d31!37!39x21a Testing & Adjusting Procedure(Wm)

Customer

EX

Date Model  _______________________________   D31/37/39X-21”A”   D31/37/39X-21”A”  SMR 

PX

Serial  ______________________________  Technician

TESTING & ADJUSTING PROCEDURE  Use the following procedure as a  sequential supplement  sequential  supplement to the Shop Manual when testing & adjusting the Komatsu D31/37/39EX/PX-21”A” D31/37/39EX/PX-21”A” KomStat II Dozers. See also the the HANDY  HANDY CARD! Postures shown on last page! Always ensure that all all FLUIDS & FILTERS are as recommended recommended for peak engine and hydraulic performance. Dirty oil and/or filters can affect a D39’s HST like no mechanical drive Dozer! Follow this procedure in order because skipping one step may affect the measurements in the following steps. FFOR fitting adapters may be needed if  any troubleshooting is being performed. Also be sure BATTERY Voltage is normal (Monitor Mode 2). See Tools Tools List “C4" *FFOR = FlatFacedO-Ring” FlatFacedO-Ring” TEST PORTS Listing Listing on last page.

Pre-Checks for Monitor Monitor & Controller such as listed below, by Monitor Codes 1) Begin with certain Machine Pre-Checks

within the SERVICE MODE (Mode 8) then DUAL DISPLAY MODE (Mode 11): MM=MonMode-Code Actual After Standard Value Standard Value Key “ON” Engine “OFF” Value Adjusting D31xX-21 D37xX-21 Service Phone No. Service Phone No. MM=8-0001 Distr TEL Input  No adj.## D31= ‘31’ D37= ‘37’ MM=10-00200 Model Code  No adj.## Ex=02 or Px=01 EX=02 or PX=01 MM=10-00200 Spec Code  No adj. 300 – (500) – 700mV 700mV 300 – (500) – 700mV 700mV MM=11-52500(R) Press. Sen.  No adj. 300 – (500) – 700mV 700mV 300 – (500) – 700mV 700mV MM=11-52502(L) Press. Sen.  No adj. Ref Ref MM=11-20215 HST Pgm Ver. F.Hours F.Frequency F.Name F.Hours MM=6 Elec.Faults (F.Name)

MM=7 Mech.Faults (F.Name)

F.Hours

F.Frequency

F.Name

F.Hours

Standard Value D39xX-21 Service Phone No. D39= ‘39’ EX=02 or PX=01 300– (500) – 700mV 700mV 300– (500) – 700mV 700mV Ref  F.Frequency

F.Frequency

3) Measure and record all of the Cycle Times listed below. See the Shop Manual for procedural details. Measurement conditions High Idle

Standard Value D31/37X-21

Standard Value D39X-21

Units Measured

Blade Raise Blade Down Blade Tilt Left

1.8 – 2.2 1.2 – 1.6 1.5 – 1.9

1.8 – 2.2 1.5 – 1.9 1.2 – 1.6

Seconds ‘’ ‘’

Blade Tilt Right Blade ANGLE Left Blade ANGLE Right Ripper (opt) UP Ripper DOWN

1.5 – 1.9 2.1 – 3.1 2.1 – 3.1 Option Option

1.2 – 1.6 2.2 – 3.2 2.2 – 3.2 Option Option

‘’ ‘’ ‘’ ‘’ Seconds

4)

Actual Values

After Adjusting

Measure, record Track Tension

Right Track Initial__________________  Right after ADJUSTMENT___________  Left Track Initial ___________________  Left after ADJUSTMENT ____________  STD VALUE = 20 – 30 mm 5) Measure and record all of the Travel Speeds listed below. See the Shop Manual for p rocedural details. *** OPTIONAL Measurement ~ use MM=11-52404+5 or 52406+7 to record Pump cc’s/Rev(ref). Measurement conditions High Idle

Actual Values F3

Actual Values R3

Standard Value D31/37EX/PX-21

Standard Value D39EX/PX-21

Units Measured

TOW Vlv

CAUTION! closed

 If Dozer moves during test(s) the KS2 HST  Controller will STOP BOTH TRACKS  while using the built-in HST Stall Check   Mode (MM=8-3016). Use this Valve for TOWING Brake release “ONLY” 

!  NOT REQUIRED when using KS2  Monitor Tests!!!

! CAUTION! Use Wire Tie or other secure means if pin (5) becomes unavailable. Valve handle must be LOCKED or PINNED “OPEN” prior to releasing D31/37/39x21A to work.

8) Measure and record HST Stall pressures – 30 SECOND TIME LIMIT! Keep HST temp at 50C. (MM=8-3016) NON ADJUSTABLE – Consult Troubleshooting if abnormal. HST Stall Track Actual D31/37/39xx-21”A” (MM=8-3016) Direction Pressure Standard Value KS2, MPa PCCS=Fwd Full fuel Right – Full F 40.2 – 44.1 PCCS=Fwd Full fuel Left – Full F 40.2 – 44.1 PCCS=Rev Full Fuel Right – R 40.2 – 44.1 PCCS=Rev Full fuel Left - R 40.2 – 44.1 rd

**Note – MM code 8-3016 will ‘lock-in’ 3 speed (@T/M) with Park Brake applied and will STOP HST PUMP if any track movement is sensed (Brake Slippage). DO NOT use “Tow Valve”! 9) Measure the Work Equipment  pressures at pump OR valve (under Operator’s seat). Compare with the standard values listed below, and adjust if necessary (work equipment relief only) This circuit not on MM.

Item

Blade Raise Blade Down Blade Tilt Left Blade Tilt Right Blade ANGLE Left Blade ANGLE Right Ripper (opt) UP Ripper DOWN

Actual pressures compared to standard values Measurement conditions Actual

Cylinder relieved Cylinder relieved Cylinder relieved Cylinder relieved Cylinder relieved Cylinder relieved Cylinder relieved Cylinder relieved

MPa (kg/cm2) D39EX/PX-21

20.6 – 30.3 (210 – 218) 20.6 – 30.3 (210 – 218) 20.6 – 30.3 (210 – 218) 20.6 – 30.3 (210 – 218) 20.6 – 30.3 (210 – 218) 20.6 – 30.3 (210 – 218) 20.6 – 30.3 (210 – 218) 20.6 – 30.3 (210 – 218)

Adjusted Value

D31/37/39ExPx-21”A” Valves List  Note – ALL 10mm ports are Komatsu STD o-ring type 1.25 thread pitch. Special NOTE – all PPC and Servo lines are Flat Face O-Ring “FFOR” #4 (9/16UNF) or #6 (11/16UNF) threads. •

•

Valve NAME

LOCATION

1. TVL PPC Valve PCCS = Electrical Potentiometers

LH Operator’s Pedestal

Direction & Steering command

None

HST Pump, LEFT SIDE center 

Charge Pressure Limiter in “N” (neutral) = 31kg/cm2

Charge Port 10mm near solenoid valves Or MM11

2. Charge Safety

FUNCTION

Test PORT Type & Location

LOC”B”

3. Charge Relief(s) …aka “Flushing Valves” 

HST Travel Motors – L/R  (see SM 10-__)

“Vents” HST hot return oil from T/M to tank 

Same as above (#2) “B” Or MM11

4. HST AS Valve KS2 = Controller function

 None

Engine RPM sensing (L=Off/M=ON/H=Off)

 None

5. HST Cut Off Valve (C/O) KS2 = Controller Function

HST Pump center case – low on LH side

Limits HST pump to 440kg/cm2 drive

MM=11-52501+52503 MM=11-52501+52503

6.

HST Safety

Top & Sides of center case (2 each)

7.

Wk.Eq. RELIEF

Lower WK.EQ.Valve

Relieves HST 410-450kg/cm2 drive  press. Limits Wk.Eq. to 210kg/cm2

8.

Wk. Eq. SAFETY

Upper WK.EQ. Valve

Protects Blade ANGLE to 240kg/cm2

9.

Unloader

10. LS Selector Piston 11. Park Brake RELEASE Solenoid 12. HST Brake Valve (EB) KS2 = Slow Brake Solenoid 13. 2nd Speed SELECT Solenoid 14. 3rd Speed SELECT Solenoid

D31.37.39ExPx21”A” KomStat II

Top INNER 10mm at Wk.Eq.Valve LOC “E” Same as #6 “E”

Lower WK.EQ.Valve

Dumps WK.EQ. 100% to cooler/Filter

Same as #6 “E”

Inside Unloader Valve

Cushions LS Pressure rise

Solenoid Valve Manifold Assembly

Releases park brake

Solenoid Valve Manifold Assembly

Delays Park Brake Apply to protect

Solenoid Valve Manifold Assembly

Speed selection PPC signal to T/M

Solenoid Valve Manifold Assembly

Speed selection PPC signal to T/M

Top Outer 10mm Wk.Eq.V. port LOC “F” Outlet PPC line requires FFOR #4 Swivel run TEE LOC “G” Outlet PPC line requires FFOR #4 Swivel run TEE LOC “H” Outlet PPC line requires FFOR #4 Swivel run TEE LOC “I” Outlet PPC line requires FFOR #4 Swivel run TEE LOC “J”

4/18/2004

D31/37/39ExPx-21”A” Hydraulic TEST FITTINGS List

LOCATION

QTY

SIZE

A “Servo-In” KS2 = NOT REQ’D

4

NONE (was #6) EPC Blocks are ported for “Servoin” tests for troubleshooting Only. Block ports = 10 x 1.25

B, C, D, E, F “See Valve List”

5

M10 x 1.25

G, H, I, J “Solenoid Bank”

4

FFOR # 4

D31.37.39ExPx21”A” KomStat II

4/18/2004