiator, oil cooler, and charge air cooler assemblies................................................. 30-28 Removal and installation of engine and HST pump assembly ................................. 30-32 Removal and installation of damper................ 30-35 Spreading and installation of track shoe assembly ................................................... 30-36 Removal and installation of HST motor and final drive assembly ................................... 30-38 Disassembly and assembly of final drive assembly ................................................... 30-40 Removal and installation of idler and recoil spring assembly ............................... 30-48
D31/37/39EX, PX-21
Disassembly and assembly of recoil spring assembly ....................................................30-49 Disassembly and assembly of idler assembly ....................................................30-52 Disassembly and assembly of track roller assembly ....................................................30-55 Disassembly and assembly of carrier roller assembly ....................................................30-59 Removal and installation of HST pump assembly ....................................................30-61 Removal and installation of idler and recoil spring assembly ....................................................30-63 Disassembly and assembly of main control valve assembly...........................................30-66 Removal and installation of blade assembly....30-74 Disassembly and assembly of hydraulic cylinder assemblies ....................................30-76 Removal and installation of operator’s seat frame assembly ..........................................30-79 Removal and installation of fuel tank assembly ....................................................30-83 Removal and installation of hydraulic tank assembly ....................................................30-84 Removal and installation of HST controller assembly ....................................................30-86
30-1 (5)
DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
HOW TO READ THIS MANUAL 1. Removal and installation of assemblies Special tools • Special tools which are deemed necessary for removal or installation of parts are described as A1,•••X1 etc. and their part names, part numbers and quantities are described in the special tool list. • Also the following information is described in the special tool list. 1) Necessity t : Special tools that cannot be substituted and should always be used (installed). q : Special tools that will be useful if available and are substitutable with commercially available tools. 2) Distinction of new and existing special tools N : Tools newly developed for this model. They respectively have a new part number. R : Tools with upgraded part numbers. They are remodeled from already available tools for other models. Blank: Tools already available for other models. They can be used without any modification. 3) Circle mark Q in sketch column: • The sketch of the special tool is presented in the section of “Sketches of special tools”. • This mark means part No. of special tools starting with 79 Tand that they can not be supplied from Komatsu in Japan (i.e. locally made parts).
* *** ****
Removal • The “Removal” section contains procedures and precautions for implementing the work, knowhow and the amount of oil or coolant to be drained. • General tools that are necessary for removal are described as [1], [2]•••etc. and their part names, part numbers and quantities are not described. • Various symbols used in the “Removal” section are explained and listed below. k : This mark indicates safety-related precautions that must be followed when implementing the work. a : Know-how or precautions for work [*1] : This mark shows that there are instructions or precautions for installing parts. 6: This mark shows the amount of oil or coolant
to be drained.
4: Weight of part or component
Installation • Except where otherwise instructed, installation of parts is done in the reverse order of removal. • Instructions and precautions for installing parts are shown with [*1] mark in the “Installation” section, identifying which step the instructions are intended for. • General tools that are necessary for installation are described as [1], [2]•••etc. and their part names, part numbers and quantities are not described. • Marks shown in the “Installation” section stand for the following. k : Precautions related to safety in execution of work. a : This mark gives guidance or precautions when doing the procedure. 2: Type of coating material 3: Tightening torque 5: Quantity of oil or coolant to be added
Sketches of special tools • Various special tools are illustrated for the convenience of local manufacture.
30-2 (5)
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
2. Disassembly and assembly of assemblies Special tools • Special tools which are deemed necessary for disassembly or assembly of parts are described as A1,•••X1 etc. and their part names, part numbers and quantities are described in the special tool list. • Also the following information is described in the special tool list. 1) Necessity t : Special tools that cannot be substituted and should always be used (installed). q : Special tools that will be useful if available and are substitutable with commercially available tools. 2) Distinction of new and existing special tools N : Tools newly developed for this model. They respectively have a new part number. R : Tools with upgraded part numbers. They are remodeled from already available tools for other models. Blank: Tools already available for other models. They can be used without any modification. 3) Circle mark Q in sketch column: • The sketch of the special tool is presented in the section of “Sketches of special tools”. • This mark means part No. of special tools starting with 79 Tand that they can not be supplied from Komatsu in Japan (i.e. locally made parts).
* *** ****
Disassembly • In “Disassembly” section, the work procedures, precautions and know-how for carrying out those procedures, and quantity of the oil and coolant drained are described. • General tools that are necessary for disassembly are described as [1], [2]•••etc. and their part names, part numbers and quantities are not described. • The meanings of the symbols used in “Disassembly” section are as follows. k : This mark indicates safety-related precautions that must be followed when implementing the work. a : Know-how or precautions for work 6: Quantity of oil or coolant drained
Assembly • In “Assembly” section, the work procedures, precautions and know-how for carrying out those procedures, and quantity of the oil and coolant added are described. • General tools that are necessary for assembly are described as [1], [2]•••etc. and their part names, part numbers and quantities are not described. • The meanings of the symbols used in “Assembly” section are as follows. k : Precautions related to safety in execution of work a : This mark gives guidance or precautions when doing the procedure. 2: Type of coating material 3: Tightening torque 5: Quantity of oil or coolant to be added
Sketches of special tools • Various special tools are illustrated for the convenience of local manufacture.
D31/37/39EX, PX-21
30-3 (5)
DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
COATING MATERIALS LIST
(Rev. 2007.06)
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disassembly and assembly are listed below. a For coating materials not listed below, use the equivalent of products shown in this manual. Category
Komatsu code
Part number
Q'ty
Container
LT-1A
790-129-9030
150 g
Tube
LT-1B
790-129-9050
20 g (2 pcs.)
Polyethylene container
LT-2
09940-00030
50 g
Adhesive
LT-3 LT-4
790-129-9040
250 g
Holtz MH 705
790-129-9120
75 g
ThreeBond 1735
Gasket sealant
(5)
790-129-9140
• Used for plastic (except polyethylene, polypropylene, tetrafluoroethylene and vinyl chloride), rubber, metal, and non-metal parts which require immediate and strong adhesion.
Polyethylene • Features: Resistance to heat and chemicals. container • Used to fix and seal bolts and plugs. Can
• Used to stick and seal metal, glass, and plastics.
Polyethylene • Used to seal plugs. container Tube
• Heat-resistant seal used to repair engines.
50 g
• Quick-setting adhesive. • Quick-setting type. Polyethylene (max. strength is obtained after 30 minutes) container • Used mainly to stick rubbers, plastics, and metals.
790-129-9130
2g
Loctite 648-50
79A-129-9110
50 cc
LG-1
790-129-9010
200 g
790-129-9080
• Used to prevent rubber gaskets, rubber cushions, and cork plugs from coming out.
• Quick-setting adhesive. Polyethylene • Setting time: Within 5 sec. to 3 min. container • Used mainly to stick metals, rubbers, plastics, and woods.
Aron-alpha 201
LG-5
30-4
790-129-9060 Adhesive: 1 kg (Set of adhesive Hardener: 500 g and hardener)
Main features and applications
1 kg
• Features: Resistance to heat and chemicals. Polyethylene • Used for fitted portions used at high temperacontainer tures. Tube
• Used to stick or seal gaskets and packings of power train case, etc.
• Used to seal various threaded portions, pipe Polyethylene joints, and flanges. container • Used to seal tapered plugs, elbows, and nipples of hydraulic piping.
LG-6
790-129-9020
200 g
Tube
• Features: Silicon-based heat and cold-resistant sealant. • Used to seal flange surfaces and threaded portions. • Used to seal oil pan, final drive case, etc.
LG-7
790-129-9070
1 kg
Tube
• Features: Silicon-based quick-setting sealant. • Used to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc.
LG-8 ThreeBond 1207B
419-15-18131
100 g
Tube
• Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant. • Used to seal transfer case, etc.
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
Seizure prevention compound
Molybdenum disulfide lubricant
Gasket sealant
CateKomatsu code gory
Part number
Q'ty
Container
Main features and applications
LG-9 ThreeBond 1206D
790-129-9310
200 g
Tube
• Used for rough surfaces such as the circle gear top seal which does not need to be clamped, water resistance of the clearance at the welded area, etc. • Can be coated with paint.
LG-10 ThreeBond 1206E
790-129-9320
200 g
Tube
• Used as lubricant/sealant when the radiator hoses are inserted. • Can be coated with paint.
LG-11 ThreeBond 1121
790-129-9330
200 g
Tube
• Feature: Can be used together with gaskets. • Used for covers of the transmission case and steering case etc.
ThreeBond 1211
790-129-9090
100 g
Tube
• Gasket sealant used to repair engine.
Tube
• Used to prevent scuffing and seizure of press-fitted portions, shrink-fitted portions, and threaded portions. • Used to lubricate linkages, bearings, etc.
—
Can
• Feature: Seizure and scuffing prevention compound with metallic super-fine-grain, etc. • Used for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.
Various
Various
LM-P
LC-G NEVER-SEEZ
09940-00040
—
SYG2-400LI SYG2-350LI SYG2-400LI-A G2-LI SYG2-160LI G0-LI SYGA-160CNLI *: For cold district SYG0-400LI-A (*) SYG0-160CNLI (*)
Molybdenum SYG2-400M disulfide grease SYG2-400M-A LM-G (G2-M) SYGA-16CNM
Grease
METHOD OF USING MANUAL
SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) *: For cold district SYG0-16CNT (*)
Hyper White Grease G2-T, G0-T (*)
SYG2-400B Biogrease G2-B, G2-BT (*) SYGA-16CNB *: For use at high SYG2-400BT (*) temperature and SYGA-16CNBT under high load (*) G2-S ThreeBond 1855
G2-U-S ENS grease
D31/37/39EX, PX-21
—
427-12-11871
200 g
• Feature: Lithium grease with extreme pressure lubrication performance. • General purpose type.
• Used for parts under heavy load. Caution: 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like swing circle bearings, etc. and spline. 400 g x 20 container • The grease should be applied to work equipment 16 kg Can pins at their assembly only, not applied for greasing afterwards. 400 g 16 kg 400 g 16 kg
200 g
2 kg
Bellows-type • Seizure resistance, heat resistance and water resiscontainer tance higher than molybdenum disulfide grease. Can • Not conspicuous on machine since color is white. Bellows-type • Since this grease is decomposed by natural bactecontainer ria in short period, it has less effects on microorganCan isms, animals, and plants.
Tube
• Feature: Silicone grease with wide using temperature range, high resistance to thermal-oxidative degradation and performance to prevent deterioration of rubber and plastic parts. • Used for oil seals of the transmission, etc.
Can
• Feature: Urea (organic system) grease with heat resistance and long life. Enclosed type. • Used for rubber, bearing and oil seal in damper. Caution: Do not mix with lithium grease.
30-5 (5)
DISASSEMBLY AND ASSEMBLY
Part number
SUNSTAR PAINT PRIMER 580 SUPER
SUNSTAR PAINT PRIMER 435-95
Main features and applications
20 ml
Glass container
• Used as primer for cab side. (Using limit: 4 months after date of manufacture)
20 ml
Glass container
• Used as primer for glass side. (Using limit: 4 months after date of manufacture)
20 ml
Glass container
417-926-3910
22M-54-27230
• Used as primer for painted surface on cab side. (Using limit: 4 months after date of manufacture) • Used as primer for black ceramic-coated surface on glass side and for hard polycarbonatecoated surface. (Using limit: 4 months after date of manufacture)
SUNSTAR GLASS PRIMER 435-41
22M-54-27240
150 ml
Can
SUNSTAR SASH PRIMER GP-402
22M-54-27250
20 ml
Glass container
• Used as primer for sash (Almite). (Using limit: 4 months after date of manufacture)
SUNSTAR PENGUINE SEAL 580 SUPER “S” or “W”
417-926-3910
320 ml
Polyethylene container
• “S” is used for high-temperature season and “W” for low-temperature season as adhesive for glass. (Using limit: 4 months after date of manufacture)
Sika Japan, Sikaflex 256HV
20Y-54-39850
310 ml
Polyethylene container
• Used as adhesive for glass. (Using limit: 6 months after date of manufacture)
SUNSTAR PENGUINE SUPER 560
22M-54-27210
320 ml
Ecocart (Special container)
SUNSTAR PENGUINE SEAL No. 2505
417-926-3920
320 ml
Polyethylene container
SEKISUI SILICONE SEALANT
20Y-54-55130
333 ml
Polyethylene container
• Used to seal front window. (Using limit: 6 months after date of manufacture)
Cartridge
• Used to seal joint of glasses. Translucent white seal. (Using limit: 12 months after date of manufacture)
GE TOSHIBA SILICONES TOSSEAL 381
30-5-1 (5)
Container
22M-54-27220
333 ml
Adhesive for cab glass
Caulking material
Adhesive
Primer
SUNSTAR GLASS PRIMER 580 SUPER
Q'ty
Adhesive for cab glass
CateKomatsu code gory
COATING MATERIALS LIST
• Used as adhesive for glass. (Using limit: 6 months after date of manufacture) • Used to seal joints of glass parts. (Using limit: 4 months after date of manufacture)
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
SPECIAL TOOL LIST
SPECIAL TOOL LIST a Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they are items to be locally manufactured). a Necessity:
t ...........Cannot be substituted, must always be installed (used) q............Extremely useful if available or can be substituted with commercially available part a New/Remodel: N............Tools with new part numbers, newly developed for this model R: ...........Tools with upgraded part numbers, remodeled from items already available for other models Blank: ....Tools already available for other models, can be used without any modification
Removal, installation of nozzle holder assembly
A
Removal, installation of cylinder head assembly Removal, installation of engine front seal
B
Removal, installation of engine rear seal
C
Gear
t
1
Cranking of engine
2 795-799-1390
Remover
t
1
Removal of injection pump gear
3 795-799-1170
Puller
q
1
Removal of nozzle holder
4 790-331-1110
Wrench
t
1
Installation of cylinder head bolt
1 795-799-2610
Installer
t
1
Installation of engine rear seal
2 795-799-2620
Installer
t
1
Installation of dust seal
795-931-1100
Seal puller
q
1
Removal of engine rear seal
791-830-1320
Rod
t
1
01580-01613
Nut
t
1
01643-31645
Washer
t
1
Washer
t
1
Disassembly, assembly of idler assembly
Disassembly, assembly of track roller assembly
Disassembly, assembly of carrier roller assembly
30-6 (1)
J
790-101-2102
Puller assembly
t
1
790-201-2830
Spacer
t
1
790-101-1102
Hydraulic pump
t
1
2 791-427-1410
Wrench
t
1
3 791-545-1510
Installer
t
1
1 791T-430-3210 Push tool
t
1
2 791-675-1510
t
1
3 791T-430-3220 Push tool
t
1
4 791-651-1510
Installer
t
1
Installation of track roller floating seal
5 790-601-1000
Oil pump
t
1
Charging with oil, air leakage check
6 791-430-3230
Installer
t
1
Installation of carrier roller floating seal
Part Name
Sketch
1 795-799-1131
Part No.
1 790-101-2540 Disassembly, assembly of final drive assembly
New/Remodel
Q'ty
Removal, installation of fuel injection pump assembly
Necessity
Component
Symbol
a Tools marked Q in the Sketch column are tools introduced in the sketches of the special tools (See SKETCHES OF SPECIAL TOOLS).
Pulling out of planetary pinion shaft
Loosening, tightening of round nut
N
Installation of floating seal Q
L Installer
L
Nature of work, remarks
Press fitting of idler bushing Installation of idler floating seal
Q
Press fitting of track roller bushing
D31/37/39EX, PX-21
Q'ty
Compressor (B)
t
1
Disassembly, assembly of recoil spring assembly
790-201-2860
Spacer
t
1
791-635-3160
Extension
t
1
790-101-1600
Cylinder (686 kN {70 tons})
t
1
790-101-1102
Pump
t
1
791-630-3200
Remover
t
1
790-101-1300
Cylinder (980 kN {100 tons})
t
1
790-101-1102
Hydraulic pump
t
1
790-502-1003
Repair stand
t
1
790-101-1102
Pump
t
1
2 790-330-1100
Wrench
t
1
Removal, installation of cylinder head
3 790-302-1270
Socket
t
1
Loosening, tightening of piston nut
4 790-720-1000
Expander
t
1
Part No.
M
Disassembly, assembly of track
R
1
Disassembly, assembly of hydraulic cylinder assembly
5 U
6
7
D31/37/39EX, PX-21
Part Name
796-720-1650
Rubber band
q
1
07281-01029
Clamp
q
1
790-201-1720
Push tool kit
790-201-1751
• Push tool
t
1
790-101-5021
• Grip
t
1
t
1
Sketch
Necessity
791-685-8006
Symbol
Component
SPECIAL TOOL LIST
New/Remodel
DISASSEMBLY AND ASSEMBLY
Nature of work, remarks
Removal, installation of recoil spring
Removal, installation of ring pin Disassembly, assembly of hydraulic cylinder
Installation of piston ring
1
01010-50816
• Bolt
790-201-1500
Push tool kit
790-201-1560
• Plate
t
1
790-101-5021
• Grip
t
1
01010-50816
• Bolt
t
1
Press fitting of bushing
1 Press fitting of dust seal
30-7 (1)
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. L1 Push tool
L3 Push tool
30-8 (1)
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
FUEL INJECTION PUMP
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY
6. Remove engine stop solenoid (5).
[*3]
7. Disconnect air tube (6).
A
1 795-799-1131 Gear
t 1
2 795-799-1390 Remover
t 1
Sketch
New/remodel
Part Name
Q'ty
Part No.
Necessity
Symbol
SPECIAL TOOLS
REMOVAL 1. Open up both engine hoods (1).
8. Disconnect fuel inlet hoses (7) and (8) and return hose (9).
2. Remove left engine side cover (2).
9. Remove fuel tubes (10) and (11).
3. Close the fuel stop valve. 4. Disconnect fuel control linkage (3).
[*1]
5. Disconnect decelerator pedal linkage (4).
[*2]
D31/37/39EX, PX-21
10. Remove lubrication tube (12). 11. Disconnect 4 fuel injection tubes (13). a Disconnect the tube end on the fuel injection pump side.
30-9 (1)
DISASSEMBLY AND ASSEMBLY
FUEL INJECTION PUMP
12. Using tool A1, rotate the crankshaft forward to match the timing gear to the fuel injection timing. a See TESTING AND ADJUSTING, Testing and adjusting fuel injection timing. 13. Remove cap (14). a Remove with a filter wrench, etc.
17. Remove 4 mounting bolts (18) and fuel injection pump assembly (19).
[*4]
[*5] 14. Remove injection pump nut (15). a Take care not to drop the nut in the case.
INSTALLATION •
15. Using tool A2, disconnect the shaft and drive gear of the fuel injection pump.
[*1] [*2] a Adjust the fuel control linkage and decelerator pedal linkage. For details, see TESTING AND ADJUSTING, Adjusting fuel control lever linkage and decelerator pedal linkage. [*3]
[*4]
[*5]
16. Remove brackets (16) and (17).
30-10 (1)
Carry out installation in the reverse order to removal.
a Adjust the engine stop solenoid linkage. For details, see TESTING AND ADJUSTING, Adjusting engine stop solenoid linkage. a Tighten the cap by turning it by 180 degrees. a Install the fuel injection pump assembly according to the following procedure. 1) Using tool A1, crank the engine forward slowly and push No. 1 cylinder compression top dead center positioning pin (20) into the gear.
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
a Referring to the following, push positioning pin (20) into the gear securely. • Dimension "a" of pin in free state: 24 mm • Dimension "b" of pin when it is in contact with gear: 20 mm • Dimension "c" of pin when it is pushed into gear: 16 mm a Stop barring immediately after the positioning pin is pushed in (to prevent the positioning pin from being broken).
2) Remove plug (21) and timing pin (22).
3) Reverse the fitting position of timing pin (22) and match the groove of the timing pin to pointer (23) in the pump and tighten plug (21) temporarily. a If the tooth of pointer (23) is not matched to the hole of the timing pin, match it by turning the fuel injection pump shaft.
D31/37/39EX, PX-21
FUEL INJECTION PUMP
4) Install fuel injection pump assembly (19) and tighten nut (18). 3 Nut: 43 ± 6 Nm {4.38 ± 0.61 kgm}
5) Tighten fuel injection pump nut (15). a When installing the nut, take care extremely not to drop it in the case. 3 Nut: 12.5 ± 2.5 Nm {1.27 ± 0.25 kgm} a This value is not the final torque. a Do not heighten the tightening torque of the nut more than above value so that the No. 1 cylinder compression top dead center positioning pin will not be damaged.
6) Disengage No. 1 cylinder compression top dead center positioning pin (20).
30-11 (1)
DISASSEMBLY AND ASSEMBLY
FUEL INJECTION PUMP
7) Remove plug (21) and install timing pin (22) in the reversed fitting position, then install the plug to the fuel injection pump. 3 Plug: 14.7 Nm {1.5 kgm}
8) Tighten fuel injection pump nut (15) securely. 3 Nut: 95 ± 10 Nm {9.7 ± 1.02 kgm}
•
After the above work, carry out installation in the reverse order to removal.
a Adjust the fuel injection timing. For details, see TESTING AND ADJUSTING, Adjusting fuel injection timing. •
Bleeding air Bleed air from the fuel circuit. For details, see TESTING AND ADJUSTING, Bleeding air from fuel circuit.
30-12 (1)
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
CYLINDER HEAD
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY
A
3 795-799-1170 Puller
q 1
4 790-331-1110 Wrench
t 1
4. Remove clip of heater hose (2) and disconnect dust indicator hose (3). a Disconnect the dust indicator hose end on the air cleaner side.
Sketch
New/remodel
Part Name
Q'ty
Part No.
Necessity
Symbol
SPECIAL TOOLS
3. Close the fuel stop valve.
REMOVAL
k Disconnect the cable from the negative (–) ter-
minal of the battery.
k If the water temperature in the radiator is high,
you may get scalded. Accordingly, wait until the water temperature lowers, then drain. 1. Remove the mounting bolts and cover (1).
5. Using eyebolts, lift off engine hood (4). 4
Engine hood: 45 kg
2. Loosen the radiator cap and drain the cooling water. 6
Radiator: Approx. 20 l
6. Remove both engine covers (5).
D31/37/39EX, PX-21
30-13 (1)
DISASSEMBLY AND ASSEMBLY
7. Disconnect charge air cooler hose (6).
CYLINDER HEAD
[*1]
12. Disconnect 3 wiring connectors (13) and remove the heater relay. [*5] • Secured with bolt (CNT5) • Secured with nut (CNT6), (CNT12) 13. Disconnect compressor (CN23) (14).
wiring
connector
14. Disconnect engine stop solenoid wiring harnesses (CNT17) and (CNT18) (15). 15. Disconnect wiring harness clamp (16).
8. Disconnect air cleaner hose (7).
[*2]
9. Remove air cleaner band (8).
[*3]
16. Disconnect engine water temperature sensor connector (CN20) (17).
10. Disconnect the 3 wiring connectors, then disconnect the wiring harness clamp. • (9): (CN1) • (10): (CN2) • (11): (CN3) 11. Remove the mounting bolt and air cleaner assembly (12). [*4] 17. Disconnect 2 alternator wiring harnesses. • (18): (CNT15) • (19): (CNT16)
30-14 (1)
[*6]
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
18. Disconnect charge air cooler hose (20).
CYLINDER HEAD
[*7]
29. Remove 2 mounting bolts (32) and alternator assembly (33).
19. Disconnect oil filler tube (21) and oil filler hose (22).
30. Remove the brackets and clamps from 2 places and disconnect 4 fuel tubes (34). [*12] a Disconnect the fuel tubes in order from the No. 1 tube (on the fan side).
20. Disconnect harness clamp (23). 21. Remove muffler clamp (24).
[*8]
22. Remove the mounting bolts and lift off muffler assembly (25). a Remove the 4 upper and 2 lower muffler mounting bolts. 4
Muffler assembly: 40 kg (Including bracket)
31. Disconnect the linkage of engine stop solenoid (35) and remove the engine stop solenoid. [*13] 32. Remove the clamp and 2 delivery tubes (36). [*14] 33. Remove the mounting bolt and bracket (37). [*15] a Remover the bracket and the fuel filter together. 34. Remove air tube (38). 35. Remove bracket (39) and spill tube (40). 36. Disconnect boost hose (41) and remove clamp (42). a Disconnect boost hose end on the intake side.
23. Remove reservoir tank (26). 24. Disconnect radiator hose (27).
[*9] [*10]
25. Disconnect heater hose (28). 26. Remove compressor bracket (29). 27. Remove fan guard (30). a Remove only the right fan guard. [*11] 28. Remove fan belt (31). a Using a wrench, etc., remove the fan belt from the tension pulley.
D31/37/39EX, PX-21
30-15 (1)
DISASSEMBLY AND ASSEMBLY
CYLINDER HEAD
37. Remove water drain tube (43). a Remove the 2 mounting bolts, and the tube is removed and divided into 2 pieces. 38. Disconnect charge air cooler hose (44).
43. Remove the intake air heater ground wire, connector (52), intake air heater (53), and cover (54). [*20]
[*16]
39. Disconnect turbocharger lubrication inlet tube (45) and outlet tube (46). [*17] a Disconnect end of tube (45) on the oil filter side. 40. Remove bracket (47) and cover (48).
44. Remove 4 nozzle holder assemblies (55).
41. Remove turbocharger exhaust manifold (50).
assembly
(49)
and [*18]
a If the nozzle holder is difficult to remove, use tool A3. a Take care that dirt and foreign matter will not enter the mounting part of the nozzle holder.
42. Remove 4 head covers (51).
30-16 (1)
[*19]
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
[*21] 45. Remove rocker arm assembly (56). a Loosen the locknut, then loosen the adjustment screw by 2 – 3 turns.
CYLINDER HEAD
INSTALLATION • [*1]
46. Remove push rod (57).
3 Air cleaner hose clamp: 5.9 ± 0.5 Nm {0.6 ± 0.05 kgm}
[*3]
3 Band: 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
[*4]
a Install the air cleaner cover with the top mark up.
[*5]
3 Bolt: 1.86 – 2.45 Nm {0.19 – 0.25 kgm} 3 Nut: 2.45 – 2.94 Nm {0.25 – 0.3 kgm}
[*6]
3 Nut: 23.5 – 29.4 Nm {2.4 – 3 kgm}
47. Lift off cylinder head assembly (58). Cylinder head assembly: 40 kg
a When connecting the hose, apply spray grease to the mating part (tube). 3 Charge air cooler hose clamp: 5.9 ± 0.5 Nm {0.6 ± 0.05 kgm}
[*2]
[*7]
4
Carry out installation in the reverse order to removal.
[*8]
48. Remove cylinder head gasket (59). [*9]
a When connecting the hose, apply spray grease to the mating part (tube). 3 Charge air cooler hose clamp: 5.9 ± 0.5 Nm {0.6 ± 0.05 kgm} a Use a new clamp. 3 Clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} a Pass the reservoir tank drain hose through the guide pipe of the shroud.
[*10] 3 Radiator hose clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} [*11] 3 Tension pulley bolt: 43 ± 6 Nm {4.38 ± 0.61 kgm} [*12] 3 Bracket mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} [*13] a Adjust the engine stop solenoid linkage. For details, see TESTING AND ADJUSTING, Adjusting engine stop solenoid linkage.
D31/37/39EX, PX-21
30-17 (1)
DISASSEMBLY AND ASSEMBLY
CYLINDER HEAD
[*14] 3 Bracket mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} [*15] 3 Bracket mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} [*16] a When connecting the hose, apply spray grease to the mating part (tube). 3 Charge air cooler hose clamp: 5.9 ± 0.5 Nm {0.6 ± 0.05 kgm} [*17] 3 Nipple: 34 ± 5 Nm {3.5 ± 0.5 kgm} 3 Bolt: 10 ± 2 Nm {1.0 ± 2.0 kgm} [*18] 3 Nut: 29.4 – 44.2 Nm {3 – 4.5 kgm} [*19] 3 Bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm}
2nd time: Tighten to 120 ± 5 Nm {12.24 ± 0.51 kgm} in the order of [3], [6], [11], and [14]. 3rd time: i) When using tool A4 • Tighten bolts by 90 ± 5° in the order of [1] – [18] with an angle tightening wrench (Tool A4).
[*20] a Secure clearance of at least 10 mm between the ground wire and fuel tube. [*21] •
1)
2) 3) 4)
5)
30-18 (1)
Install the rocker arm assembly and cylinder head assembly according to the following procedure. a Check that there is not dirt or foreign matter on the mating face of the cylinder head and in the cylinders. Set cylinder head gasket (59) to the cylinder block. a Check that the gasket is matched to the holes of the block. Sling cylinder head assembly (58) and set it to the cylinder block. Install push rod (57). Install rocker arm assembly (56) and tighten the bolt with your fingers. a Check that the adjustment screw ball is fitted to the socket of the push rod. Tighten the cylinder head mounting bolts in the order shown in the following figure. 2 Apply engine oil (SAE15W-40) to the threads and seats of the mounting bolts. 3 Cylinder head mounting bolt: 1st time: Tighten to 90 ± 5 Nm {9.18 ± 0.51 kgm} in the order of [1] – [18].
ii) •
When not using tool A4 Make marks on the bolts and head with a marker pen, then tighten each bolt by 90 ± 5°.
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
CYLINDER HEAD
6) Tighten rocker arm assembly (56). 3 Rocker arm mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm}
a Adjust the valve clearance. For details, see TESTING AND ADJUSTING, Adjusting valve clearance. •
Refilling with water a Add water through the water filler to the specified level. Run the engine until the water is heated, then check the water level again.
•
Bleeding air a Bleed air from the fuel circuit. For details, see TESTING AND ADJUSTING, Bleeding air from fuel circuit.
D31/37/39EX, PX-21
30-19 (1)
DISASSEMBLY AND ASSEMBLY
ENGINE FRONT SEAL
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL
5. Remove 4 mounting bolts (4) and crankshaft pulley/vibration damper (5). [*1] 6. Remove 27 mounting bolts (6) and cover (7). [*2]
B
1 795-799-2610 Installer
t 1
2 795-799-2620 Installer
t 1
Sketch
New/remodel
Part Name
Q'ty
Part No.
Necessity
Symbol
SPECIAL TOOLS
REMOVAL
k Disconnect the cable from the negative (–) ter-
minal of the battery. 1. Remove the radiator guard assembly. For details, see REMOVAL OF RADIATOR GUARD ASSEMBLY.
7. Remove dust seal (8).
2. Remove 4 mounting bolts and fan (1).
8. Remove seal (9).
[*3]
3. Using lever [1], remove fan belt (2). k Take care not catch your fingers between the tensioner and fan pulley. 4. Remove fan pulley (3).
30-20 (1)
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
INSTALLATION •
Carry out installation in the reverse order to removal.
[*1]
3 Mounting bolt of crankshaft pulley/ vibration damper: 125 ± 5 Nm {12.75 ± 0.51 kgm} a Install the crankshaft pulley/vibration damper lightly, then install the fan belt and tighten the mounting bolts to the specified torque.
[*2]
ENGINE FRONT SEAL
4) Tighten the 20 mounting bolts in the following order. 3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm}
a Install the front cover according to the following procedure. 1) Apply ThreeBond 1207D or equivalent in the form of a string 1 – 2 mm thick to the gasket fitting face of the front cover. a Limit the projection of the gasket from the oil pan fitting face to 0.25 mm. 2) Install the gasket to the front cover, and then install them to the engine. 3) Tighten the 7 mounting bolts in the following order. 3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm}
D31/37/39EX, PX-21
30-21 (1)
DISASSEMBLY AND ASSEMBLY
[*3]
a Install the dust seal to the crankshaft according to the following procedure. a Even if a dust seal has not been installed, install the dust seal contained in the front seal kit. 1) Install dust seal (8) to the end of the crankshaft. 2) Using tool B2, press fit dust seal (8). a Press fit the dust seal until the inside end of tool B2 touches the end of the crankshaft.
30-22 (1)
ENGINE FRONT SEAL
[*4]
a Install the engine front seal to the front cover according to the following procedure. 1) Set engine front seal (7) to tool B1. a Since plastic part [2] on the inside of the engine front seal is used to guide the front cover to the crankshaft, do not remove it from the engine front seal. 2) Press fit engine front seal (7) to front cover (6). a Press fit the engine front seal until the shoulder of tool B1 touches the inside end of the front cover.
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
ENGINE REAR SEAL
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL
2) Screw the tip of seal puller C into the drilled hole and slide the hammer to remove engine rear seal (2).
C
795-931-1100 Seal puller
Sketch
New/remodel
Part Name
Q'ty
Part No.
Necessity
Symbol
SPECIAL TOOLS
q 1
REMOVAL 1. Remove the coupling. For details, see REMOVAL AND INSTALLATION OF DAMPER. 2. Remove the mounting bolts, set guide bolts [1], and lift off flywheel assembly (1). [*1] 4
Flywheel assembly: 35 kg
a Method of removing with screwdriver • Break the seal carrier of engine rear seal (2) with a screwdriver to remove the engine rear seal. a Take care not to damage the seal fitting part of the flywheel housing and the seal contact surface of the crankshaft.
[*2] 3. Remove engine rear seal (2). a Method of removing with seal puller 1) Make a hole about 3 mm in diameter on the seal carrier with a drill.
D31/37/39EX, PX-21
30-23 (1)
DISASSEMBLY AND ASSEMBLY
INSTALLATION • [*1]
[*2]
Carry out installation in the reverse order to removal. a Tighten the mounting bolts in the order show below. 3 Flywheel mounting bolt: 137 ± 7 Nm {13.97 ± 0.71 kgm}
a Install the engine rear seal according to the following procedure. 1) Insert pilot [2] in new seal (3). a Before inserting the pilot, clean, degrease, and dry the lip surface of the seal.
30-24 (1)
ENGINE REAR SEAL
2) Insert seal (3) and pilot [2] together in the crankshaft and push the seal carrier into the flywheel housing. a Before inserting the seal, clean, degrease, and dry the seal contact surface of the crankshaft. 3) Pull out pilot [2] and push in seal (3) further.
4) Using aligning tool [3], insert the seal to the proper depth. a Lightly hit the top, bottom, right, and left of the aligning tool with a hammer to push in the seal, taking care that the seal carrier will not be bent.
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF RADIATOR GUARD ASSEMBLY
RADIATOR GUARD
4. Using eyebolts, lift off engine hood (4). 4
Engine hood: 80 kg
REMOVAL
k Disconnect the cable from the negative (–) ter-
minal of the battery.
k Lower the work equipment to the ground and
stop the engine. Then, loosen the hydraulic oil filler cap slowly to release the internal pressure of the hydraulic tank. k If the water temperature in the radiator is high, you may get scalded. Accordingly, wait until the water temperature lowers, then drain. 1. Remove the mounting bolts and cover (1).
5. Remove both engine covers (5).
2. Loosen the radiator cap and drain the cooling water. 6
Radiator: Approx. 15 l
6. Remove reservoir tank bracket (6) and disconnect reservoir tank hose (7). [*1] 7. Disconnect charge air cooler outlet hose (8). 3. Remove clip of heater hose (2) and disconnect dust indicator hose (3). a Disconnect the dust indicator hose end on the air cleaner side.
D31/37/39EX, PX-21
8. Disconnect radiator inlet hose (9). 9. Disconnect horn wiring connector (CN22) (10). 10. Remove both fan guards (11).
30-25 (1)
DISASSEMBLY AND ASSEMBLY
RADIATOR GUARD
11. Disconnect oil cooler outlet hose (12). a Prepare a blind plug before disconnecting the hose.
15. Sling radiator guard assembly (17) temporarily and remove 8 mounting bolts (16) from both sides and 2 from the underside. [*2]
12. Disconnect radiator outlet hose (13).
16. Lift off radiator guard assembly (17).
13. Disconnect charge air cooler inlet hose (14).
4
Radiator guard assembly: 370 kg
14. Disconnect oil cooler inlet hose (15). a Prepare a blind plug before disconnecting the hose.
30-26 (1)
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
RADIATOR GUARD
INSTALLATION • [*1]
[*2]
Carry out installation in the reverse order to removal. a Pass the reservoir tank drain hose through the guide pipe of the shroud. a When connecting the hose, apply spray grease to the mating part (tube). 3 Radiator hose clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} 3 Charge air cooler hose clamp: 5.9 ± 0.5 Nm {0.6 ± 0.05 kgm} a When installing the radiator guard assembly, peep through hole "a" to check that there is not clearance between the stopper and frame on each side. k Never insert your finger in hole "a". 3 Mounting bolt: 245 – 309 Nm {25 – 31.5 kgm} a Install the radiator guard assembly so that distance "b" between back side of the shroud and the compressor bracket of the air conditioner will be 142 mm.
•
Refilling with water a Add water through the water filler to the specified level. Run the engine to heighten the water temperature. Then, check the water level again.
•
Refilling with oil (Hydraulic tank) a Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.
•
Bleeding air (HST circuit) a Bleed air from the HST pump circuit. For details, see REMOVAL OF HST PUMP ASSEMBLY.
D31/37/39EX, PX-21
30-27 (1)
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF RADIATOR, OIL COOLER, AND CHARGE AIR COOLER ASSEMBLIES
RADIATOR, OIL COOLER, AND CHARGE AIR COOLER
2. Oil cooler assembly 1) Remove 4 upper mounting bolts (9) and 2 lower mounting bolts (10).
DISASSEMBLY 1. Charge air cooler assembly 1) Remove horn wiring (1). 2) Remove tube (2). 3) Remove cover (3) and shroud (4).
4) Remove upper covers (5) and (6). 5) Remove lower cover (7).
6) Remove charge air cooler assembly (8).
30-28 (1)
2) Remove left cleaning and inspection cover (11). a If the mounting bolt of the cleaning and inspection cover is loosened with an impact wrench, it is loosened too much and the bolt pin is broken. Accordingly, loosen it with a wrench by hand. a If the oil cooler assembly is removed without removing the cleaning and inspection cover, the pin may touch and break the core. Accordingly, remove the cleaning and inspection cover first.
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
3) Lift off oil cooler assembly (12). 4
Oil cooler: 35 kg
RADIATOR, OIL COOLER, AND CHARGE AIR COOLER
2) Remove right cleaning and inspection cover (15). a If the mounting bolt of the cleaning and inspection cover is loosened with an impact wrench, it is loosened too much and the bolt pin is broken. Accordingly, loosen it with a wrench by hand. a If the oil cooler assembly is removed without removing the cleaning and inspection cover, the pin may touch and break the core. Accordingly, remove the cleaning and inspection cover first.
3. Radiator assembly 1) Remove 4 upper mounting bolts (13) and 2 lower mounting bolts (14).
3) Lift off radiator (16). 4
D31/37/39EX, PX-21
Radiator: 80 kg
30-29 (1)
DISASSEMBLY AND ASSEMBLY
ASSEMBLY 1. Radiator assembly 1) Sling and install radiator assembly (16). a When inserting the radiator assembly in the radiator guard, apply grease to the seat. 4
RADIATOR, OIL COOLER, AND CHARGE AIR COOLER
3) Install 2 lower mounting bolts (14) and 4 upper mounting bolts (13).
Radiator: 80 kg
2) Install right cleaning and inspection cover (15). a If the mounting bolt of the cleaning and inspection cover is tightened with an impact wrench, it is tightened too much and the bolt pin is broken. Accordingly, tighten it with a wrench by hand. 2. Oil cooler assembly 1) Sling and install oil cooler assembly (12). a When inserting the oil cooler assembly in the radiator guard, apply grease to the seat. 4
30-30 (1)
Oil cooler: 35 kg
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
2) Install left cleaning and inspection cover (11). a If the mounting bolt of the cleaning and inspection cover is tightened with an impact wrench, it is tightened too much and the bolt pin is broken. Accordingly, tighten it with a wrench by hand.
RADIATOR, OIL COOLER, AND CHARGE AIR COOLER
3. Charge air cooler assembly 1) Install charge air cooler assembly (8).
2) Install lower cover (7). 3) Install upper covers (6) and (5).
3) Install 2 lower mounting bolts (10) and 4 upper mounting bolts (9).
4) Install shroud (4) and cover (3). 5) Install tube (2). 6) Install horn wiring (1).
D31/37/39EX, PX-21
30-31 (1)
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF ENGINE AND HST PUMP ASSEMBLY REMOVAL 1. Remove the radiator guard assembly. For details, see REMOVAL OF RADIATOR GUARD ASSEMBLY. 2. Remove the operator's seat frame assembly. For details, see REMOVAL AND INSTALLATION OF OPERATOR'S SEAT FRAME ASSEMBLY.
ENGINE AND HST PUMP
[*1] 6. Disconnect 8 HST pump hoses. • (10): Drain port T3 • (11): Charge pump suction port S3 • (12): PPC inlet • (13): From charge filter • (14): To charge filter • (15): To right HST motor reverse (Hose color band: Blue) • (16): To left HST motor forward (Hose color band: Yellow) • (17): To right HST motor forward (Hose color band: Green) • (18): To left HST motor reverse (Hose color band: Orange)
3. Disconnect wiring connectors (1) – (6) above the HST pump. • (1): RH pump pressure sensor connector RP • (2): LH pump pressure sensor connector LP • (3): RH pump R-EPC solenoid valve connector RR (Color band: Blue) • (4): RH pump F-EPC solenoid valve connector RF (Color band: Green) • (5): LH pump R-EPC solenoid valve connector LR (Color band: Red) • (6): LH pump F-EPC solenoid valve connector LF (Color band: Yellow)
4. Disconnect work equipment valve hoses (7) and (8). • (7): To oil cooler (Hose color band: Blue) • (8): To work equipment pump (Hose color band: Red)
7. Remove 2 fuse boxes (19) and disconnect 3 wiring harness clamps (20). a There is 1 wiring harness clamp inside.
5. Disconnect hydraulic tank hose (9). • From oil cooler to hydraulic tank filter
30-32 (1)
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
8. Disconnect 4 wiring harness clamps (21). a There are 1 wiring harness clamp inside and 1 installed together with other parts.
ENGINE AND HST PUMP
14. Disconnect the 4 wiring connectors. • (32): CN1 • (33): CN2 • (34): CN3
9. Disconnect starting motor wiring harness (22). a Disconnect only the positive (+) side. 10. Disconnect safety relay connector CN4 (23) and intermediate connectors CN2 (24), CN1 (25), and CN3 (26).
•
(35): CN-EN
11. Remove the 8 mounting bolts and lift off front bracket (27). [*2] 4
Front bracket: 65 kg
15. Disconnect starting motor wiring harness (36). • CN-T1: Starting motor terminal B • CN-T2: Starting motor terminal C 16. Disconnect engine ground wire (37).
[*4]
12. Disconnect the 2 hoses of work equipment pump (28). [*3] • Upper hose: Discharge • Lower hose: Suction 13. Disconnect the 3 fuel hoses. • (29): Fuel outlet • (30): Fuel inlet • (31): Fuel outlet
D31/37/39EX, PX-21
30-33 (1)
DISASSEMBLY AND ASSEMBLY
17. Disconnect heater hoses (38) and (39). 18. Sling the engine and HST pump assembly temporarily and remove 4 mounting bolts (40) at the front and rear. [*5]
ENGINE AND HST PUMP
INSTALLATION •
Carry out installation in the reverse order to removal.
[*1]
3 Flange mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}
[*2]
2 Mounting bolt: Adhesive (LT-2)
[*3]
3 Hose clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*4]
19. Lift off engine and HST pump assembly (41). 4
30-34 (1)
Engine and HST pump assembly: 650 kg
[*5]
a Install the engine ground terminal straight down. 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 245 – 308.7 Nm {25 – 31.5 kgm}
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
DAMPER
REMOVAL AND INSTALLATION OF DAMPER
INSTALLATION •
REMOVAL 1. Remove the operator’s cab frame assembly. For details, see REMOVAL OF OPERATOR’S CAB FRAME ASSEMBLY.
[*1]
2. Remove the HST pump assembly. For details, see REMOVAL OF HST PUMP ASSEMBLY. 3. Remove 12 cover mounting bolts (1).
[*1]
[*2]
Carry out installation in the reverse order to removal. a Clean the pump mating face thoroughly. a Take care not to apply too much gasket sealant. a Apply gasket sealant to the mating faces of the HST pump assembly and cover and to those of flywheel housing and cover. 2 Mating face: Gasket sealant (LG-6) 3 Mounting bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm} a Install the coupling with the inside projection directed toward the output (pump) side. 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 44.1 – 53.9 Nm {4.5 – 5.5 kgm}
4. Using guide bolt [1] and forcing screw [2], remove cover (2).
5. Remove 8 coupling mounting bolts (3) and coupling (4). [*2]
D31/37/39EX, PX-21
30-35 (1)
DISASSEMBLY AND ASSEMBLY
TRACK SHOE
SPREADING AND INSTALLATION OF TRACK SHOE ASSEMBLY
3. Loosen lubricator (2) to lower the tension of the track shoe. [*1] k Since the pressure in the recoil spring cylinder is very high, do not loosen the lubricator more than one turn. If the track tension is not lowered, move the machine forward and in reverse.
791-630-3200 Remover R
790-101-1300
Sketch
New/remodel
Part Name
Q'ty
Part No.
Necessity
Symbol
SPECIAL TOOLS
t 1
Cylinder t 1 (980 kN {100 tons})
790-101-1102 Hydraulic pump
t 1
SPREADING 1. Position the master link properly. a Start the engine and position each master link in front of the idler. a Set a block, jack, etc. under the track shoe in front of each idler. 2. Remove mounting bolts and cover (1).
[*2] 4. Remove the track shoe of master link (3). a Pull both sides of the master link with wires and chain blocks and remove the master link bolts to disconnect the master link.
5. Guiding the track link end with a crane, move the machine slowly in reverse to spread the track shoe assembly (4).
30-36 (1)
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
TRACK SHOE
INSTALLATION • [*1]
Carry out installation in the reverse order to removal. a Adjust the tension of the track shoe. For details, see TESTING AND ADJUSTING, Testing adjusting tension of track shoe. a Tension of track shoe: 20 – 30 mm
[*2] a When winding the track shoe, use a bar, etc. to prevent the link from parting from the sprocket. a Take proper measures so that the mating faces and threads of the master link will not be rusted, bruised, or deformed. In addition, check that the mating faces and threads are free from dirt. a Tighten the master link bolts in the order of [1] – [4] in 2 steps. 2 Master link bolt: Seizure prevention compound (MARUZEN MOLYMAX No. 2 or equivalent) 3 Master link bolt: Initial torque: 147.1 ± 19.6 Nm {15 ± 2 kgm} Retightening angle: 180 ± 10°
D31/37/39EX, PX-21
30-37 (1)
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF HST MOTOR AND FINAL DRIVE ASSEMBLY
HST MOTOR AND FINAL DRIVE
4. Disconnect speed sensor connector LRS (3a) and remove all the wiring harness clamps on the sensor side. a The HST motor speed sensor connector on the right side is RRS.
REMOVAL
k Lower the work equipment to the ground and
stop the engine. Then, loosen the hydraulic oil filler cap slowly to release the internal pressure of the hydraulic tank. k Disconnect the cable from the negative (–) terminal of the battery. For details, see 1. Spread the track shoe. SPREADING TRACK SHOE. 2. Using hydraulic jacks, lift up the machine body and set stand [1] under the steering case.
3. Remove covers (1), (2), and (3).
[*1] 5. Disconnect main hoses (4) and (5). • (4): Left HST motor, reverse (Hose color band: Orange) • (5): Left HST motor, forward (Hose color band: Yellow) • (4): Right HST motor, reverse (Hose color band: Blue) • (5): Right HST motor, forward (Hose color band: Green) 6. Disconnect pilot hoses (6) and (7). • (6): Left HST motor, change to 3rd gear speed (Hose color band: Green) • (7): Left HST motor, change to 2nd gear speed (Hose color band: Yellow) • (6): Right HST motor, change to 2nd gear speed (Hose color band: Yellow) • (7): Right HST motor, change to 3rd gear speed (Hose color band: Green) 7. Disconnect parking brake hose (8). • Hose color band: Orange 8. Disconnect drain hose (9).
30-38 (1)
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
9. Remove the mounting bolts and guard (10). [*2]
HST MOTOR AND FINAL DRIVE
INSTALLATION •
Carry out installation in the reverse order to removal.
[*1]
3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}
[*2]
2 Guard mounting bolt: Adhesive (LT-2) a Take extreme care that each hose will not be twisted when connected.
•
Refilling with oil (Hydraulic tank) a Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.
•
Bleeding air (HST circuit) a Bleed air from the HST pump circuit. For details, see INSTALLATION OF HST PUMP ASSEMBLY.
10. Sling HST motor and final drive assembly (11) temporarily. 11. Remove the 24 mounting bolts and HST motor and final drive assembly (11). a If shims are inserted, check their quantity and positions. 4
HST motor and final drive assembly (Each side): 300 kg
D31/37/39EX, PX-21
30-39 (1)
DISASSEMBLY AND ASSEMBLY
FINAL DRIVE
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY
2) Using 2 forcing screws [1], remove cover (2).
J
791-830-1320 Rod
t 1
01580-01613
Nut
t 1
01643-31645
Washer
t 1
1 790-101-2540 Washer
t 1
790-101-2102 Puller assembly
t 1
790-201-2830 Spacer
t 1
790-101-1102 Hydraulic pump
t 1
2 791-427-1410 Wrench
t 1
3 791-545-1510 Installer
t 1
Sketch
New/remodel
Part Name
Q'ty
Part No.
Necessity
Symbol
SPECIAL TOOLS
3. Ring gear 1) Remove 18 mounting bolts (3). N
DISASSEMBLY 1. Draining oil Remove the drain plug to drain the oil from the final drive case. 6
Final drive case: 3.91 l
2. Cover 1) Remove 12 mounting bolts (1).
30-40 (1)
2) Using 2 forcing screws [2], remove ring gear (4).
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
4. No. 1 planetary carrier assembly 1) Remove thrust washer (5). 2) Remove No. 1 planetary carrier assembly (6).
3) Disassemble No. 1 planetary carrier assembly according to the following procedure. i) Drive pin (7) into shaft (8). a 3 sets ii) Remove shaft (8) from No. 1 planetary carrier assembly. a After removing the shaft, remove pin (7) from shaft (8). a 3 sets iii) Remove 2 thrust washers (9), gear (10), and bearing (11). a 3 sets.
FINAL DRIVE
6. No. 2 sun gear 1) Remove thrust washer (13). 2) Remove No. 2 sun gear (14).
7. No. 2 planetary carrier assembly (HST motor case) 1) Remove mounting bolts (15). a 3 sets
2) Using tools J1, pull shaft (16) out of No. 2 planetary carrier assembly. a 3 sets
5. No. 1 sun gear Remove No. 1 sun gear (12) first.
D31/37/39EX, PX-21
30-41 (1)
DISASSEMBLY AND ASSEMBLY
3) Remove ball (17). a 3 sets 4) Remove gear (18) from No. 2 planetary carrier assembly. a 3 sets 5) Remove 2 inner race bearings (19) from gear (18). a 3 sets
FINAL DRIVE
8. Hub assembly 1) Remove lock plate (22).
2) Using tool J2, remove nut (23).
6) Remove 2 outer race bearings (20) from the gear. a 3 sets
3) Using 2 eyebolts [3], remove hub assembly (24) from No. 2 planetary carrier assembly (HST motor case).
7) Remove thrust washer (21).
30-42 (1)
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
4) Disassemble the hub assembly according to the following procedure. i) Remove floating seal (25). ii) Remove 2 inner race bearings (26).
iii) Remove 2 outer race bearings (27).
9. HST motor case (No. 2 planetary carrier assembly) Remove floating seal (28) from HST motor case (29).
D31/37/39EX, PX-21
FINAL DRIVE
ASSEMBLY a Clean the all parts and check them for dirt or damage. Coat their sliding surfaces with engine oil before installing. a Adjust the pre-load at the normal temperature while the temperature difference between the travel motor case, bearing, hub, and nut is 3° or less. 1. HST motor case (No. 2 planetary carrier assembly) Using tool J3, install floating seal (28). a Remove all oil and grease from the O-ring and O-ring contact surface, and dry them before installing the floating seal. a Insert the tool by pushing the O-ring. a After installing the floating seal, check that its slant is within 1 mm. a After installing the floating seal, thinly apply power line oil (TO30) to the sliding parts.
2. Assembly of hub assembly 1) Using the push tool, press fit 2 outer race bearings (27). a Press fit each bearing until its outer race end comes in full contact with the hub. a After press fitting each bearing, check that a thickness gauge of 0.03 mm cannot go through the clearance between the outer race end and hub.
30-43 (5)
DISASSEMBLY AND ASSEMBLY
2) Using the push tool, press fit 2 inner race bearing (26). 3) Using tool J3, install floating seal (25) to the hub assembly. a For the installation procedure, see step 1 above.
4) Using eyebolts [3], set hub assembly (24) to No. 2 planetary carrier assembly (HST motor case). a When inserting the hub assembly in the No. 2 planetary carrier assembly (HST motor case), check that the bearing and HST motor case insertion surface are free from flaws, burrs and dirt and take care that the bearing will not slant.
FINAL DRIVE
5) Using push tool [4], press the inner race on the bearing on the nut side with a press. a Pressing force on inner race: 8.8 – 12.7 kN {0.9 – 1.3 tons} a After installing hub assembly (24), revolve the hub by 2 – 3 turns against the HST motor case.
6) Tighten the nut and adjust the pre-load on the bearing according to the following procedure. a If nut (23) is not tightened sufficiently (bearings (26) slant and do not go all the way), the contact surfaces of floating seals (25) and (28) may be damaged. Accordingly, tighten nut (23) securely according to the shown procedure.
1] Using tool J2, tighten nut (23) to 490 Nm {50 kgm} temporarily. Rotate hub assembly (24) to the right by 3 turns and then to the left by 3 turns, and then tighten nut (23) again to 490 Nm {50 kgm}. a Tighten the nut to 490 Nm {50 kgm} to prevent the bearing from slanting. 2 Nut: Molybdenum disulfide lubricant (LM-P) 2] Loosen nut (23) to below 196 Nm {20 kgm}. a Do not loosen to 0 Nm {0 kgm}. If you have loosened to 0 Nm {0 kgm}, tighten again to 490 Nm {50 kgm}.
30-44 (5)
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
3] Tighten nut (23) to 245 Nm {25 kgm}. Rotate hub assembly (24) to the right by 3 turns and then to the left by 3 turns, and then tighten nut (23) again to 245 Nm {25 kgm}.
4] Make match mark (a) between nut (23) and HST motor case (29).
5] Tighten nut (23) to the range of 245 – 490 Nm {25 – 50 kgm}. Using push-pull scale [5], adjust the pre-load on the bearing (the rotating force of the hub at a bolt hole on its periphery). Both of the following must be satisfied. (1) Rotating force at bolt hole on periphery of hub: 127 – 206 N {13 – 21 kg}
D31/37/39EX, PX-21
FINAL DRIVE
(2) When tightening the nut, check that the rotation angle of the nut is 0.5 – 1 adjustment notch of the nut by the deviation of the nut from the match mark made in step 4].
7) Install lock plate (22).
a If the lock plate is turned over, it deviates by 1/2 notch. Accordingly, install it so that its claw will be fitted to a notch of the nut. 2 Threads of mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm}
30-45 (5)
DISASSEMBLY AND ASSEMBLY
3. No. 2 planetary carrier assembly 1) Install thrust washer (21).
FINAL DRIVE
6) Tighten mounting bolt (15). 3 Mounting bolt: 98 – 122.5 Nm {10 – 12.5 kgm} a After assembling No. 2 planetary carrier assembly, check that gear (18) rotates smoothly. a 3 sets
2) Install 2 outer race bearings (20) to the gear. a 3 sets
4. No. 2 sun gear Install sun gear (14) and thrust washer (13) to No. 2 planetary carrier assembly.
3) Install 2 inner race bearings (19) to gear (18). a 3 sets 4) Install gear (18) to No. 2 planetary carrier assembly. a 3 sets 5) Install shaft (16) and ball (17) to No. 2 planetary carrier assembly. a Install the shaft by expansion fit. a Match the hole of the shaft to that of the carrier and install the shaft by hitting it lightly with a plastic hammer, etc. a 3 sets
30-46 (5)
5. No. 1 sun gear Install No. 1 sun gear (12).
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
6. No. 1 planetary carrier assembly 1) Assemble No. 1 planetary carrier assembly according to the following procedure. a Replace the thrust washers and pin with new ones. i) Install bearing (11) to gear (10) and fit upper and lower thrust washers (9), then set gear (10) to No. 1 planetary carrier assembly. ii) Match the pin hole of shaft (8) to that of the carrier and install shaft (8) by hitting it lightly with a plastic hammer, etc. a Take care not to damage the thrust washers. iii) Insert pin (7).
FINAL DRIVE
2) Install No. 1 planetary carrier assembly (6). 3) Install thrust washer (5).
7. Ring gear 1) Fit the O-ring to the hub side. Using eyebolts [2] and matching the bolt holes of ring gear (4) to those of the hub, install ring gear (4). a Degrease the mating faces of the ring gear and hub.
a After inserting the pin, bend pin "a" of the carrier.
2) Tighten ring gear (4) with 18 mounting bolts (3). 3 Mounting bolt: 245 – 308.7 Nm {25 – 31.5 kgm}
a After assembling No. 1 planetary carrier assembly, check that gear (10) rotates smoothly.
D31/37/39EX, PX-21
30-47 (5)
DISASSEMBLY AND ASSEMBLY
FINAL DRIVE
8. Cover 1) Using 2 through bolts [1], install cover (2). 2) Install cover (2) to the ring gear with 12 mounting bolts (1). 2 Cover mating face: Gasket sealant (1207B) 3 Mounting bolt: 98 – 122.5 Nm {10 – 12.5 kgm}
9. Refilling with oil Tighten the plug and add power line oil through the oil filler. 3 Plug: 58.8 – 78.4 Nm {6.0 – 8.0 kgm} 5
Final drive case: Approx. 3.91 l (TO30) a Check the oil level after installing the travel motor and final drive assembly to the machine body.
30-47-1 (5)
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF IDLER AND RECOIL SPRING ASSEMBLY
IDLER AND RECOIL SPRING
INSTALLATION •
Carry out installation in the reverse order to removal.
REMOVAL For details, see 1. Spread the track shoe. SPREADING TRACK SHOE. 2. Pull out idler and recoil spring assembly (1) and sling it by the rod to remove it. 4
Idler and recoil spring assembly: 170 kg
3. Remove bolt (2) and separate idler (3) and recoil spring assembly (4) from each other. 4
4
30-48 (1)
Idler: 100 kg Recoil spring assembly: 70 kg
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
RECOIL SPRING
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY
M
791-685-8006 Compressor (B)
t 1
790-201-2860 Spacer
t 1
791-635-3160 Extension
t 1
790-101-1600
Cylinder (686 kN {70 tons})
790-101-1102 Pump
Sketch
New/remodel
Part Name
Q'ty
Part No.
Necessity
Symbol
SPECIAL TOOLS
t 1 t 1
DISASSEMBLY 1. Remove the mounting bolts and lock plate (1). 2. Remove valve (3) 3. Remove rod assembly (5) from recoil spring assembly (4). 4. Disassembly of recoil spring assembly 1) Set recoil spring assembly (4) to tool M. kSince the installed load of the spring is large and dangerous, set it securely. a Installed load of spring: 71.54 kN {7,300 kg}
D31/37/39EX, PX-21
2) Apply hydraulic pressure slowly to compress the spring and tighten nut (6). 3) Remove 2 lock plates (7) and nut (6). a Compress the spring until the nut becomes loose. a Release the hydraulic pressure slowly to lower the tension of the spring to zero. 4) Remove pilot (9) and cylinder (10) from spring (8). 5) Remove snap ring (11), spacer (12), dust seal (13), and bushing (14) from cylinder (10). 5. Disassembly of rod assembly 1) Remove wear ring (16) from rod assembly (5). 2) Remove snap ring (17) and U-packing (18).
30-49 (1)
DISASSEMBLY AND ASSEMBLY
RECOIL SPRING
ASSEMBLY
1. Assembly of rod assembly 1) Install U-packing (18) to rod assembly (5) and secure it with snap ring (17). 2) Install wear ring (16).
3) Using push tool [3], install spacer (12) and secure it with snap ring (11).
2. Assembly of recoil spring assembly 1) Using push tool [1], press fit bushing (14) to cylinder (10). a Secure the cylinder with block [2].
2) Install seal (13) to cylinder (10).
30-50 (1)
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
RECOIL SPRING
4) Install cylinder (10) and pilot (9) to spring (8), then set them to tool M. 5) Apply hydraulic pressure slowly to compress the spring. 6) Set the installed length of the spring to "a". 7) Position the spring with nut (6) and lock it with lock plate (7). 3 Nut: 294 Nm {30.0 kgm} 8) Remove recoil spring assembly (4) from the tool. 3. Supply at least 120 ml of grease to cylinder (10), taking care not to leave any bubble in part "A". 2 Inside of cylinder: Grease (G2-LI)
4. Install rod assembly (5) to recoil spring assembly (4). a Install the rod with valve (3) loosened, then insert the rod assembly. 5. Secure valve (3) with lock plate (1). a Install the valve with the fitting out. 3 Valve: 58.8 – 88.2 Nm {6 – 9 kgm}
D31/37/39EX, PX-21
30-51 (1)
DISASSEMBLY AND ASSEMBLY
IDLER
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY
L
1 791T-430-3210 Push tool
t 1
2 791-675-1510 Installer
t 1
Sketch
New/remodel
Part Name
Q'ty
Part No.
Necessity
Symbol
SPECIAL TOOLS
Q
DISASSEMBLY
5. Pull idler (7) out of the shaft and support assembly. a Oil of 160 cc is filled in. Drain it at this time or spread cloths so that the floor will not be stained with it. 6. Remove floating seals (9) from idler (7) and shaft and support assembly.
7. Remove nut (11) and bolt (12). 8. Remove 2 bushings (13) from idler (7).
1. Remove mounting bolts, guide (1), and shims (2). a Check the quantity of the shims. 2. Remove nut (3) and bolt (4). 3. Remove support (5). 4. Remove floating seals (6) from support (5) and idler (7).
30-52 (1)
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
ASSEMBLY
IDLER
4. Using tool L2, install floating seal (9) to idler (7).
a When installing the floating seal, degrease and dry the mating faces of the O-ring and floating seal (indicated with thick line A) completely. The contact surfaces of the floating seal must be free from dirt. a After installing the floating seal, check that its slant is within 1mm and its projection [a] is 6.5 – 10.5 mm.
1. Using tool L1, press fit 2 bushings (13) to idler (7).
2. Fit the O-ring to shaft (8), then install them to support (10). 3. Insert bolt (12) in support (10) and tighten nut (11). 2 Bolt: Liquid adhesive (LT-2) 3 Nut: 89 – 123 Nm {9 – 12.5 kgm}
D31/37/39EX, PX-21
30-53 (1)
DISASSEMBLY AND ASSEMBLY
IDLER
5. Using tool L2, install floating seal (9) to support (10). a For precautions for installing the floating seal, see a in step 4 above.
8. Using tool L2, install floating seal (6) to support (5). a For precautions for installing the floating seal, see ain step 4 above.
6. Install idler (7) to the shaft and support assembly.
9. Fit the O-ring to shaft (8).
7. Using tool L2, install floating seal (6) to idler (7).
10. Supply oil through the hole of shaft (8) and tighten the plug. 5 Oil: Approx. 160 ml l (SAE30-CD) 3 Plug: 98 – 137 Nm {10 – 14 kgm}
a For precautions for installing the floating seal, see a in step 4 above. 11. Install support (5). 12. Insert bolt (4) in support (5) and tighten nut (3). 2 Bolt: Liquid adhesive (LT-2) 3 Nut: 89 – 123 {9 – 12.5 kgm} 13. Install shims (2) and guide (1). 2 Bolt: Liquid adhesive (LT-2)
30-54 (1)
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
TRACK ROLLER
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY
4. Remove floating seal (5) from collar (3). 5. Pull out roller (6) from shaft.
3 791T-430-3220 Push tool L 4 791-651-1510 Installer 5 790-601-1000 Oil pump
t 1
Sketch
New/remodel
Part Name
Q'ty
Part No.
Necessity
Symbol
SPECIAL TOOLS
Q
t 1 t 1
DISASSEMBLY 1. Remove plug (1) and drain oil. 6
Track roller: Approx. 150 ml l
2. Set roller assembly (2) to block [1].
6. Remove floating seals (7) and (8) from roller (6). 7. Remove bushing (9) and (10) from roller (6).
8. Remove ring (11), then remove collar (12) from shaft (13).
3. Push collar (3) and pull out ring (4), then remove collar (3).
D31/37/39EX, PX-21
30-55 (1)
DISASSEMBLY AND ASSEMBLY
9. Remove floating seal (14) from collar (12). 10. Remove O-rings (15) from shaft (13).
TRACK ROLLER
a Precautions when assembling floating seal. 1) When assembling the floating seal, degrease and dry the parts indicated with thick line A (O-ring and mating face of the O-ring). 2) After assembling the floating seal, check that the angle of the seal is less than 1 mm. 3) After assembling, check that protrusion [a] of the floating seal is within a range of 7 – 11 mm.
ASSEMBLY 1. Fit O-rings (15) to shaft (13) and assemble collar (12), then install ring (11). a After assembling, tighten plug (1) temporarily. 2. Using tool L4, install floating seal (14) to collar (12).
30-56 (1)
3. Using push tool [1], press fit bushings (9) and (10) to roller (6). 2 Bushing press-fitting portion: Engine oil (EO30-CD) a Bushing press-fitting force: 29.4 ± 3.92 kN {3.0 ± 0.4 ton}
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
TRACK ROLLER
4. Install floating seal (8) to roller (6). a For details of the precautions when installing the floating seals, see Step 2, a Precautions when assembling floating seal.
7. Install floating seal (8). a For details of the precautions when installing the floating seals, see Step 2, a Precautions when assembling floating seal.
5. Set shaft (13) and collar (12) assembly on block [2], then assemble roller (6). a Coat the sliding surface of the floating seal with engine oil, and make sure that no dirt or dust sticks to the surface. a When assembling the roller, coat the shaft or bushing with engine oil.
8. Install floating seal (5) to collar (3). a For details of the precautions when installing the floating seals, see Step 2, a Precaution when assembling floating seal. a Coat the sliding surface of the floating seal with engine oil, and make sure that no dirt or dust sticks to the surface.
6. Refilling with oil Pour oil through clearance between shaft (13) and roller (6).
9. Fit roller (2) to collar (3), then install ring (4).
5 Roller: Approx. 150 ml l (EO30-CD) a When using tool B to add the oil, add the oil after completing the total assembly.
D31/37/39EX, PX-21
30-57 (1)
DISASSEMBLY AND ASSEMBLY
10. Using tool L5, apply basic pressure to roller oil filler port, and check for leakage of air from seal. a Basic pressure: 0.1 MPa {1 kg/cm2} a Method of checking The basic pressure shall be maintained for 10 seconds and the indicator of the gauge shall not go down.
TRACK ROLLER
12. Checking oil level Stand the track roller as shown in the diagram below and leave it for a short time, then insert a wire from the oil filler port and check height L to the oil surface. a Distance L from end face of shaft to oil surface: 106 mm 13. Tighten plug (1). 3 Plug: 117.7 ± 19.6 Nm {12 ± 2 kgm}
11. If oil was not added in Step 6, use tool L5, to fill track roller assembly with oil. 5
30-58 (1)
Track roller oil: l (EO30-CD) Approx. 150 ml
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
CARRIER ROLLER
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY
5. Disassembly of shaft, support assembly 1) Remove floating seal (8) from shaft and support assembly (7). 2) Set shaft and support assembly (7) on block [3], and using push tool [4], remove shaft (10) from support (9) with press.
L 6 791-430-3230 Installer
Sketch
New/remodel
Part Name
Q'ty
Part No.
Necessity
Symbol
SPECIAL TOOLS
t 1
DISASSEMBLY 1. Remove cap (1) from carrier roller assembly. 2. Remove bolt (2), then remove plate (3). 3. Remove roller assembly (4).
4. Disassembly of roller assembly 1) Remove floating seal (5) from roller assembly (4). 2) Set roller assembly on block [1], and using push tool [2], remove bushing (6).
D31/37/39EX, PX-21
30-59 (1)
DISASSEMBLY AND ASSEMBLY
ASSEMBLY 1. Assembly of shaft, support assembly. 1) Set support (9) on block [5], and using push tool [6], press fit shaft (10). a Press-fitting force: 19.6 – 106.8 kN (2 – 10.9 ton) 2 Shaft: Anti-friction compound (LM-P) 2) Install floating seals (8) and (5). a When installing the floating seal, degrease and dry the parts indicated with thick line A (O-ring and mating face of the O-ring). a After installing the floating seal, check that its slant is within 1 mm and its projection [a] is 4 – 8 mm.
CARRIER ROLLER
2. Assembly of roller assembly. Using push tool [7], press fit bushing (6). 3. Set shaft and support assembly (7) in position, and assemble roller assembly (4). 4. Assemble plate (3), and tighten with bolt (2). 3 Mounting bolt: 176.5 ± 19.6 Nm {18 ± 2 kgm}
5. Fill roller with oil. 5
Carrier roller: Approx. 200 – 220 ml l (Engine oil EO30-CD)
6. Fit O-ring to cap (1) and install to carrier roller assembly.
30-60 (1)
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF HST PUMP ASSEMBLY REMOVAL
k Lower the work equipment to the ground and
stop the engine. Then, loosen the hydraulic oil filler cap slowly to release the residual pressure in the hydraulic tank. 1. Remove the operator's seat frame assembly. For details, see REMOVAL AND INSTALLATION OF OPERATOR'S SEAT FRAME ASSEMBLY. 2. Disconnect wiring connectors (1) – (6) above the HST pump. • (1): RH pump pressure sensor connector RP • (2): LH pump pressure sensor connector LP • (3): RH pump R-EPC solenoid valve connector RR (Color band: Blue) • (4): RH pump F-EPC solenoid valve connector RF (Color band: Green) • (5): LH pump R-EPC solenoid valve connector LR (Color band: Red) • (6): LH pump F-EPC solenoid valve connector LF (Color band: Yellow)
D31/37/39EX, PX-21
HST PUMP
3. Disconnect work equipment valve hoses (7) and (8). • (7): To oil cooler (Hose color band: Blue) • (8): To work equipment pump (Hose color band: Red) 4. Disconnect hydraulic tank hose (9). • From oil cooler to hydraulic tank filter [*1] 5. Disconnect 8 HST pump hoses. • (10): Drain port T3 • (11): Charge pump suction port S3 • (12): PPC inlet • (13): From charge filter • (14): To charge filter • (15): To right HST motor reverse (Hose color band: Blue) • (16): To left HST motor forward (Hose color band: Yellow) • (17): To right HST motor forward (Hose color band: Green) • (18): To left HST motor reverse (Hose color band: Orange)
30-61 (1)
DISASSEMBLY AND ASSEMBLY
6. Sling HST pump assembly (19) temporarily and remove the 6 mounting bolts. [*2] • M12 bolt: 4 pieces • M16 bolt: 2 pieces 7. Lift off HST pump assembly (19). 4
HST pump assembly: 140 kg
HST PUMP
INSTALLATION •
Carry out installation in the reverse order to removal.
a When assembling the parts, take extreme care not to twist the hoses. [*1]
3 Mounting bolts of flanges of hoses (15) – (18): 98 – 123 Nm {10 – 12.5 kgm}
[*2]
2 Threads of mounting bolt: Gasket sealant (LG-5)
•
Bleeding air a Bleed air from the HST circuit. For details, see TESTING AND ADJUSTING, Bleeding air from HST circuit.
•
Refilling with oil (Hydraulic tank) a Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.
a If the HST pump assembly was replaced, adjust the new HST pump assembly according to TESTING AND ADJUSTING, Special functions of monitor panel (EMMS), 8-SERVICE ADJUST MODE.
30-62 (1)
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF MAIN CONTROL VALVE ASSEMBLY REMOVAL
k Lower the work equipment to the ground and
stop the engine. Then, loosen the hydraulic oil filler cap slowly to release the internal pressure of the hydraulic tank. a Plug the disconnected pipes and hoses to prevent foreign matter from entering them. a Put tags to the disconnected hoses to prevent a mistake in re-connecting them.
MAIN CONTROL VALVE
3. Disconnect the following 8 main control valve PPC hoses. • (3): Return to hydraulic tank • (4): To suction pipe • (5): Angle right (Hose color band: Green) • (6): Tilt left (Hose color band: White) • (7): Lift up (Hose color band: Red) • (8): Angle left (Hose color band: Blue) • (9): Tilt right (Hose color band: Brown) • (10): Lift down (Hose color band: Orange)
1. Remove the 4 mounting bolts and rear cover (1).
4. Disconnect 2 heater hoses (11). 5. Remove the 2 mounting bolts and seat belt (12). 6. Remove mounting bolts (13). 2. Remove the 4 mounting bolts and charge pump oil filter bracket (2). a Move the bracket aside so that it will not be an obstacle to the work to disconnect the equipment hoses.
7. Lean the operator’s seat assembly (14) forward.
D31/37/39EX, PX-21
30-63 (1)
DISASSEMBLY AND ASSEMBLY
MAIN CONTROL VALVE
8. Disconnect the following 10 main control valve main hoses. • (15): Angle left • (16): Angle right • (17): Tilt right • (18): Tilt left • (19), (20): Lift down • (21), (22): Lift up • (23): To oil cooler (Hose color band: Blue) • (24): To hydraulic pump (Hose color band: Red)
INSTALLATION
9. Remove clamp (25). 10. Remove the 4 mounting bolts and main control valve assembly (26).
30-64 (1)
•
Carry out installation in the reverse order to removal. a Take extreme care that each hose will not be twisted when connected.
•
Refilling with oil (Hydraulic tank) a Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.
•
Bleeding air (HST circuit) a Bleed air from the HST pump circuit. For details, see INSTALLATION OF HST PUMP ASSEMBLY.
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
MAIN CONTROL VALVE
DISASSEMBLY AND ASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY DISASSEMBLY Disassembly of main control valve assembly 1/2 a Since the safety valve assembly cannot be set to proper pressure while it is mounted on the machine, do not disassemble it. a Do not remove the upper and lower covers and each block. 1. Plug (Pressure releasing) 1) Remove plug (1) to release the pressure from the circuit. 2) Remove the O-ring and backup rings (2) and (3). 2. Unload valve 1) Remove unload valve assembly (4). 2) Remove the O-ring and ring (6) from sleeve (5). 3) Remove plug (7) and spring (8) from sleeve (5). 4) Remove plug (9) and spring (10). a Do not remove the spool, seal, and LS selector valve. 3. Pressure compensation valve Remove 6 plugs (11), 3 springs (12), and 3 springs (13). a Do not remove the valve and piston. 4. Suction valve assemblies Remove 3 suction valve assemblies (14). a Do not disassemble the suction valve assembly. 5. Main relief valve assembly Remove main relief valve assembly (15), O-ring, and ring (16). a Do not disassemble the main relief valve. 6. Check valves (Angle) Remove 2 plugs (17), 2 valves (18), and 2 springs (19). 7. Cooler bypass valve Remove plug (20), valve (21), and spring (22). 8. Plugs Remove 2 plugs (23), plug (24), plug (25), and 2 plugs (26).
30-66 (1)
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
D31/37/39EX, PX-21
MAIN CONTROL VALVE
30-67 (1)
DISASSEMBLY AND ASSEMBLY
MAIN CONTROL VALVE
Disassembly of main control valve assembly 2/2 1. Angle control valve 1) Remove the mounting bolts, case (27), bolt (28), spring (29), and retainer (30). a When loosening bolt (28), take care extremely not to damage the spool. 2) Remove the mounting bolts and case (31). a Do not remove the retainer, spool, and plug. a Since the spring has a part No. different from the others, check its free length. 2. Tilt control valve 1) Remove the mounting bolts, case (32), bolt (33), spring (34), and retainer (35). a When loosening bolt (33), take care extremely not to damage the spool. 2) Remove the mounting bolts and case (36). a Do not remove the retainer, spool, and plug. a Since the spring has a part No. different from the others, check its free length. 3. Lift control valve 1) Remove the mounting bolts, cases (37) and (38), spring (39), retainer (40), spring (41), retainer (42), and plug (43). a When loosening plug (43), take care extremely not to damage the spool. 2) Remove the mounting bolts, cases (44) and (45), bolt (46), spring (47), retainer (48), spring (49), and retainer (50). a Remove bolt (46) from the spool without taking the spool out of the block. a When loosening bolt (46) take care extremely not to damage the spool. a Do not remove the spool and retainer. a Since the spring has a part No. different from the others, check its free length.
30-68 (1)
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
D31/37/39EX, PX-21
MAIN CONTROL VALVE
30-69 (1)
DISASSEMBLY AND ASSEMBLY
ASSEMBLY Assembly of main control valve assembly 1/2 a Apply engine oil to the sliding surfaces before assembling. a As a result of disassembly, if the spool or block has any defect, replace the assembly. a Degrease the plug and female screw of the spool with DRYSOL, etc. and dry them completely before tightening. Do not apply pressure on them for at least 2 hours after they are tightened.
MAIN CONTROL VALVE
3) Install retainer (30) and spring (29) to the block with bolt (28). 3 Bolt: 6.9 – 9.8 Nm {0.7 – 1.0 kgm} 4) Fit the O-ring to case (27). 5) Install case (27) to the block with the mounting bolts. 3 Bolt: 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
1. Lift control valve 1) Install retainer (50), spring (49), retainer (48), and spring (47) to the spool. 2) Tighten bolt (46) in the spool. a Apply 1 drip (approx. 0.02 g) of LOCTITE (No. 638) to the bolt. a Tighten the bolt without taking the spool out of the block. 3 Bolt: 6.9 – 9.8 Nm {0.7 – 1.0 kgm} 3) Fit the O-ring to cases (45) and (44). 4) Install cases (45) and (44) to the block with the mounting bolts. 3 Bolt: 11.8 – 14.7 Nm {1.2 – 1.5 kgm} 5) Fit the O-ring to plug (43) and install them to the block. 6) Install retainer (42), spring (41), retainer (40), and spring (39) to the block. 7) Tighten plug (43). 3 Plug: 14.7 – 19.6 Nm {1.5 – 2 kgm} 8) Fit the O-ring to cases (38) and (37). 9) Install cases (38) and (37) to the block with the mounting bolts. 3 Bolt: 11.8 – 14.7 Nm {1.2 – 1.5 kgm} 2. Tilt control valve 1) Fit the O-ring to case (36). 2) Install case (36) to the block with the mounting bolts. 3 Bolt: 11.8 – 14.7 Nm {1.2 – 1.5 kgm} 3) Install retainer (35) and spring (34) to the block with bolt (33). 3 Bolt: 6.9 – 9.8 Nm {0.7 – 1.0 kgm} 4) Fit the O-ring to case (32). 5) Install case (32) to the block with the mounting bolts. 3 Bolt: 11.8 – 14.7 Nm {1.2 – 1.5 kgm} 3. Angle control valve 1) Fit the O-ring to case (31). 2) Install case (31) to the block with the mounting bolts. 3 Bolt: 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
30-70 (1)
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
D31/37/39EX, PX-21
MAIN CONTROL VALVE
30-71 (1)
DISASSEMBLY AND ASSEMBLY
Assembly of main control valve assembly 2/2 1. Plugs 1) Fit the O-ring and tighten plug (26). a 2 sets 3 Plug: 147 – 186.2 Nm {15 – 19 kgm} 2) Fit the O-ring and tighten plug (25). 3 Plug: 49 – 58.8 Nm {5 – 6 kgm} 3) Fit the O-ring and tighten plug (24). 3 Plug: 147 – 186.2 Nm {15 – 19 kgm} 4) Fit the O-ring and tighten plug (23). 3 Plug: 19.6 – 27.5 Nm {2 – 2.8 kgm} 2. Cooler bypass valve 1) Fit the O-ring to plug (20). 2) Install spring (22) and valve (21) to the block with plug (20). 3 Plug: 147 – 186.2 Nm {15 – 19 kgm} 3. Check valve (Angle) 1) Fit the O-ring to plug (17). 2) Install spring (19) and valve (18) to the block with plug (17). a 2 sets 3 Plug: 19.6 – 24.5 Nm {2 – 2.5 kgm}
MAIN CONTROL VALVE
7. Unload valve 1) Install spring (10) to the block. 2) Fit the O-ring to plug (9) and screw them into the block 3 Plug: 147 – 186.2 Nm {15 – 19 kgm} 3) Fit the O-ring to plug (7). 4) Install spring (8) and plug (7) to sleeve (5). 5) Screw plug (7) into sleeve (5). 3 Plug: 34.3 – 44.1 Nm {3.5 – 4.5 kgm} 6) Fit the O-ring and ring (6) to sleeve (5). 7) Screw unload valve assembly (4) into the block. 3 Unload valve assembly: 117.6 – 161.8 Nm {12 – 16.5 kgm} 8. Plug (Pressure releasing) 1) Fit the O-ring and backup rings (3) and (2) to plug (1). 2) Screw pressure releasing plug (1) into the block. 3 Plug: 34.3 – 44.1 Nm {3.5 – 4.5 kgm}
4. Main relief valve assembly 1) Fit the O-ring and ring (16). 2) Screw main relief valve assembly (15) into the block. 3 Main relief valve assembly: 137 – 157 Nm {14 – 16 kgm} 5. Suction valve Fit the O-ring and screw suction valve (14) into the block. a 3 sets 3 Suction valve: 39.2 – 49 Nm {4 – 5 kgm} 6. Pressure compensation valve 1) Install 3 springs (13) and 3 springs (12) to the block. 2) Fit 6 O-rings to 6 plugs (11). 3) Screw plug (11) into the block. 3 Plug: 47 – 58.8 Nm {4.8 – 6 kgm}
30-72 (1)
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
D31/37/39EX, PX-21
MAIN CONTROL VALVE
30-73 (1)
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF BLADE ASSEMBLY
BLADE
6. Disconnect the following 6 cylinder hoses. • (6): Tilt hose (Left side: 2) • (7): Angle hoses (Left side: 2, Right side: 2)
REMOVAL
k Referring to TESTING AND ADJUSTING, Bleed-
ing air from hydraulic cylinder, release the pressure from the piping, then loosen the oil filler cap of the hydraulic tank to release the pressure from the tank. 1. Lower the blade to level ground and set block [1] under the work equipment frame.
7. Sling work equipment assembly (8) temporarily. a Connect the rear hanging wires to a chain block, etc. to balance the work equipment assembly.
2. Sling lift cylinder (1) temporarily. a Perform the following procedures up to 5 for both right and left sides. 3. Remove lock plate (2) and pull out cylinder head pin (3). [*1] a Both sides 4. Secure the head side of lift cylinder (1) to the engine hood knob with ropes, etc. a The head side of the cylinder may be secured to the knob of the cab or ROPS. a Both sides
8. Remove lock plate (9) and pull out frame fitting pin (10). [*2] a Both sides
5. Remove covers (4) and (5). a Both sides
30-74 (1)
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
9. Lift off work equipment assembly (8). 4
Work equipment assembly: 950 kg (D31EX-21) 1,050 kg (D31PX-21) 1,000 kg (D37EX-21) 1,100 kg (D37PX-21) 1,150 kg (D39EX-21) 1,200 kg (D39PX-21)
BLADE
INSTALLATION • [*1]
Carry out installation in the reverse order to removal. k When aligning the pin holes, use a bar.
Never insert your fingers in the pin holes. [*2]
k When aligning the pin holes, use a bar.
Never insert your fingers in the pin holes.
D31/37/39EX, PX-21
•
Refilling with oil (Hydraulic tank) a Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.
•
Greasing a After assembling the blade assembly, apply grease to the removed pins securely.
30-75 (1)
DISASSEMBLY AND ASSEMBLY
HYDRAULIC CYLINDER
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLIES
3) Pull out piston rod assembly (3). a Place an oil receiving pan, etc. under the cylinder bottom to receive the oil.
790-502-1003 Repair stand
t 1
790-101-1102 Pump
t 1
2 790-330-1100 Wrench
t 1
3 790-302-1270 Socket
t 1
4 790-720-1000 Expander
t 1
1
5
796-720-1650 Rubber band
q 1
07281-01029
q 1
Clamp
790-201-1720 Push tool kit
U 6
7
t 1
790-101-5021 • Grip
t 1
01010-50816
t 1
• Bolt
2. Piston assembly and head assembly 1) Set piston rod assembly (3) to tool U1. 2) Using tool U3, remove nylon nut (4). a Width across flats: 50 mm (Common to all cylinders) 3) Remove piston assembly (5) and head assembly (6).
1
790-201-1560 • Plate
t 1
790-101-5021 • Grip
t 1
01010-50816
t 1
• Bolt
Sketch
1
790-201-1751 • Push tool
790-201-1500 Push tool kit
New/remodel
Part Name
Q'ty
Part No.
Necessity
Symbol
SPECIAL TOOLS
DISASSEMBLY 1. Piston rod assembly 1) Set cylinder assembly (1) to tool U1. 2) Using a hydraulic pump or a power wrench and tool U2, disconnect head assembly (2). 4) Disassembly of piston assembly i) Remove wear ring (7). ii) Remove piston ring (8).
30-76 (1)
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
5) Disassembly of head assembly i) Remove backup ring (9) and O-ring. ii) Remove packing (10) iii) Remove snap ring (11) and dust seal (12). iv) Remove bushing (13).
ASSEMBLY (Blade lift, angle, and tilt cylinders) a Apply engine oil to the sliding surfaces of each part and take care not to damage the rod, packing, dust seal, and O-ring.
HYDRAULIC CYLINDER
iii) Install snap ring (11). iv) Install packing (10). v) Install backup ring (9) and O-ring. a Warm the backup ring in water at 50 – 60°C before installing it.
2) Disassembly of piston assembly i) Set piston ring (8) to tool U4. ii) Rotate the handle by 8 – 10 turns to expand the piston ring. iii) Remove piston ring (8) from tool U4. iv) Install piston ring (8) to piston assembly (5). v) Using tool U5, reduce piston ring (8).
1. Head assembly and piston assembly 1) Assembly of head assembly i) Press fit bushing (13) with tool U6.
vi) Install wear ring (7).
ii)
Using tool U7, install dust seal (12).
D31/37/39EX, PX-21
30-77 (1)
DISASSEMBLY AND ASSEMBLY
HYDRAULIC CYLINDER
2. Piston rod assembly 1) Set the piston rod to tool U1. 2) Install head assembly (6) and piston assembly (5). 3) Using tool U3, tighten nut (4). 3
6) Using a hydraulic pump or a power wrench and tool U2, tighten head assembly (2). 3 Cylinder name
Tightening torque of head
Blade lift
637 ± 63.7 Nm {65 ± 6.5 kgm}
Cylinder name
Width across flats
Tightening torque of nut
Blade angle
569 ± 56.9 Nm {58 ± 5.8 kgm}
Blade lift
46 mm
785 ± 78.5 Nm {80 ± 8 kgm}
Blade tilt
677 ± 67.5 Nm {69 ± 6.9 kgm}
Blade angle
46 mm
785 ± 78.5 Nm {80 ± 8 kgm}
Blade tilt
50 mm
1,080 ± 108 Nm {110 ± 11 kgm}
a Before installing the nut, degrease the threads of the piston rod thoroughly. 2 Threads of rod: Adhesive (LOCTITE N262)
4) Set cylinder (1) to tool U1. 5) Install piston rod assembly (3) to the cylinder.
30-78 (1)
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF OPERATOR’S SEAT FRAME ASSEMBLY
OPERATOR’S SEAT FRAME
5. Remove rear covers (3), (4), and (5).
REMOVAL
k Disconnect the cable from the negative (–) ter-
minal of the battery.
k Lower the work equipment to the ground and
stop the engine. Then, loosen the hydraulic oil filler cap slowly to release the internal pressure of the hydraulic tank. k Loosen the heater hose valve (If the machine is equipped with the heater or air conditioner). k Close the fuel stop valve.
6. Disconnect rear lamp wiring connector (CN33) (6).
1. Drain the hydraulic oil. 6
Hydraulic tank: 47 l
2. Remove the mounting bolts and cover (1). 3. Loosen the radiator cap and drain the cooling water. 6
Radiator: Approx. 15 l
7. Lift off ROPS guard (7). 4
[*1]
ROPS guard: 340 kg
4. Remove the mounting bolts and cover (2). a Both sides
D31/37/39EX, PX-21
30-79 (1)
DISASSEMBLY AND ASSEMBLY
8. Remove the 2 mounting bolts and seat belt (8).
OPERATOR’S SEAT FRAME
11. Remove the mounting bolts and cover (11). 12. Disconnect center brake limit switch connector PB1 (12), brake potentiometer connector BP1 (13), and decelerator pedal potentiometer connector DP1 (14).
9. Remove 2 pins (9).
13. Disconnect decelerator pedal linkage (17) and fuel control linkage (18). [*2]
10. Lift off operator’s seat assembly (10). 4
Operator’s seat assembly: 45 kg
14. Remove the mounting bolts and lift off floor cover (19). 4
30-80 (1)
Floor cover: 35kg
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
15. Disconnect the 4 wiring connectors of the 4spool solenoid valve. • (20): Parking brake solenoid valve connector S4 (Color band: Brown) • (21): Slow brake solenoid valve connector (Color band: Blue) S3 • (22): 3rd gear speed solenoid valve connector S2 (Color band: Green) • (23): 2nd gear speed solenoid valve connector S1 (Color band: Yellow)
OPERATOR’S SEAT FRAME
17. Disconnect the 4 floor wiring harness connectors and floor ground wire. • (36): CN7 • (37): CN6 • (38): CN8 • (46): CN5 • (47): Floor ground wire
18. Disconnect centralized drain block hose (39). 16. Disconnect the 6 work equipment PPC hoses. • (30): Angle right (Hose color band: Green) • (31): Tilt left (Hose color band: White) • (32): Lift raise (Hose color band: Red) • (33): Angle left (Hose color band: Blue) • (34): Tilt right (Hose color band: Brown) • (35): Lift lower (Hose color band: Orange)
D31/37/39EX, PX-21
19. Disconnect 2 heater hoses (40). (Only the model equipped with the heater or air conditioner) 20. Remove 3 floor wiring harness clamps (41). 21. Disconnect heater unit wiring connector (CN92) (42). (Only the model equipped with the heater or air conditioner)
30-81 (1)
DISASSEMBLY AND ASSEMBLY
22. Remove the mounting bolts and lift off operator's seat frame assembly (45). 4
OPERATOR’S SEAT FRAME
INSTALLATION •
Carry out installation in the reverse order to removal.
[*1]
3 Mounting bolt: 245 – 309 Nm {25.0 – 31.5 kgm}
Operator's seat frame assembly: 170 kg
[*2]
30-82 (1)
a Adjust the fuel control linkage and decelerator pedal linkage. For details, see TESTING AND ADJUSTING, Adjusting fuel control lever linkage and decelerator pedal linkage.
•
Refilling with coolant a Add coolant through the coolant filler to the specified level. Run the engine to raise the coolant temperature. Then, check the coolant level again.
•
Refilling with oil (Hydraulic tank) a Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.
•
Bleeding air (HST circuit) a Bleed air from the HST circuit. For details, see TESTING AND ADJUSTING, Bleeding air from HST circuit.
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
FUEL TANK
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY
8. Lift off fuel tank assembly (10). 4
Fuel tank assembly: 110 kg (Dry weight)
REMOVAL
k Disconnect the cable from the negative (–) ter-
minal of the battery. 1. Remove the operator’s cab frame assembly. For details, see REMOVAL OF OPERATOR’S CAB FRAME ASSEMBLY. 2. Close the fuel stop valve. 3. Distance 2 fuel return hoses (1). 4. Disconnect the 2 fuel tank hoses. • Hose (2): From fuel tank to fuel filter • Hose (3): From fuel tank to fuel drain valve 5. Remove clamp (4) and disconnect fuel hose (5). a When removing the clamp, remove the fuel drain valve bracket, too. 6. Remove clamp (6) and disconnect the following 2 connectors. • (7): (CN13) Fuel sensor connector • (8): (CN14) Backup alarm relay connector
7. Remove cap (9) and eyebolts.
D31/37/39EX, PX-21
INSTALLATION •
Carry out installation in the reverse order to removal.
[*1]
2 Mounting bolt: Adhesive (LT-2)
[*1]
30-83 (1)
DISASSEMBLY AND ASSEMBLY
HYDRAULIC TANK
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY
4. Remove cap (7) and mounting bolts.
REMOVAL
k Disconnect the cable from the negative (–) ter-
minal of the battery.
k Lower the work equipment to the ground and
stop the engine. Then, loosen the hydraulic oil filler cap slowly to release the internal pressure of the hydraulic tank. 1. Remove the operator’s cab frame assembly. For details, see REMOVAL OF OPERATOR’S CAB FRAME ASSEMBLY. 2. Disconnect the following 5 hoses. • (1): Delivery hose • (2): Work equipment valve return hose • (3): Left travel motor return hose • (4): Right travel motor return hose • (5): HST pump return hose
[*1]
5. Remove battery cover bolt (8). a After removing the bolt, move the battery cover so that the hydraulic tank assembly will come off easily.
6. Lift off hydraulic tank assembly (9). 4
Hydraulic tank assembly: 70 kg
3. Disconnect oil filter hose (6).
30-84 (1)
D31/37/39EX, PX-21
DISASSEMBLY AND ASSEMBLY
HYDRAULIC TANK
INSTALLATION •
Carry out installation in the reverse order to removal. a Take extreme care that each hose will not be twisted when connected.
[*1]
3 Clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
•
Refilling with oil (Hydraulic tank) a Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.
•
Bleeding air (HST circuit) a Bleed air from the HST pump circuit. For details, see INSTALLATION OF HST PUMP ASSEMBLY.
D31/37/39EX, PX-21
30-85 (1)
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF HST CONTROLLER ASSEMBLY REMOVAL
k Disconnect the cable from the negative (–) ter-
minal of the battery.
HST CONTROLLER
INSTALLATION •
Carry out installation in the reverse order to removal.
a If the HST controller assembly was replaced, adjust the new HST controller assembly according to TESTING AND ADJUSTING, Special functions of monitor panel (EMMS), 8-SERVICE ADJUST MODE.
1. Fold the operator's seat forward. 2. Disconnect the 3 wiring connectors. • (1): ST1 • (2): ST2 • (3): ST3 3. Remove HST controller assembly (4).
30-86 (1)
D31/37/39EX, PX-21
90 OTHERS Hydraulic circuit diagram (1/2) .........................90- 3 Hydraulic circuit diagram (2/2) .........................90- 5 Electrical circuit diagram (1/4) ..........................90- 7 Electrical circuit diagram (2/4) ..........................90- 9 Electrical circuit diagram (3/4) ..........................90- 11 Electrical circuit diagram (4/4) ..........................90-13 Air conditioner circuit diagram..........................90-15
D31/37/39EX, PX-21
90-1
HYDRAULIC CIRCUIT DIAGRAM (1/2)
D31/37/39EX, PX-21
90-3
HYDRAULIC CIRCUIT DIAGRAM (2/2)
D31/37/39EX, PX-21
90-5
ELECTRICAL CIRCUIT DIAGRAM (1/4)
D31/37/39EX, PX-21
90-7
ELECTRICAL CIRCUIT DIAGRAM (2/4)
D31/37/39EX, PX-21
90-9
ELECTRICAL CIRCUIT DIAGRAM (3/4)
D31/37/39EX, PX-21
90-11
ELECTRICAL CIRCUIT DIAGRAM (4/4)
D31/37/39EX, PX-21
90-13
AIR CONDITIONER CIRCUIT DIAGRAM
D31/37/39EX, PX-21
90-15
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