Customer

Date _______________________________ SMR

Model

EX PX

D31/37/39X-21A

Serial ______________________________ Technician

TESTING & ADJUSTING PROCEDURE

Use the following procedure as a sequential supplement to the Shop Manual when testing & adjusting the Komatsu D31/37/39EX/PX-21A KomStat II Dozers. See also the HANDY CARD! Postures shown on last page! Always ensure that all FLUIDS & FILTERS are as recommended for peak engine and hydraulic performance. Dirty oil and/or filters can affect a D39s 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 List C4" *FFOR = FlatFacedO-Ring TEST PORTS Listing on last page.

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 300 (500) 700mV MM=11-52500(R) Press. Sen. No adj. 300 (500) 700mV 300 (500) 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)

1) Begin with certain Machine Pre-Checks for Monitor & Controller such as listed below, by Monitor Codes
Standard Value D39xX-21 Service Phone No. D39= 39 EX=02 or PX=01 300 (500) 700mV 300 (500) 700mV Ref F.Frequency

w w w . k o ma t s u p a r t s b o o k . c o m
F.Hours F.Frequency F.Name F.Hours 24000mV (min)

MM=7 Mech.Faults (F.Name)

F.Frequency

24000mV (min) MM=2-02 Battery Voltage ## Adjusting either Model or Spec can erase controller settings!

24000mV (min)

2) Warm machine and HYD OIL (MM=2-03 HST Temp) up to operating temp 50C(Blade over relief ). Record all of the
following Engine Speeds using the Monitor (MM=2-01). Use BOOST gauge with C3 (10mm) nipple. Adjust the engine speed if necessary ~ HOWEVER ~ Adjusting Lo/Hi idle requires 3 initialization codes be reset (3008, 3009, 3010).** MM=MonMode-Code Actual After Standard Value Standard Value Units Measured Measurement conditions Value Adjusting D31/37X-21 D39X-21 High Free Idle, MM=2-01 ** 2100 2250 2300 - 2450 RPM Low Idle MM=2-01 ** 800 850 800 - 850 RPM High Idle + HST Relief(-01) No Adj. D31/37=2000 2200 RPM High Idle Blade+HST Relief Ref Only No Std. Value No Std. Value RPM, No Adj. Boost Pressure - mmHg MIN No Adj. D31 = 730 minimum 1010 minimum MmHg BOOST at conditions in c above. D37 = 860 minimum (using Gauge)

a. b. c. d. e.

D31.37.39ExPx21A KomStat II

4/18/2004

3) Measure and record all of the Cycle Times listed below. See the Shop Manual for procedural details.
Measurement conditions High Idle Blade Raise Blade Down Blade Tilt Left Blade Tilt Right Blade ANGLE Left Blade ANGLE Right Ripper (opt) UP Ripper DOWN Actual Values After Adjusting Standard Value D31/37X-21 1.8 2.2 1.2 1.6 1.5 1.9 1.5 1.9 2.1 3.1 2.1 3.1 Option Option Standard Value D39X-21 1.8 2.2 1.5 1.9 1.2 1.6 1.2 1.6 2.2 3.2 2.2 3.2 Option Option Units Measured

Seconds Seconds

4) Measure, record Track Tension

Right Track Initial__________________ Right after ADJUSTMENT___________ Left Track Initial ___________________

w w w . k o ma t s u p a r t s b o o k . c o m
Left after ADJUSTMENT ____________
STD VALUE = 20 30 mm 5) Measure and record all of the Travel Speeds listed below. See the Shop Manual for procedural details. *** OPTIONAL Measurement ~ use MM=11-52404+5 or 52406+7 to record Pump ccs/Rev(ref).
Measurement conditions High Idle MM=11-52404+52405 MM=11-52406+52407 Travel Speeds MM=2-04 **Travel Speed 1st **Travel Speed 2nd **Travel Speed 3rd Travel speed @950 RPM F1 R1 Actual Values F3 + + Km/h Actual Values R3 + + Km/h 3.2 3.6F 3.9 4.3R 5.3 5.9F 6.2 6.8R 8 9F/R No Propel 3.2 3.6F 3.9 4.3R 5.3 5.9F 6.2 6.8R 8 9F/R No Propel Standard Value D31/37EX/PX-21 Ref only Ref only D31/37-21 Standard Value D39EX/PX-21 Ref only Ref only D39-21 Units Measured CCs/Revolution CCs/Revolution Top Mount Or Running** Km/h Km/h Km/h Km/Hr

**Travel Deviation Check (Field): If suspected layout a 65 foot cord or rope, knotted at 32.5 foot point (1/2 way). This is equal to the 20 meter course needed for BOTH speed runs and deviation testing. Follow measuring instructions in Shop Manual and re-set Initial HST Pump MAP (MM=8-3001) system as needed, then retest.

D31.37.39ExPx21A KomStat II

4/18/2004

TOW Vlv closed

CAUTION! 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.

w w w . k o ma t s u p a r t s b o o k . c o m

Charge Safety Valve on Left Side below EPC CNs

Charge Reliefs Flushing Valves (no change)

6) Measure, record (and re-record, if adjusted) the Charge Oil pressure at the Monitor (MM=11-52501+52503). Adjust charge pump safety (aka Chg.Relief Valve) if necessary. Hi Idle, [see conditions]. Oil temp 50C.
Standard Value, MPa 2.74 3.34 ( 31+/- 3.0 Kg/cm2) 7) Adjust T/M charge reliefs (aka FlushingValves) if necessary. Hi Idle, BLOCKED UP Track Spinning. Oil temp 50C. (Use 60kg/cm2 gauge at 4 solenoid valve 10mm port). Charge Reliefs @ T/M Actual value Adjusted Value Standard Value, MPa(kg/cm2) 2.54 3.14 (26 - 32) LH Travel Mtr. [Steer R] 2.54 - 3.14(26 - 32) RH Travel Mtr. [Steer L] ( 29+/- 3.0Kg/cm2) Charge Pump SAFETY Neutral + High Idle Actual value Adjusted Value

D31.37.39ExPx21A KomStat II

4/18/2004

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-21A (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

**Note MM code 8-3016 will lock-in 3rd 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 Operators seat). Compare with the
standard values listed below, and adjust if necessary (work equipment relief only) This circuit not on MM. 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

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

Adjusted Value

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)

w w w . k o ma t s u p a r t s b o o k . c o m

D31.37.39ExPx21A KomStat II

4/18/2004

D31/37/39ExPx-21A 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
1. TVL PPC Valve PCCS = Electrical Potentiometers 2. Charge Safety

LOCATION
LH Operators Pedestal

FUNCTION
Direction & Steering command None

Test PORT Type & Location

HST Pump, LEFT SIDE center

Charge Pressure Limiter in N (neutral) = 31kg/cm2 Vents HST hot return oil from T/M to tank

Charge Port 10mm near solenoid valves Or MM11 Same as above (#2) B Or MM11 None MM=11-52501+52503 MM=11-52501+52503

LOCB

3. Charge Relief(s) aka Flushing Valves 4. HST AS Valve KS2 = Controller function

w w w . k o ma t s u p a r t s b o o k . c o m
None Engine RPM sensing (L=Off/M=ON/H=Off) HST Pump center case low on LH side
Top & Sides of center case (2 each) Lower WK.EQ.Valve Upper WK.EQ. Valve Lower WK.EQ.Valve Inside Unloader Valve Solenoid Valve Manifold Assembly Solenoid Valve Manifold Assembly Solenoid Valve Manifold Assembly Solenoid Valve Manifold Assembly

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

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

6. 7. 8. 9. HST Safety Wk.Eq. RELIEF Wk. Eq. SAFETY Unloader

Limits HST pump to 440kg/cm2 drive

Relieves HST 410-450kg/cm2 drive press. Limits Wk.Eq. to 210kg/cm2 Protects Blade ANGLE to 240kg/cm2 Dumps WK.EQ. 100% to cooler/Filter Cushions LS Pressure rise Releases park brake Delays Park Brake Apply to protect Speed selection PPC signal to T/M Speed selection PPC signal to T/M

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

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

D31.37.39ExPx21A KomStat II

4/18/2004

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

LOCATION
A Servo-In KS2 = NOT REQD

QTY
4

SIZE
NONE (was #6) EPC Blocks are ported for Servoin tests for troubleshooting Only. Block ports = 10 x 1.25 M10 x 1.25

B, C, D, E, F See Valve List

G, H, I, J Solenoid Bank

w w w . k o ma t s u p a r t s b o o k . c o mFFOR # 4 4

D31.37.39ExPx21A KomStat II

4/18/2004