D31 D37 EX PX-21 Shop Manual
D31 D37 EX PX-21 Shop Manual
D31 D37 EX PX-21 Shop Manual
• 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.
© 2004
All Rights Reserved
Printed in Japan 02-04 (01)
00-1
(7)
GENERAL
CONTENTS
No. of page
01 GENERAL ............................................................................................................................ 01-1
00-2 D31/37EX,PX-21
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
Proper service and repair is 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 ¤ is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.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, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
W h en a m an u a l is r e vis ed , a n e d itio n ma rk
VOLUMES
Shop manuals are issued as a guide to carrying out 123
( ....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
}
Electrical volume: Each issued as one
PAGES next to the CONTENTS page.
Attachments volume: · volume to cover all
models
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
4
number.
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3 tems. Caution necessary
Weight when selecting hoisting
3
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
Places that require special
2
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
Places to be coated with
5
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
6
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
item. Places where oil or water
Drain m u s t b e d r a i n e d , a nd
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
4
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol
¤
but sling with two or more ropes symmetrically
wound onto the load.
WIRE ROPES
Slinging with one rope may cause turning
1) Use adequate ropes depending on the
of the load during hoisting, untwisting of
weight of parts to be hoisted, referring to
the rope, or slipping of the rope from its
the table below:
original winding position on the load, which
can result in a dangerous accident.
Wire ropes
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
When hoisting a load with two or more ropes,
Rope diameter Allowable load the force subjected to each rope will increase
mm kN tons
with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6 vertically, at various hanging angles.
14 21.6 2.2 When two ropes sling a load vertically, up to
16 27.5 2.8 19.6 kN {2000 kg} of total weight can be sus-
18 35.3 3.6
pended. This weight becomes 9.8 kN {1000 kg}
20 43.1 4.4
22.4 54.9 5.6
when two ropes make a 120° hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150°.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
¤
tank.
Disconnection
1) Release the residual pressure from the hydrau-
lic tan k. Fo r d e tails , se e TES TIN G AN D
ADJUSTING, Releasing residual pressure from
hydraulic tank.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
★ Do not hold rubber cap portion (4).
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
★ For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
00-11
FOREWORD STANDARD TIGHTENING TORQUE
mm mm Nm kgm
mm mm Nm kgm
6 10 0
7.85 1.95 0.8 0 0.2
8 13 0
18.6 4.9 1.9 0 0.5
10 14 0
40.2 5.9 4.1 0 0.6
12 27 0
82.35 7.85 8.4 0 0.8
Sealing surface
mm mm Nm kgm
14 19 0
24.5 4.9 0
2.5 0.5
18 24 0
49 19.6 5 2 0
22 27 0
78.5 19.6 8 2 0
24 32 0
137.3 29.4 14 3 0
30 36 0
176.5 29.4 18 3 0
33 41 0
196.1 49 20 5 0
36 46 0
245.2 49 25 5 0
42 55 0
294.2 49 30 5 0
00-12
FOREWORD STANDARD TIGHTENING TORQUE
mm mm Nm kgm
10 14 0
65.7 6.8 0
6.7 0.7
12 17 112 9.80 11.5 1 0
16 22 279 290 28.5 3 0
02 14 0
34.3 4.9 3.5 0 0.5
03, 04 20 Varies depending 0
93.1 9.8 9.5 01
05, 06 24 on type of 0
142.1 19.6 14.5 02
10, 12 33 connector. 0
421.4 58.8 43 06
14 42 0
877.1 132.3 89.5 0 13.5
08 08 14 0
7.35 1.47 0.75 0.15 0
10 10 17 0
11.27 1.47 1.15 0.15 0
12 12 19 0
17.64 1.96 1.8 0.2 0
14 14 22 0
22.54 1.96 2.3 0.2 0
16 16 24 0
29.4 4.9 3 0.5 0
18 18 27 0
39.2 4.9 4 0.5 0
20 20 30 0
49 4.9 5 0.5 0
24 24 32 0
68.6 9.8 7 1 0
30 30 32 0
107.8 14.7 11 1.5 0
33 33 n 0
127.4 19.6 13 2 0
36 36 36 0
151.9 24.5 15.5 2.5 0
42 42 n 0
210.7 29.4 21.5 3 0
52 52 n 0
323.4 44.1 33 4.5 0
00-13
FOREWORD STANDARD TIGHTENING TORQUE
00-14
FOREWORD ELECTRIC WIRE CODE
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands
(mm2) (mm 2)
Circuits
Priori-
ty Classi- Charging Ground Starting Lighting Instrument Signal Other
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR n BW RW YR GW LW
2
Color White & Red n White & Black Red & White Rellow & Red Green & White Blue & White
Code WB n BY RB YB GR LR
3
Color White & Black n Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL n BR RY YG GY LY
4 Auxi-
liary
Color White & Blue n Black & Red Red & Yellow
Yellow &
Green
Green &
Yellow
Blue & Yellow
Code WG n n RG YL GB LB
5
Color White & Green n n Red & Green Yellow & Blue Green & Black Blue & Black
Code n n n RL YW GL n
6
Color n n n Red & Blue Yellow & White Green & Blue n
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
A
(1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line
A
from .
B
(2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down
B
from .
C
(3) Take the point where the two lines cross as . This point C gives the value when converting from mil-
limeters 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 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.
B
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
C
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
A 50
60
1.969
2.362
2.008
2.402
2.047
2.441
2.087
2.480
2.126
2.520
2.165
2.559
2.205
2.598
2.244
2.638
2.283
2.677
2.323
2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-16
FOREWORD CONVERSION TABLE
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
FOREWORD CONVERSION TABLE
0 1 2 3 4 5 6 7 8 9
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
0 1 2 3 4 5 6 7 8 9
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
FOREWORD CONVERSION TABLE
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
FOREWORD CONVERSION TABLE
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
FOREWORD CONVERSION TABLE
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22
01 GENERAL
SPECIFICATION DRAWING
D31EX-21 Power angle, power tiltdozer with ROPS canopy
D31PX-21 Power angle, power tiltdozer with ROPS canopy
D31EX-21 D31PX-21
Item Unit 400 mm 600 mm 600 mm
Single shoe Single shoe Swamp shoe
D37EX-21 D37PX-21
400 mm 600 mm 600 mm
Single shoe Single shoe Swamp shoe
5001 and up
Gear type x 1
40.2
20.6 {210}
3-spool valve x 1
WEIGHT TABLE
★ This Weight Table is for reference when handling components or when transporting the machine.
Unit: kg
Machine model D31EX-21 D31PX-21 D37EX-21 D37PX-21
Serial No. 50001 and up 5001 and up
Engine, damper assembly (not including water or
485 485 485 485
oil)
• Engine assembly 400 400 400 400
• Damper assembly 27 27 27 27
• Engine related parts (engine mount, air
58 58 58 58
cleaner, muffler, etc.)
Cooling assembly 177 177 176 176
• Radiator 71 71 71 71
• Oil cooler 33 33 33 33
• Charge air cooler 15 15 15 15
Fuel tank (not including fuel) 106 106 106 106
HST pump 124 124 124 124
HST motor (each side) 130 130 130 130
Final drive (each side) 162 162 162 162
Sprocket (each side) 26 26 26 26
Frame assembly 1,790 1,880 1,860 1,900
• Main frame 1,110 1,150 1,130 1,170
• Front underguard 8 8 8 8
• Rear underguard (including inspection cover) 41 41 41 41
• Idler assembly (each side) 93 93 93 93
• Recoil spring assembly (each side) 70 70 70 70
• Track roller (each side) 27 x 5 27 x 6 27 x 6 27 x 6
• Carrier roller (each side) 16 16 16 16
Track shoe assembly
• Single grouser shoe (400 mm) 520 x 2 520 x 2 560 x 2 560 x 2
• Single grouser shoe (600 mm) — 690 x 2 — 710 x 2
• Swamp shoe (600 mm) — 680 x 2 — 700 x 2
Hydraulic tank (not including hydraulic oil) 65 65 65 65
Hydraulic pump 6 6 6 6
Control valve
• 3-spool valve 16 16 16 16
• 4-spool valve (with ripper) 19 — 19 —
Unit: kg
Machine model D31EX-21 D31PX-21 D37EX-21 D37PX-21
Serial No. 50001 and up 5001 and up
Power angle tiltdozer assembly 945 1,020 990 1,050
• Blade 460 530 505 565
• Dozer frame 380 380 380 380
• Tilt cylinder assembly 20 20 20 20
• Angle cylinder assembly 22 x 2 22 x 2 22 x 2 22 x 2
Lift cylinder assembly 23 x 2 23 x 2 23 x 2 23 x 2
ROPS cab assembly 620 620 620 620
ROPS canopy assembly 310 310 310 310
Operator's seat 60 60 60 60
Floor frame assembly 220 220 220 220
Radiator guard assembly (including radiator
175 175 180 180
mask)
Engine hood assembly 40 40 40 40
Engine side cover assembly (including left,
60 60 60 60
right, top, bottom)
Front bracket (engine dividing wall) 45 45 45 45
Fender (left) 107 107 107 107
Fender (right) 113 113 113 113
SAE30
SAE10W
Engine oil pan 14 12.5
SAE10W-30
SAE15W-40
Cooling system
Coolant Add antifreeze 27
(including sub-tank)
COOLING SYSTEM
Specifications
ENGINE CONTROL
1. Decelerator pedal
2. Clutch
3. Fuel control lever
4. Fuel control cable
5. Decelerator cable
6. Governor lever
Outline
• The control of the engine speed is carried out
with fuel control lever (3) or decelerator pedal
(1).
POWER TRAIN
Outline
• The power generated by the 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 pis-
ton 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 accor-
dance with the movement of the swash plate of
each pump to match the movement of the steer-
ing, 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 mech-
an ism. It re d uc es th e sp ee d an d ro ta tes
sprocket (7) to drive track shoe (8).
Outline
• Steering, direction, and speed lever (2) changes
the volume of the HST pump continuously
through steering and directional PPC valve (3)
to steer and drive the machine forward or in
reverse.
• If steering, direction, and speed lever (2) is oper-
ated to FORWARD and slightly to the left, the
machine will turn gradually to the left. If the
lever is operated fully to the left, it will carry out a
spin turn to the left.
• Brake pedal (7) operates the spool of inching
valve (6) according to the amount that it is
depressed and actuates the left and right HST
hydraulic brakes simultaneously.
If brake pedal (7) is depressed fully, the left and
right HST hydraulic brakes are at actuated sud-
denly at the same time, and the signal from cen-
ter brake limit switch (5) is sent to the solenoid
valve. After the machine stops, the parking
brake built into the left and right HST motors is
actuated.
• Parking brake lever (1) is interconnected with
shut-off valve (4) and neutral safety and parking
brake limit switch (8), and acts also as the park-
ing brake.
D31EX-21 Serial No. 50098 and up D37EX-21 Serial No. 5105 and up
D31PX-21 Serial No. 50182 and up D37PX-21 Serial No. 5091 and up
Outline
• Steering, direction, and speed lever (2) changes
the volume of the HST pump continuously
through steering and directional PPC valve (3)
to steer and drive the machine forward or in
reverse.
• If steering, direction, and speed lever (2) is oper-
ated to FORWARD and slightly to the left, the
machine will turn gradually to the left. If the
lever is operated fully to the left, it will carry out a
pivot turn to the left.
• Brake pedal (7) operates the spool of inching
valve (6) according to the amount that it is
depressed and actuates the left and right HST
hydraulic brakes simultaneously.
If brake pedal (7) is depressed fully, the left and
right HST hydraulic brakes are at actuated sud-
denly at the same time, and the signal from cen-
ter brake limit switch (5) is sent to the solenoid
valve. After the machine stops, the parking
brake built into the left and right HST motors is
actuated.
• Parking brake lever (1) is interconnected with
shut-off valve (4) and neutral safety and parking
brake limit switch (8), and acts also as the park-
ing brake.
DAMPER
Unit: mm
No. Check item Criteria Remedy
Distance between HST pump mounting Standard size Repair limit
1 Adjust
surface and tip of boss 62.0 ±0.8
2 Wear of inner teeth of coupling (resin) Repair limit: 1.0 Replace
3. Coupling Outline
4. Boss • The damper reduces the torsional vibration
5. HST pump input shaft caused by variations in the engine torque, and
6. Cover acts to protect the engine and downstream drive
7. Flywheel 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.
SOLENOID VALVE
For 2nd selector, 3rd selector, HST brake selector, parking brake
Operation
FINAL DRIVE
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
Unit: mm
No. Check item Criteria Remedy
Backlash of No. 1 sun gear and Standard clearance Clearance limit
15
No. 1 planetary pinion 0.13 – 0.35 1.00
Backlash of No. 1 planetary
16 0.17 – 0.54 1.10
pinion and ring gear
Backlash of No. 1 planetary Replace
17 0.27 – 0.46 1.00
carrier and No. 2 sun gear
Backlash of No. 2 sun gear and
18 0.14 – 0.38 1.00
No. 2 planetary pinion
Backlash of No. 2 planetary
19 0.18 – 0.54 1.10
pinion and ring gear
HST PUMP
Type: HPV63 + 63
Structure
• This pump consists of a variable displacement
swash plate tandem piston pump, drive piston,
AS valve, safety-suction valve, charge safety
valve, cut-off valve, and charge pump.
Outline
• The rotation and torque transmitted to the pump • Rocker cam (4) has flat surface A, and shoe (7)
shaft is converted into hydraulic energy, and is always pressed against this surface while slid-
pressurized oil is discharged according to the ing in a circular movement. Rocker cam (4)
load. positions cradle bearing (3) between case (2)
• It is possible to change the discharge amount by and cylindrical surface B, and rocks.
changing the swash plate angle (normal ←→ 0 • Piston (8) carries out relative movement in the
←→ reverse discharge). axial direction inside each cylinder chamber of
cylinder block (9).
Structure • Cylinder block (9) seals the pressure oil to valve
• Cylinder block (9) is supported to shaft (1) by plate (10) and carries out relative rotation. This
spline (13). Shaft (1) is supported by front and surface is designed so that the oil pressure bal-
rear bearings (12) and (14). ance is maintained at a suitable level. The oil
• The tip of piston (8) is a concave ball, and shoe inside each cylinder chamber of cylinder block
(7) is caulked to it to form one unit. Piston (8) (9) is sucked in and discharged through valve
and shoe (7) form a spherical bearing. plate (10).
Operation
1. Operation of pump
SAFETY-SUCTION 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 pres-
sure 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.
Function
• This ensures the oil flow in in the HST closed
circuit. It prevents the charge oil flow from flow-
ing to the pump high-pressure side (discharge
side).
Operation
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 (A1<A2), and the seat
of sleeve (3C) opens.
• As a result, the charge pressure oil at port B
passes through this gap, flows to port PB, and
carries out the charge action in the HST circuit.
CUT-OFF VALVE
1. HST pump
2. Charge pump
3. Cut-off valve
3A. Spool
3B. Sleeve
3C. Seat
3D. Spring
3E. Adjustment screw
3F. Locknut
Function
• The cut-off valve is installed to the HST pump.
When the inside of the HST circuit reaches the
maximum pressure, it limits the basic pressure
of the HST pump PPC valve, reduces the swash
plate angle of the HST pump, and limits the
maximum pressure.
Operation
• Port A is connected to the HST circuit, port B is
connected to the travel PPC basic circuit, and
port C is connected to the HST pump drain. The
pressure oil at chamber B is sealed by spool
(3A) and sleeve (3B).
1. Charge pump
2. Charge safety valve
2A. Valve
2B. Spring
2C. Valve seat
2D. Poppet
2E. Spring
2F. Adjustment screw
3. Safety-suction valve
Function
• The charge safety valve is installed to the HST
pump. It limits the maximum pressure in the
charge circuit and protects the charge circuit.
Operation
• Port A is connected to the charge circuit, and
port B is connected through the HST pump case
to the tank drain circuit. The pressure oil passes
through orifice a in valve (2A) and fills chamber
C. Poppet (2D) is in tight contact with valve
seat (2C).
CHARGE PUMP
1. Side plate
2. Coupling
3. Shaft
4. Outer ring
5. Case
6. Inner rotor
7. Outer rotor
Outline
• The HST charge pump is built into the HST
pump and drives at the same time as the HST
pump.
• It supplies oil to the AS valve and HST pump
charge safety valve.
• The charge pump sucks in the oil from the
hydraulic tank.
Specifications
Type: Trochoid pump
Theoretical discharge amount: 35 cc/rev
Operation
• The charge pump is connected to the HST
pump shaft by coupling (2) and rotates inner
rotor (6) and outer rotor (7).
• When inner rotor (6) and outer rotor (7) rotate,
the capacity of chamber A increases, oil is
sucked in, the capacity of c hamber B
decreases, and the oil is discharged.
Operation
• When the center brake is depressed fully, sole-
noid valve (1) is turned OFF and the pressure
becomes the drain pressure.
• Because the oil pressure in the pilot circuit of the
HST brake valve (2) becomes the drain pres-
sure, HST brake valve (2) sends oil to pump
EB1 and EB2.
• Oil flows to PPC priority valve (3) through the
passage at the outside circumference of control
piston (6), pushes against spring (4), and moves
spool (5) to the left. The oil flows into piston
chamber a, so control piston (6) returns to Neu-
tral.
• When control piston (6) returns to Neutral, the
flow of oil from EB1 and EB2 to the PPC priority
valve is shut off. It is also connected to the
drain, so the control piston remains at Neutral.
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length Installed Installed Free Installed Replace spring
PPC priority
7 x OD length load length load if damaged or
valve spring
18.5 N/mm 14.8 N/mm deformed
19.9 x 10.6 16.1 —
{1.89 kg/mm} {1.50 kg/mm}
TOWING VALVE
Function
• These valves are built into the top surface of the
pump. There are two valves: the F valve (for the
left track) and the R valve (for the right track).
• If there is a failure on the machine, it is possible
to tow the machine by connecting the HST cir-
cuit.
• However, it is necessary to cancel the shaft
brake of the motor at the same time.
Operation
• To actuate the towing valves, loosen the two
valves a maximum of 4.5 mm (3 turns).
Function Operation
• This valve is mounted to the pump and controls
the parking brake (built into the travel motor). 1. Parking brake actuated
• It detects if the machine is stopped or traveling,
and controls the parking brake timer time to two • When the center brake is depressed fully, the
stages to prevent the parking brake from being limit switch is actuated.
actuated when the machine is traveling. • Solenoid valve (1) is turned OFF, the drain cir-
cuit opens, and the oil from the parking brake
passes through brake valve (2) and flows to the
drain circuit of solenoid valve (1).
• Therefore, the parking brake is actuated by the
spring force of the parking brake.
2) Parking brake actuated when machine has been 2. Parking brake released
traveling
• When the machine has been traveling, the CN • When the center brake is released, the limit
pressure is high, so it pushes against spring (4), switch is turned OFF.
and spool (3) moves up. • Solenoid valve (1) is turned ON and the oil pres-
• When this happens, opening a of the spool land sure rises.
is closed, so oil flows only from orifice (5). • The oil from solenoid valve (1) passes through
• Therefore, the timer time of the parking brake the brake valve and flows to the parking brake.
becomes longer and prevents the parking brake • Therefore, the parking brake cylinder is actuated
from being applied when the machine is travel- and the parking brake is released.
ing.
• When the traveling machine comes to a stop,
the actuation is the same as in Item 1) above.
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Parking Free length Installed Installed Free Installed Replace spring
6 brake valve x OD length load length load if damaged or
spring 14.4 N/mm 11.5 N/mm deformed
24.0 x 10.2 20.9 —
{1.47 kg/mm} {1.18 kg/mm}
AS VALVE
Function
• This valve is installed to the main piston pump. 1. Locknut
It reduces the pressure of the oil from the 2. Adjustment screw
charge pump and controls it to the basic pres- 3. Spring (plug end)
sure of the travel PPC valve for the travel speed 4. Spring (inside piston)
control. 5. Spring (valve end)
• This outputs an oil pressure proportional to the 6. Valve
change in the engine speed. 7. Orifice
Operation
• The oil from the charge pump passes through • At the same time, the pressure oil is reduced
orifice (7), and always flows from port B to the from the charge relief pressure of port B, and is
piston pump charge circuit. output to port C (valve area difference: D2>D1)
• When the oil from the charge pump passes to balance with F.
through orifice (7), a difference in pressure is • In other words, the control pressure matches the
formed between port A and port B. This differ- oil flow from the charge pump that increases or
ence in pressure is taken to chambers D and E decreases according to the engine speed, and
of valve (6) and generates a hydraulic propul- is output to port C.
sion force in direction F.
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Installed Installed
Free Installed Free
load load
1 Spring length length length
(N{kg}) (N{kg})
Replace spring
117.6 94.1
23.0 18.6 — if damaged or
{12} {9.6}
deformed
158.8 127
2 Spring 27.6 17.7 —
{16.2} {13.0}
29.4 23.5
3 Spring 31.3 23.8 —
{3.0} {2.4}
HST MOTOR
Model: KMV105
T: Drain
MA: (high pressure when traveling forward) Discharge port
MB: (high pressure when traveling in reverse) Discharge port
PB: Parking brake cancel signal port
PCMIN: 3rd spool q min signal port
PCMID: 3rd spool q mid signal port
T: Drain
MA: (high pressure when traveling forward) Discharge port
MB: (high pressure when traveling in reverse) Discharge port
PB: Parking brake cancel signal port
PCMIN: 3rd spool q min signal port
PCMID: 3rd spool q mid signal port
Specifications
Model: KMV105
Type: 3-speed variable displacement, bent axis type piston pump
Theoretical discharge amount: 1st speed: 105 cc/rev; 2nd speed: 68 cc/rev; 3rd speed: 52 cc/rev
Charge relief valve set pressure: 2.06 – 2.16 MPa {21 – 22 kg/cm2}
Parking brake release pressure: 0.78 – 1.27 MPa {8 – 13 kg/cm 2}
Principle
• Let us assume that the shaft of a disc is sup-
ported to allow the disc to rotate freely. If force F
is applied to this disc at an angle, this force F
can be divided into force F1 applied at a right
angle to th e face of the disc and force F2
applied in the direction of the circumference of
the disc. Force F1 pushes the disc in the axial
direction, and force F2 rotates the disc in a
clockwise direction.
• If force F' is applied to the disc instead of force
F, the force can be divided in the same way into
forces F'1 and F'2, and force F'2 will rotate the
disc in a counterclockwise direction.
Structure
• Seven pistons (2) are installed with a spherical
connection to the disc portion of output shaft (1).
Pistons (2) are at a certain angle to drive shaft
(1) and are fitted inside cylinder block (3).
• The angle of cylinder block (3) and pistons (2) is
decided by the ON-OFF signal of the control
pressure to PCMIN and PCMID of 3rd speed
valve (4). The combination is as shown in the
table.
PCMIN PCMID
Motor capacity MAX (1st) OFF OFF
Motor capacity MID (2nd) OFF ON
Motor capacity MIN (3rd) ON OFF
Operation
• The oil sent under pressure from the main piston
pump enters from the piston motor inlet port. Oil
pressure is formed at the rear face of piston (2),
and drive shaft (1) is rotated by angle Q of pis-
ton (2) and the cylinder block.
Motor capacity MAX (1st) Motor capacity MID (2nd) Motor capacity MIN (3rd)
Chamber A ON ON OFF
Chamber B ON OFF OFF
Chamber C ON ON ON
Function
• As shown in the diagram above, when the main • When the motor capacity is MAX (1st speed),
piston is at the lowest position, the motor capac- high pressure (self pressure) is being supplied
ity is MAX (1st speed). to all of chamber A, chamber B, and chamber C.
• When the main piston is at the highest position, However, the main piston is at the lowest posi-
the motor capacity is MIN (3rd speed). tion because the area on which the high pres-
• When it is at the midpoint position, the motor sure is acting in chamber B is larger than the
capacity is MID (2nd speed). A sub piston is area on which the high pressure is acting in
provided to produce the MID (2nd speed) motor chamber C. As a result, the combined force
capacity. generates a force in the downward direction.
• The area on which the self pressure is acting in
Operation chamber A and chamber B of the sub piston is
• The 3rd speed mechanism includes chamber A, the same. However, the high pressure (self
chamber B, and chamber C. Each of these pressure) acting on chamber A is greater than
chambers has its high pressure (self pressure) the high pressure acting on chamber B (the
turned ON (supplied) and OFF (drained) by the pressure is lower than the self pressure for
3rd speed valve, and the main piston and sub chamber A because the self pressure passes
piston are actuated. through a throttle), so the sub piston is pushed
down.
Function
• The pressure at the high-pressure side is
selected at HST main pressures MA and MB,
and is supplied to the 3rd speed spool.
• A shuttle valve is provided to select the pressure
from the low-pressure side and supply it to the
charge relief valve.
Operation
• With cross section D-D, HST main pressure MA
is taken to the left end face of the shuttle valve;
HST main pressure MB is taken to the right end
face of the shuttle valve.
• The position of the shuttle valve at cross section
D-D is the neutral position when the difference
in pressure between MA and MB is small. Pres-
sures MA and MB are both taken to the 3rd
speed spool.
• Because of the two check valves, a higher pres-
sure than MA and MB is taken to the spool of
the shuttle valve. In this case, the passage to
the charge relief valve is shut off.
• With the position of the shuttle valve at cross
section D-D, when MA>MB, 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<MB, the shuttle valve moves to the
left, MB is selected as the high pressure, and is
taken to the 3rd speed spool. MA is selected as
the low pressure and is taken to the charge
relief valve.
a: Check valve
b: Shuttle valve
c: Charge relief valve
Function Operation
• The HST main pressure at the high-pressure • When both PCMIN (3) and PCMID (4) are OFF,
side is selected by the shuttle valve and is taken 3rd speed spool (1) is at neutral, and pressure P
to portion P. is supplied to all of A, B, and C.
• 3rd speed spool (1) is moved by pressures • However, the supply to A passes through the
PCMIN and PCMID, so this pressure is supplied groove on the outside circumference of the
to rounds A, B, and C, which are connected to spool. Compared with this, the supply to B and
chamber A, chamber B, and chamber C of the C passes through flow control valve (2) built into
3rd speed mechanism. 3rd speed spool (1).
• As a result, the pressure at A is the highest and
the pressure at B and C is slightly lower.
[q = MAX (1st speed)]
• When PCMIN (3) is OFF and PCMID (4) is ON,
3rd speed spool (1) moves to the left and pres-
sure P is supplied to A and C, while B is drained
to the tank. [q = MID (2nd speed)]
• When PCMIN (3) is ON and PCMID (4) is OFF,
3rd speed spool (1) moves to the right and pres-
sure P is supplied to C, while A and B are
drained to the tank.
1. Spring
2. Spool
Function Operation
• The high pressure of the HST main pressure is • The oil inside spool (2) of the flow control valve
selected by the shuttle valve and is taken to por- flows W → X → Y. Portion X is a throttle.
tion P. • The position of the spool (area of opening at
• The pressure at this portion P changes from portion W) is determined by the differential pres-
approx. 2.45 MPa {25 kg/cm2} (charge pressure) sure between chamber Y and chamber Z and
to a maximum of 47.1 MPa {48 kg/cm 2}. the force of spring (1).
• The flow control valve supplies an almost con-
stant oil flow to B and C, regardless of the 1) When oil does not flow W → X → Y
change in pressure at portion P. • There is no difference in pressure between
• This constant oil flow can be set as desired by chamber Y and chamber Z, so spool (2) is
the diameter of the throttle and spring (1). moved to the right end by the force of spring (1),
and the area of opening at portion W becomes
the maximum.
1. Valve 4. Poppet
2. Spring 5. Spring
3. Valve seat 6. Adjustment screw
Function
• The charge relief valve is installed inside the 3rd
speed valve. It prevents the pressure at the
HST main low-pressure side (charge pressure)
selected by the shuttle valve from going above
the set pressure. At the same time, it relieves
the determined oil flow inside the motor case
and prevents the motor from overheating.
• In addition, it discharges the dirtiest oil inside the
HST main circuit to the outside and acts to keep
the inside of the HST main circuit clean.
Operation
• Port A connects the pressure at the HST main
low-pressure side (charge circuit) selected by
the shuttle valve.
• In addition, ports B and D are connected to the
tank drain circuit through the HST motor case.
• The pressure oil passes through orifice g in
valve (1) and fills chamber C. Poppet (4) is fit-
ted tightly to valve seat (5).
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Installed Installed
Free length Installed Free
Centering spring load load
1 x OD length length
(for P1, P2) (N{kg}) (N{kg})
35.3 28.2
33.8 x 15.5 31.9 —
{3.60} {2.88}
Metering spring 9.7 7.7
2 26.65 x 8.1 25.6 — Replace spring
(for P1, P2) {0.99} {0.79}
if damaged or
Centering spring 51.5 41.3 deformed
3 50.05 x 15.5 31.9 —
(for P3, P4) {5.26} {4.21}
Metering spring 2.4 1.9
4 25.82 x 8.25 25.6 —
(for P3, P4) {0.24} {0.19}
49.0 39.2
5 Notch spring 26.96 x 13.2 24.5 —
{5.0} {4.0}
Disc brake 1195.6 956.5
6 1.55 x 20.0 1.28 —
spring {122.0} {97.6}
Operation
1. At Neutral
D31EX-21 Serial No. 50098 and up D37EX-21 Serial No. 5105 and up
D31PX-21 Serial No. 50182 and up D37PX-21 Serial No. 5091 and up
★ Do not disassemble this valve. If it is disassembled, its output pressure characteristics and operating effort
characteristics need to be adjusted.
2) Steering operation
• Free return
(When a pivot turn is started, the operating
effort rises sharply.)
2) Steering operation
When the operation patterns are as shown in
the following table, the output ports have char-
acteristics A, B, and C shown below.
Output
port Port 1 Port 2 Port 3 Port 4
Operating
direction
3 Forward io Right B – C A
4 Forward io Left C A B –
5 Reverse io Right A C – B
6 Reverse io Left – B A C
Function
• The 1st, 2nd, and 3rd travel speeds are set by • If the load pressure becomes smaller when trav-
operating the button in the operator's compart- eling in 1st speed, it makes the motor capacity
ment. This actuates the electromagnetic valve smaller and shifts up to 2nd speed.
and inputs a signal to the 3rd speed selector • In this way, the towing force from 1st speed to
valve built into the travel motor. (Manual opera- 2nd speed is effectively used, so the ease of
tion) operation is improved.
• Compared with this, when the load pressure of
the HST pump becomes high when traveling in
2nd speed, the automatic gearshifting valve
automatically increases the motor capacity and
shifts down to 1st speed.
Operation
No. Travel mode HST pump load pressure Automatic gearshifting valve control
2
1 When traveling in 2nd speed PH < 35.3 MPa {360 kg/cm } Holds 2nd speed
2 When traveling in 2nd speed PH † 35.3 MPa {360 kg/cm } 2
Shifts down to 1st
2
3 When traveling in 1st speed PH > 12.7 MPa {130 kg/cm } Holds 1st speed
4 When traveling in 1st speed PH z 12.7 MPa {130 kg/cm } 2
Shifts up to 2nd
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free Installed Installed Free Installed Replace spring
7 Spring length length load length load if damaged or
142.1 N 135.2 N deformed
35.9 30 —
{14.5 kg} {13.8 kg}
INCHING VALVE
1. Inching valve
2. Shaft
3. Center brake pedal
Function Operation
• Shaft (2) of inching valve (1) reduces the basic • Inching valve (1) is interconnected with center
pressure of the speed control valve (travel PPC brake pedal (3), and shaft (2) rotates. The basic
valve) according to the angle of rotation, and pressure of the travel PPC valve closes the pas-
controls the HST hydraulic braking force. sage from AS to PC and opens the passage
• When center brake pedal (3) is depressed, inch- from PC to T, so PC is gradually drained to the
ing valve (1) closes the passage from AS to PC tank. When the brake pedal is depressed fully,
and opens the passage from PC toT. the basic pressure of the travel PPC valve
closes the passage from AS to PC completely
and opens the passage from PC toT.
FRAME ASSEMBLY
★ The drawing shows the D31PX-21.
1. Engine mount
2. Frame assembly
3. Rear underguard
4. Front underguard
Outline
• A hull frame structure with the main frame, track
frame, and underguard forming one unit is used.
Unit: mm
No. Check item Criteria Remedy
Name of Standard Tolerance Standard Clearance
cylinder size Shaft Hole clearance limit
–0.025 +0.132 0.031 –
Lift φ 40 0.519
Clearance between –0.087 +0.006 0.219
1
piston rod and bushing –0.025 +0.152 0.032 –
Tilt φ 45 0.539
–0.087 +0.007 0.239
–0.025 +0.132 0.031 –
Angle φ 40 0.519
–0.087 +0.006 0.219
–0.025 +0.142 0.105 –
Lift φ 45 1.0
–0.064 +0.080 0.206 Replace
Clearance between bushing
–0.025 +0.003 0.010 –
2 piston rod support Tilt φ 45 0.5
–0.064 –0.015 0.067
shaft and bushing
–0.025 +0.003 0.010 –
Angle φ 40 0.5
–0.087 –0.015 0.090
–0.025 +0.142 0.105 –
Lift φ 45 1.0
–0.064 +0.080 0.206
Clearance between
–0.025 +0.003 0.010 –
3 cylinder bottom support Tilt φ 45 0.5
–0.064 –0.015 0.067
shaft and bushing
–0.025 +0.003 0.010 –
Angle φ 40 0.5
–0.087 –0.015 0.090
Lift 637 ± 63.5 Nm {65 ± 6.5 kgm}
Tightening torque of
4 Tilt 677 ± 67.5 Nm {69 ± 6.9 kgm}
cylinder head
Angle 569 ± 57.0 Nm {58 ± 5.8 kgm}
Tighten
Lift 785 ± 78.5 kNm {80 ± 8 kgm} (Width across flats: 46 mm)
Tightening torque of
5 Tilt 1.08 ± 0.11 kNm {110 ± 11 kgm} (Width across flats: 50 mm)
cylinder piston lock nut
Angle 785 ± 78.5 kNm {80 ± 8 kgm} (Width across flats: 46 mm)
CONTROL VALVE
Outline
P: Pump port
T: Tank port (to tank)
C: Cooler port (oil cooler)
(1/5)
(2/5)
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Installed Installed
Free length Installed Free
load load
12 Spool return spring (lift RAISE) x OD length length
(N{kg}) (N{kg})
34.0 26.9
19.34 x 17.2 18.57 —
{3.43} {2.74}
34.0 26.9 Replace
13 Spool return spring (lift RAISE) 11.28 x 12.6 8.73 —
{3.43} {2.74} spring if
55.9 44.7 damaged or
14 Spool return spring (tilt) 32.0 x 17.4 28.5 — deformed
{5.7} {4.56}
24.5 19.6
15 Spool return spring (angle, ripper) 29.3 x 17.6 28.5 —
{2.5} {2.0}
13.7 11.0
16 Spool return spring (lift LOWER) 17.05 x 17.2 16.5 —
{1.4} {1.12}
188.8 151.0
17 Spool return spring (lift FLOAT) 40.73 x 17.4 28.5 —
{19.25} {15.4}
(3/5)
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Installed Installed
Free length Installed Free
Pressure compensation valve spring load load
12 x OD length length
(flow control valve end) (N{kg}) (N{kg})
7.45 5.96
15.4 x 6.0 8.0 —
{0.76} {0.61} Replace
Pressure compensation valve spring 6.86 5.49 spring if
13 23.0 x 8.4 15.0 —
(reducing pressure valve end) {0.7} {0.56} damaged or
70.6 56.49 deformed
14 Unload valve spring 37.6 x 18.0 18.0 —
{7.2} {5.76}
3.43 2.75
15 LS selector piston spring 18.72 x 9.3 16.0 —
{0.35} {0.28}
98.1 78.5
16 Cooler bypass valve spring 43.8 x 13.2 29.0 —
{10.0} {8.0}
(4/5)
(5/5)
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit Replace
Check valve spring Free length Installed Installed load Free Installed load spring if
13
(angle, ripper) x OD length (N{kg}) length (N{kg}) damaged or
21.9 x 5.0 15.8 1.96 {0.2} — 1.57 {0.16} deformed
CLSS
1. Outline of CLSS
Features
CLSS stands for Closed center Load Sensing Sys-
tem, and has the following features.
Structure
• The CLSS consists of a gear pump, control
valve, and the actuators.
2. Basic principle
2) Unload valve
Function
• When the control valve is at HOLD, pump dis-
charge amount Q is all relieved to the tank cir-
cuit. This reduces the pressure loss from the
pump to the tank.
Operation
• At the left end of spool (1), pump pressure PP2
( PP1) is acting on area S1, and at the right end
of spool (1), pump pressure PP3 and the force
of spring (2) are acting on area S2. In addition,
LS pressure PLS is acting on area S3.
• When the control valve is at HOLD, LS pressure
PLS is not generated. Piston (3) is set at the left
position by spring (4), pressure PP3 is con-
nected to TS, and becomes much lower than
pump pressure PP1.
• Therefore, pump pressure PP2 ( PP1) is set
only by the force of spring (2) to a maximum of
0.53 MPa {5.4 kg/cm 2}.
Function
• When the control valve is operated, an amount
of oil corresponding to the opening of the spool
flows to the actuator.
• When the control valve is operated, pump dis-
charge pressure PP1 is set to LS pressure PLS
+ 1.5 MPa {15 kg/cm 2}.
Operation
• The operation is the same regardless of whether
the control valve is being fully operated or used
for fine control.
• When more than one actuator is used that the
same time, and the condition becomes pump
discharge < actuator demand, spool (1) moves
further to the left to the end of the stroke.
• As a result, pump circuits PP1 and PP2 and
tank circuit T are shut off, and all the pump dis-
charge amount flows to the actuators.
• When the control valve is operated fully, LS
pressure PLS is generated and acts on area S1
at the left end of piston (3) and area S3 at the
right end of spool (1).
• When LS pressure PLS reaches 0.07 MPa {0.7
kg/cm2}, piston (3) overcomes the force of spring
(4) and moves fully to the right.
• As a result, the connection between the spring
chamber of spring (2) and port TS is cut off and
the condition becomes PP1 = PP2.
• S pool (1) m oves to the left so that the difference
in pressure betw een pum p pressure PP1 and LS
pressure PLS becom es 1.5 M P a {15 kg/cm 2 }.
• In addition, when the control valve is at neutral,
the oil being drained to the circuit T all flows to
the actuators.
4) LS bypass plug
Function
• It releases the residual pressure of LS pressure
PLS.
• It makes the speed of the rise in pressure of LS
pressure PLS more gentle. In addition, with this
discarded throttled flow, it creates a pressure
loss in the throttled flow of the spool or shuttle
valve, and increases the stability by lowering
the effective LS differential pressure.
Operation
• The pressurized oil for LS circuit PLS passes
from clearance filter a (formed by the clearance
between LS bypass plug (1) and the valve body)
through orifice b and flows to seal drain circuit
TS.
5) Introduction of LS pressure
Unit: mm
No. Check item Criteria Remedy
Name of Standard Tolerance Standard Clearance
cylinder size Shaft Hole clearance limit
–0.025 +0.132 0.031 –
Lift φ 40 0.519
Clearance between –0.087 +0.006 0.219
1
piston rod and bushing –0.025 +0.152 0.032 –
Tilt φ 45 0.539
–0.087 +0.007 0.239
–0.025 +0.132 0.031 –
Angle φ 40 0.519
–0.087 +0.006 0.219
–0.025 +0.142 0.105 –
Lift φ 45 1.0
–0.064 +0.080 0.206 Replace
Clearance between bushing
–0.025 +0.003 0.010 –
2 piston rod support Tilt φ 45 0.5
–0.064 –0.015 0.067
shaft and bushing
–0.025 +0.003 0.010 –
Angle φ 40 0.5
–0.087 –0.015 0.090
–0.025 +0.142 0.105 –
Lift φ 45 1.0
–0.064 +0.080 0.206
Clearance between
–0.025 +0.003 0.010 –
3 cylinder bottom support Tilt φ 45 0.5
–0.064 –0.015 0.067
shaft and bushing
–0.025 +0.003 0.010 –
Angle φ 40 0.5
–0.087 –0.015 0.090
Lift 637 ± 63.5 Nm {65 ± 6.5 kgm}
Tightening torque of
4 Tilt 677 ± 67.5 Nm {69 ± 6.9 kgm}
cylinder head
Angle 569 ± 57.0 Nm {58 ± 5.8 kgm}
Tighten
Lift 785 ± 78.5 kNm {80 ± 8 kgm} (Width across flats: 46 mm)
Tightening torque of
5 Tilt 1.08 ± 0.11 kNm {110 ± 11 kgm} (Width across flats: 50 mm)
cylinder piston lock nut
Angle 785 ± 78.5 kNm {80 ± 8 kgm} (Width across flats: 46 mm)
CONTROL VALVE
Outline
P: Pump port
T: Tank port (to tank)
C: Cooler port (oil cooler)
(1/5)
(2/5)
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Installed Installed
Free length Installed Free
load load
12 Spool return spring (lift RAISE) x OD length length
(N{kg}) (N{kg})
34.0 26.9
19.34 x 17.2 18.57 —
{3.43} {2.74}
34.0 26.9 Replace
13 Spool return spring (lift RAISE) 11.28 x 12.6 8.73 —
{3.43} {2.74} spring if
55.9 44.7 damaged or
14 Spool return spring (tilt) 32.0 x 17.4 28.5 — deformed
{5.7} {4.56}
24.5 19.6
15 Spool return spring (angle, ripper) 29.3 x 17.6 28.5 —
{2.5} {2.0}
13.7 11.0
16 Spool return spring (lift LOWER) 17.05 x 17.2 16.5 —
{1.4} {1.12}
188.8 151.0
17 Spool return spring (lift FLOAT) 40.73 x 17.4 28.5 —
{19.25} {15.4}
(3/5)
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Installed Installed
Free length Installed Free
Pressure compensation valve spring load load
12 x OD length length
(flow control valve end) (N{kg}) (N{kg})
7.45 5.96
15.4 x 6.0 8.0 —
{0.76} {0.61} Replace
Pressure compensation valve spring 6.86 5.49 spring if
13 23.0 x 8.4 15.0 —
(reducing pressure valve end) {0.7} {0.56} damaged or
70.6 56.49 deformed
14 Unload valve spring 37.6 x 18.0 18.0 —
{7.2} {5.76}
3.43 2.75
15 LS selector piston spring 18.72 x 9.3 16.0 —
{0.35} {0.28}
98.1 78.5
16 Cooler bypass valve spring 43.8 x 13.2 29.0 —
{10.0} {8.0}
(4/5)
(5/5)
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit Replace
Check valve spring Free length Installed Installed load Free Installed load spring if
13
(angle, ripper) x OD length (N{kg}) length (N{kg}) damaged or
21.9 x 5.0 15.8 1.96 {0.2} — 1.57 {0.16} deformed
CLSS
1. Outline of CLSS
Features
CLSS stands for Closed center Load Sensing Sys-
tem, and has the following features.
Structure
• The CLSS consists of a gear pump, control
valve, and the actuators.
2. Basic principle
2) Unload valve
Function
• When the control valve is at HOLD, pump dis-
charge amount Q is all relieved to the tank cir-
cuit. This reduces the pressure loss from the
pump to the tank.
Operation
• At the left end of spool (1), pump pressure PP2
( PP1) is acting on area S1, and at the right end
of spool (1), pump pressure PP3 and the force
of spring (2) are acting on area S2. In addition,
LS pressure PLS is acting on area S3.
• When the control valve is at HOLD, LS pressure
PLS is not generated. Piston (3) is set at the left
position by spring (4), pressure PP3 is con-
nected to TS, and becomes much lower than
pump pressure PP1.
• Therefore, pump pressure PP2 ( PP1) is set
only by the force of spring (2) to a maximum of
0.53 MPa {5.4 kg/cm 2}.
Function
• When the control valve is operated, an amount
of oil corresponding to the opening of the spool
flows to the actuator.
• When the control valve is operated, pump dis-
charge pressure PP1 is set to LS pressure PLS
+ 1.5 MPa {15 kg/cm 2}.
Operation
• The operation is the same regardless of whether
the control valve is being fully operated or used
for fine control.
• When more than one actuator is used that the
same time, and the condition becomes pump
discharge < actuator demand, spool (1) moves
further to the left to the end of the stroke.
• As a result, pump circuits PP1 and PP2 and
tank circuit T are shut off, and all the pump dis-
charge amount flows to the actuators.
• When the control valve is operated fully, LS
pressure PLS is generated and acts on area S1
at the left end of piston (3) and area S3 at the
right end of spool (1).
• When LS pressure PLS reaches 0.07 MPa {0.7
kg/cm2}, piston (3) overcomes the force of spring
(4) and moves fully to the right.
• As a result, the connection between the spring
chamber of spring (2) and port TS is cut off and
the condition becomes PP1 = PP2.
• S pool (1) m oves to the left so that the difference
in pressure betw een pum p pressure PP1 and LS
pressure PLS becom es 1.5 M P a {15 kg/cm 2 }.
• In addition, when the control valve is at neutral,
the oil being drained to the circuit T all flows to
the actuators.
4) LS bypass plug
Function
• It releases the residual pressure of LS pressure
PLS.
• It makes the speed of the rise in pressure of LS
pressure PLS more gentle. In addition, with this
discarded throttled flow, it creates a pressure
loss in the throttled flow of the spool or shuttle
valve, and increases the stability by lowering
the effective LS differential pressure.
Operation
• The pressurized oil for LS circuit PLS passes
from clearance filter a (formed by the clearance
between LS bypass plug (1) and the valve body)
through orifice b and flows to seal drain circuit
TS.
5) Introduction of LS pressure
Function
• During compound operations, if the load pres-
sure becomes lower than the other actuator and
the oil flow tries to increase, compensation is
received. (When this happens, the other actua-
tor being used for compound operation (right
side) is at a higher load than the actuator on
this side (left side).)
Operation
• If the load pressure of the other actuator (right • Flow control valve (2) and pressure reducing
side) becomes higher during compound opera- valve (1) are balanced in position where the dif-
tions, the oil flow in actuator circuit A on this side ference in pressure between PLS and PA acting
(left side) tries to increase. on both ends of pressure reducing valve (2) and
• If this happens, the LS pressure PLS of the the pressure loss between PP and PPA on both
other actuator acts on spring chamber PLS1, sides of flow control valve (2) are the same.
and pressure reducing valve (1) and flow control • In this way, the pressure difference between
valve (2) are pushed to the left. upstream pressure PPA and downstream pres-
• Flow control valve (2) throttles the area of open- sure PA of both spools used during compound
in g b e t w e e n p u m p c i r c u i t P P a n d s p o o l operations is the same, so the pump flow is
upstream PPA, and pressure loss is generated divided in proportion to the area of opening of
between PP and PPA. notch a of each spool.
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x Installed Installed load Installed load
Centering spring Free length
11 OD length (N{kg}) (N{kg})
(for port P1, P2)
80.8 64.6
50.05 x 15.5 31.9 —
{8.24} {6.59}
Metering spring 16.7 13.7
12 26.8 x 8.15 24.6 —
(for port P1, P2) {1.7} {1.4}
Centering spring 62.8 50.0
13 50.35 x 15.5 31.9 —
(for port P3) {6.4} {5.1}
Metering spring 9.0 7.2
14 26.53 x 8.15 24.6 — Replace
(for port P3) {0.92} {0.73}
spring if
Centering spring 137.4 109.9 damaged or
15 52.06 x 15.5 31.6 —
(for port P4) {14.0} {11.2} deformed
Metering spring 9.02 7.22
16 26.0 x 8.15 24.9 —
(for port P4) {0.92} {0.74}
Detent spring 159.3 127.5
17 20.39 x 19.5 13.0 —
(for port P4) {16.25} {13.0}
Detent spring 38.44 30.79
18 45.36 x 7.5 26.0 —
(for port P3) {3.92} {3.14}
Centering spring 19.6 15.7
19 33.42 x 15.5 23.2 —
(for port P5, P6) {2.0} {1.6}
Metering spring 15.7 12.6
20 21.5 x 8.15 20.7 —
(for P5, P6) {1.6} {1.28}
Operation
1. At Neutral
WORK EQUIPMENT
WORK EQUIPMENT
★ The drawing shows the D31PX-21.
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between frame connecting size Shaft Hole clearance limit
1
pin and bushing +0.174 0.130 –
1.2
–0.030 +0.100 0.250
φ 60
Clearance between frame connecting –0.076 +0.300 0.130 –
2 1.0
pin and frame bracket +0.100 0.376
Clearance between lift cylinder bottom +0.142 0.105 –
3 1.0
pin and bushing –0.025 +0.080 0.206
φ 45
Clearance between lift cylinder bottom –0.064 +0.039 0.025 –
4 1.0
pin and frame bracket 0 0.103
Clearance between lift cylinder head +0.142 0.105 –
5 1.0
pin and bushing –0.025 +0.080 0.206
φ 45
Clearance between lift cylinder head –0.064 +0.400 0.125 –
6 1.0
pin and frame bracket +0.100 0.464
Clearance between angle cylinder +0.003 0.010 –
7 0.5
bottom pin and bushing –0.025 –0.015 0.067
φ 40
Clearance between angle cylinder –0.087 +0.400 0.125 –
8 1.0
bottom pin and frame bracket +0.100 0.487
Replace
Clearance between angle cylinder +0.003 0.010 –
9 0.5
head pin and bushing –0.025 +0.015 0.090
φ 40
Clearance between angle cylinder –0.087 +0.400 0.125 –
10 1.0
head pin and blade bracket +0.100 0.487
Clearance between tilt cylinder bottom +0.003 0.010 –
11 0.5
pin and bushing –0.025 –0.015 0.067
φ 45
Clearance between tilt cylinder bottom –0.064 +0.400 0.125 –
12 1.0
pin and frame bracket +0.100 0.464
Clearance between tilt cylinder head +0.003 0.010 –
13 0.5
pin and bushing –0.025 –0.015 0.067
φ 45
Clearance between tilt cylinder head –0.064 +0.400 0.125 –
14 1.0
pin and blade bracket +0.100 0.464
Clearance between pitching rod pin +0.039 0.025 –
15 0.5
and bushing –0.025 0 0.103
φ 40
Clearance between pitching rod pin –0.064 +0.300 0.125 –
16 1.0
and frame bracket +0.100 0.364
Clearance between blade spherical –0.250 +1.500 0.250 –
17 S φ 70 —
portion and pitching rod cap –0.750 0 2.250
Clearance between blade center
18 S φ 110 — — 0.5 —
spherical portion and frame cap Adjust
Standard shim thickness at blade shim
19 8.0
center spherical portion and frame cap
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Height of cutting edge
160 110
2 Height of end bit 160 110
D31EX 380 — Replace
D31PX 380 —
3 Width of end pit
D37EX 370 —
D37PX 405 —
CAB RELATED
AIR CONDITIONER PIPING
1. Battery Function
2. Battery relay • Neutral safety, parking brake limit switch (5) is
3. Starting switch linked to parking brake lever (6), so if parking
4. Fuse box brake lever (6) is not set to the LOCK position,
5. Neutral safety, parking brake limit switch the starting circuit is not switched ON and the
6. Parking brake lever engine cannot be started.
7. Neutral safety, parking brake relay • When parking brake lever (6) is set to the LOCK
8. Safety relay position, the steering, direction, and speed lever
9. Starting motor is automatically returned to the Neutral position.
10. Engine stop solenoid
1. Battery Function
2. Battery relay • Each time shift UP switch (5) on the steering,
3. Fuse box direction, and speed lever is pressed, the trans-
4. Shift controller mission shifts up 1st → 2nd → 3rd; each time
5. Shift UP switch shift DOWN switch (6) is pressed, the transmis-
6. Shift DOWN switch sion shifts down 3rd → 2nd → 1st. The speed
7. Monitor panel range display lamp on monitor panel (7) lights
8. 2nd speed selector solenoid valve up according to the transmission speed.
9. 3rd speed selector solenoid valve (When the starting switch is turned ON, it auto-
10. L.H. HST motor matically displays 1st.)
11. R.H. HST motor • If any abnormality occurs in the shift signal
12. Engine (short circuit in wiring, etc.), the existing speed
13. Charge pump range is held. If there is an abnormal drop in the
voltage of the power supply (less than 16 – 18
V), the speed range is held in 1st.
1. Battery Function
2. Battery relay • Neutral safety, parking brake limit switch (4) is
3. Fuse box interconnected with parking brake lever (5). If
4. Neutral safety, parking brake limit switch parking brake lever (5) is not set to the FREE
5. Parking brake lever position, parking brake (9) is not released, and
6. Center brake limit switch the machine cannot travel.
7. Brake pedal • Center brake limit switch (6) is interconnected
8. Parking brake solenoid valve with brake pedal (7). If brake pedal (7) is
9. Parking brake depressed fully, parking brake (9) is applied.
10. Engine
11. Charge pump
1. Controller
2. Connector
Input/output signals
AMP040-16P [CN-41]
Input/output
Pin No. Signal Name
signal
1 Power source (24 V) —
2 GND —
3 Shift UP switch N. O. Input
4 Shift UP switch N. C. Input
5 Shift DOWN switch N. O. Input
6 Shift DOWN switch N. C. Input
7 Shift switch power source (12 V) —
8 Speed range display lamp (1st) Output
9 Speed range display lamp (2nd) Output
10 Speed range display lamp (3rd) Output
11 2nd speed selector solenoid valve Output
12 2nd speed selector solenoid valve Output
SAFETY RELAY
1. Relay body
MONITOR PANEL
★ See section on monitor system.
MONITOR SYSTEM
MONITOR PANEL
Outline
• The monitor panel consists of the monitor portion that issues a warning when there is any abnormality in the
machine, the gauges that always display the condition of the machine, and the service meter.
• Inside the monitor, there is the CPU (Central Processing Unit). This processes the data and outputs or dis-
plays the result.
• Lamps are used for the monitor display.
• Analog meters with indicators are used for the gauge display.
Input/output signal
Operation
DETAILS OF GAUGES
SENSORS
• The signals from the sensors are input directly to the panel.
• There are two types of sensors: contact type and resistance type.
• The contact type sensors always have one side connected to the chassis ground.
Category of display Type of sensor Method of sensor When normal When abnormal
Engine oil pressure Contact OFF (open) ON (closed)
Caution
Charge filter clogging Contact OFF (open) ON (closed)
Coolant temperature Resistance — —
Gauges HST oil temperature Resistance — —
Fuel level Resistance — —
1. Plug Function
2. Contact ring • The engine oil pressure sensor is installed to the
3. Contact engine cylinder block. Diaphragm (4) detects
4. Diaphragm the oil pressure, and if it goes below the speci-
5. Spring fied pressure, the switch is turned ON, the relay
6. Terminal is actuated, the output is turned OFF, and the
caution lamp lights up.
1. Connector Function
2. Plug • These sensors are installed to the engine cylin-
3. Thermistor der block and pump suction pipe. Any change
in temperature is detected as a change in the
resistance of thermistor (3), and the signal is
sent to the monitor panel to display the tempera-
ture.
1. Float Function
2. Arm • The fuel level sensor is installed to the fuel tank,
3. Connector and the float (1) moves up and down according
4. Variable resistance to the amount of fuel remaining in the tank. The
5. Contact movement of float (1) actuates variable resistor
6. Body (4) through arm (2), and the signal is sent to
the monitor panel to display the fuel level.
TROUBLESHOOTING ..........................................................................................................................20-201
★ Note the following when making judgements using the standard value tables for testing, adjusting, or trou-
bleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the
results of various tests. It is used for reference together with the state of repair and the history of operation
to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
k When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert the safety
pins, and use blocks to prevent the machine from moving.
k When carrying out work together with other workers, always use signals and do not let unauthorized people
near the machine.
k When checking the water level, always wait for the water to cool down. If the radiator cap is removed when
the water is still hot, the water will spurt out and cause burns.
k Be careful not to get caught in the fan, fan belt or other rotating parts.
D31/37EX,PX-21 20-1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
D31EX-21:50001 and up
Machine serial No.
D31PX-21:50001 and up
Engine SAA4D102E-2
Oil temperature Whole speed range (inside oil pan) ºC 90–110 120
20-2 D31/37EX,PX-21
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
D37EX-21, D37PX-21
D37EX-21:5001 and up
Machine serial No.
D37PX-21:5001 and up
Engine SAA4D102E-2
Boost pressure HST relief + work equipment relief kPa Min. 115 103
{mmHg} {Min. 860} {770}
Oil temperature Whole speed range (inside oil pan) ºC 90–110 120
D31/37EX,PX-21 20-3
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
• Center of pedal
• Engine stopped
Decelerator pedal 66±10 66±10
• Center of pedal
Neutral–Raise 47±10 47±20
• Engine stopped Neutral–Lower 47±10 47±20
Work equipment
• Center of lever knob Neutral–Float 71±10 71±20
control lever
• Angle:Incline of lever Neutral–LH, RH tilt 52±10 52±20
Neutral–LH, RH angle Degree 15±3 15±6
Low idling→ 29.4±19.6 58.8
• Engine stopped High idling {3.0±2} {6.0}
Fuel control lever • 20 mm from end of
lever knob High idling 68.6±19.6 108
→Low idling {7±2} {11.0}
• Engine:low idling 19.6 – 67.6 11.8 – 84.3
Directional lever N–Forward, reverse
• Center of lever knob {2 – 6.9} {1.2 – 8.6}
6.9 – 12.7 14.7
Shift up
• Engine:low idling {0.7 – 1.3} {1.5}
Gear shift switch
• Button switch 6.9 – 12.7 14.7
Shift down
{0.7 – 1.3} {1.5}
• Engine:low idling 17.6 – 41.2 10.8 – 51.9
Operating force
Travel PPC
PPC valve output
20-4 D31/37EX,PX-21
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
D31/37EX,PX-21 20-5
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
20m
10m BKP00107
★ Measure dimension x
Measure
the dis-
tance the
Hydraulic drift of travel m Max. 3.6 Min. 4.0
machine
• Engine: full throttle moves in 1
• Hydraulic oil temperature: 45–55ºC minute
• Travel lever : neutral
• Speed range: 1st speed
• Safety lock lever : FREE
• Stop machine on 20º slope.
20-6 D31/37EX,PX-21
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
Lift
Ground sec.
Tilt
Angle
LH
2.6±0.5 3.3
angle
Blade angle
RH angle fully
RH
★ Raise blade 300 mm from ground 2.6±0.5 3.3
angle
• Machine on level ground
• Engine: full throttle
• Hydraulic oil temperature: 40–60ºC
Hydraulic
mm/
drift of work Blade Max. 50 Max. 50
15min
equipment
D31/37EX,PX-21 20-7
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
Hydraulic
mm/
drift of work Blade tilt Max. 100 Max. 100
★ Tilt blade fully and contact ground. 15min
equipment
• Machine on level ground
• Controll lever in Neutral
Work equipment
• Engine stopped
• Hydraulic oil temperature: 40–60ºC
• Start to measure immediately after setting in
position.
• Measure the amount of hydraulic drift for the
next 15 minutes.
Lift cylinder • Engine: full throttle 1.6 6.5
• Hydraulic oil temperature: 45–55ºC
Leakage of cc/
Tilt cylinder • Fully extend piston rod of cylinder to be 1.6 6.5
cylinder min.
measured, disconnect head side hose.
Angle cylinder • Amount of leakage after relieved 1 minute. 1.5 6.0
• Engine: full throttle
• Hydraulic oil temperature: 45–55ºC
• Lower blade from max. RAISE position and
Blade time lag sec. 1.0 Max.1.5
measure time taken from point where blade
contacts ground to point where idlers rise
from ground.
20-8 D31/37EX,PX-21
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
1) Turn starting
Power train oil Sensor switch OFF and
teperature resistance value insert dummy
30ºC Approx. 205 Ω resistance or
60ºC Approx. 56 Ω measure resist-
ance value of
80ºC Approx. 30 Ω
Machine monitor
sensor.
Monitor panel
CN13 Measure
Fuel level
(1)–(2) resistance
D31/37EX,PX-21 20-9
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
Min.
Charge filter clog- 0.2 MPa Continuity
— Continuity Differential {2 kg/cm2}
ging sensor
pressure of
filter Max.
No
0.2 MPa
Continuity
{2 kg/cm2}
20-10 D31/37EX,PX-21
TESTING AND ADJUSTING
D31/37EX,PX-21 20-101
TESTING AND ADJUSTING TOOLS LIST FOR TESTING AND ADJUSTING
20-102 D31/37EX,PX-21
TESTING AND ADJUSTING MEASURING ENGINE SPEED
D31/37EX,PX-21 20-103
TESTING AND ADJUSTING MEASURING EXHAUST COLOR
Measuring with H1
1. Install filter paper to tool H1.
2. Insert exhaust gas suction adapter in the
exhaust pipe. Heighten the engine speed
sharply and operate the handle of tool H1 simul-
taneously to have the filter paper absorb the
exhaust gas.
3. Remove the filter paper and compare it with the
attached scale.
2. Connect the probe hose, accelerator switch out-
let, and air hose to H2.
★ Limit the applied air pressure to 1.47 MPa
{15 kg/cm2}.
3. Connect the power cable to an AC 100 V outlet.
★ When connecting the power cable, check
that the power switch of H2 is turned off.
4. Loosen the cap nut of the suction pump and set
the filter paper.
★ Set the filter paper securely so that the ex-
haust gas will not leak.
5. Turn on the power switch of H2.
6. Heighten the engine speed sharply and depress
the accelerator pedal of tool H2 simultaneously
to have the filter paper absorb the exhaust gas.
7. Remove the contaminated filter paper and place
it on clean filter paper (at least 10 sheets) in the
filter paper holder and read the indicated value.
20-104 D31/37EX,PX-21
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
D31/37EX,PX-21 20-105
TESTING AND ADJUSTING MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
20-106 D31/37EX,PX-21
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
D31/37EX,PX-21 20-107
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
20-108 D31/37EX,PX-21
TESTING AND ADJUSTING TESTING ADJUSTING FUEL INJECTION TIMING
D31/37EX,PX-21 20-109
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
20-110 D31/37EX,PX-21
TESTING AND ADJUSTING ADJUSTING ENGINE STOP SOLENOIDE LINKAGE
D31/37EX,PX-21 20-111
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
1. Remove plug (1) (PT 1/8) from the oil filter top
and install adapter and nipple C3 of oil pres-
sure kit C1, then connect oil pressure gauge C2
(9.8 MPa {10 kg/cm2}).
20-112 D31/37EX,PX-21
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT
D31/37EX,PX-21 20-113
TESTING AND ADJUSTING TENSION OF
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT
2. Adjusting belt
1) Loosen 4 compressor mounting bolts (1).
2) Loosen locknut (2) and tighten adjustment
bolt (3) to adjust the belt tension.
3) After adjusting the belt tension to the stand-
ard value, tighten locknut (2) and compres-
sor mounting bolts (1).
20-114 D31/37EX,PX-21
TESTING AND ADJUSTING MEASURING AND ADJSUTING HST OIL PRESSURE
D31/37EX,PX-21 20-115
TESTING AND ADJUSTING MEASURING AND ADJSUTING HST OIL PRESSURE
20-116 D31/37EX,PX-21
TESTING AND ADJUSTING MEASURING AND ADJSUTING HST OIL PRESSURE
5) Set tachometer A2. For details, see MEAS- 4. Measuring servo piston operating pressure
URING ENGINE SPEED. (Output pressure of travel and steering PPC
valves)
1) Stop the engine.
2) Loosen the hydraulic oil filler cap to release
the residual pressure from the hydraulic
tank.
3) Remove the floor cover.
4) Turn tow valve lever (1) of the travel brake
circuit downward until it stops (to the full
close position).
5) Disconnect the hose of the circuit to be
measured among "front" ends (7) and (8)
and "rear" ends of the servo piston inlet
hoses.
The hoses to be disconnected are forward
side (7) and reverse side (8) of front pump
and forward side and reverse side of rear
pump
6) Install adapter C4 and nipple C3 of oil pres-
sure kit C, then connect oil pressure gauge
C1 (5.9 MPa {60 kg/cm2}).
D31/37EX,PX-21 20-117
TESTING AND ADJUSTING MEASURING AND ADJSUTING HST OIL PRESSURE
20-118 D31/37EX,PX-21
MEASURING SOLENOID VALVE OUTPUT
TESTING AND ADJUSTING PRESSURE
Measurement condition
Solenoid State of State of Oil pressure
Fuel control Safety lock Remarks
name Travel lever machine solenoid (MPa {kg/cm2})
lever lever
1st gear
OFF 0
speed
2nd gear
2nd gear 3.2 ± 0.3
1 speed Full Neutral — ON —
speed {32 ± 3}
selector
3rd gear
OFF 0
speed
1st gear
OFF 0
speed
3rd gear
2nd gear
2 speed Full Neutral — OFF 0 —
speed
selector
3rd gear 3.2 ± 0.3
ON
speed {32 ± 3}
Brake is 3.2 ± 0.3
Released ON
Parking released {32 ± 3}
3 Full Neutral —
brake Brake is
Locked OFF 0
applied
HST (Oil Signal is
Released OFF 0
pressure OFF
4 Full Neutral —
changeover Signal is 3.2 ± 0.3
valve) Locked ON
ON {32 ± 3}
D31/37EX,PX-21 20-121
MEASURING AND ADJUSTING WORK
TESTING AND ADJUSTING EQUIPMENT MAIN RELIEF PRESSURE
1. Measuring
★ Oil temperature for measurement: 45 – 55°C
1) Remove the engine side cover (left upper).
2) Remove oil pressure pickup plug (1)
(Thread dia. = 10 mm, Pitch = 1.25 mm) and
install adapter and nipple C3 of oil pres-
sure gauge kit C, then connect oil pressure
gauge C1 (39.2 MPa {400 kg/cm2}).
★ A safety valve is installed to only the angle
cylinder circuit. If only the angle cylinder re-
lief pressure is low, the safety valve may be
set low.
20-122 D31/37EX,PX-21
TESTING AND ADJUSTINGMEASURING AND ADJUSTING WORK EQUIPMENT MAIN RELIEF PRESSURE
2. Adjusting
1) Remove the mounting bolts of the opera-
tor’s seat and turn the seat forward.
2) Loosen locknut (3) of relief valve (2) and
turn adjustment nut (4) to adjust the relief
pressure.
k Never remove adjustment nut (4). (If it is
loosened too much, it will be removed
from the threaded part. Accordingly,
take care extremely when removing.)
★ The function of the adjustment nut is as
shown below.
• If it is turned to the right, the pres-
sure is heightened.
• If it is turned to the left, the pressure
is lowered.
★ Quantity of adjustment by 1 turn of ad-
justment nut: 19.6 MPa {200 kg/cm2}
3 Adjusutment nut:
39 – 49 Nm {4 – 5 kgm}
D31/37EX,PX-21 20-123
TESTING AND ADJUSTING MEASURING PPC VALVE OUTPUT PRESSURE
20-124 D31/37EX,PX-21
TESTING AND ADJUSTING BLEEDING AIR FROM HYDRAULIC CYLINDERS
2. Measuring
1) Disconnect the piping on the head side and
plug the piping on the machine side.
kTake care not to disconnect the piping on
the bottom side.
2) Run the engine at full throttle to apply relief
pressure to the bottom side of the cylinder.
3) Measure leakage for 1 minute after 30 sec-
onds.
D31/37EX,PX-21 20-125
TESTING AND ADJUSTING TESTING AND ADJUSTING TRACK SHOE TENSION
20-126 D31/37EX,PX-21
TESTING AND ADJUSTING TESTING AND ADJUSTING TRAVEL DEVIATION
1. Measurement by traveling
1) Set the machine in the traveling position.
★ When driving the machine, raise the
blade to about 300 mm above the
ground.
2) After approach run of 10 m, measure the
travel deviation a in the travel of 20 m.
★ When measuring the travel deviation,
run the engine at full throttle.
★ At this time, install a pressure gauge and
measure the pump discharge pressure,
too.
D31/37EX,PX-21 20-127
TESTING AND ADJUSTING TESTING AND ADJUSTING TRAVEL DEVIATION
2. Adjusting travel deviation 3) Fix the hexagonal wrench and loosen lock-
1) Check the position of the adjustment plug of nut (3).
the HST pump. ★ Before loosening the locknut, make
• When machine deviates during reverse match mark on the adjustment plug to
travel: Adjust with adjustment plug (1). check the turning angle of the plug.
• When machine deviates during forward ★ Loosening angle of locknut: 90 – 180º
travel: Adjust with adjustment plug (2). 4) Turn the angled by the adjustment angle
guessed in advance.
5) Tighten the locknut.
3 Locknut: 49 – 56.8 Nm {5 – 6 kgm}
6) Check the travel deviation again. If it is not
within the standard range, adjust it again.
★ Never touch screws (4) and (5).
20-128 D31/37EX,PX-21
TESTING AND ADJUSTING TESTING AND ADJUSTING TRAVEL DEVIATION
D31/37EX,PX-21 20-129
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL LINKAGE
3. General adjustment
1) Install rod (11) between governor relay (12)
and lever (13).
★ Adjust the length of rod (11) so that gov-
ernor relay (12) will be in contact with the
FULL-side stopper and there will be no
clearance between the pin of part P and
the oblong hole end of the rod.
★ Standard dimension "k" of rod (11): 366
mm
20-130 D31/37EX,PX-21
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL LINKAGE
D31/37EX,PX-21 20-131
TESTING AND ADJUSTING ADJUSTING DECELERATOR PEDAL LINKAGE
2. Adjust screwing distance "c" of cable (3) in yoke 4. Adjust pedal idle stopper bolt (6) and fix it with
(4) and length "d" of the tip of cable (3). the locknut so that the engine speed will be as
★ Dimension "c": 11 mm, Dimension "d": 141 follows when the pedal is pressed to the stroke
mm end.
★ Low idling speed: 825 ± 25 rpm
20-132 D31/37EX,PX-21
ADJUSTING BRAKE PEDAL LINKAGE
TESTING AND ADJUSTING
D31/37EX,PX-21 20-133
ADJUSTING STEERING/DIRECTIONAL/
TESTING AND ADJUSTING GEAR SHIFT LEVER AND LOCK LEVER
20-134 D31/37EX,PX-21
ADJUSTING STEERING/DIRECTIONAL/
TESTING AND ADJUSTING GEAR SHIFT LEVER AND LOCK LEVER
4) Check that clearance "d" between lock lever ADJUSTING PROXIMITY SWITCH OF BACKUP
(4) and lock plate (7) is 2 ± 1 mm, then con- BUZZER (ALARM)
nect rod (13) to part A in the illustration on
the previous page. 1. Adjusting operation to turn on alarm
1) Adjust clearance "a" between proximity
switch (1) and reflection lever (2) for reverse
travel.
★ Clearance "a": 2 ± 0.5 mm
★ Precaution for installing bracket (3)
If bracket (3) is not installed in parallel
with lever (2), lever (2) will scuff and the
lapping distance of the switch-on posi-
tion marked ★ will change.
2) Move the directional lever slowly to the
reverse position and adjust the height of the
proximity switch with adjustment bolt (4) so
that the alarm will sound at point "P" where
the operating effort of the lever changes.
k After adjusting, move the directional lever to the
forward or reverse position and then move the
lock lever to the lock position and check that the
lever is returned to the neutral position securely.
Then, move the directional lever to the opposite
position and perform the same operation again.
D31/37EX,PX-21 20-135
TESTING AND ADJUSTING ADJUSTING STEERING/DIRECTIONAL/GEAR SHIFT LEVER AND LOCK LE-
20-136 D31/37EX,PX-21
TESTING AND ADJUSTING ADJUSTING BLADE CONTROL LEVER AND LOCK LEVER
D31/37EX,PX-21 20-137
TESTING AND ADJUSTING ADJUSTING WORK EQUIPMENT PPC VALVE
20-138 D31/37EX,PX-21
TESTING AND ADJUSTING PROCEDURE FOR RELEASING PARKING BRAKE
D31/37EX,PX-21 20-139
TESTING AND ADJUSTING PROCEDURE FOR RELEASING PARKING BRAKE
3 Valve:
24.5 – 34.5 Nm {2.5 – 3.5 kgm}
Locknut:
24.5 – 34.5 Nm {2.5 – 3.5 kgm}
20-140 D31/37EX,PX-21
TROUBLESHOOTING
D31/37EX,PX-21 20-201
TESTING AND ADJUSTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and func-
tion.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry 5) Other maintenance items can be checked
to disassemble the components. externally, so check any item that is consid-
If components are disassembled immediately ered to be necessary.
any failure occurs:
• Parts that have no connection with the failure 4. Confirming failure
or other unnecessary parts will be disassem- • Confirm the extent of the failure yourself, and
bled. judge whether to handle it as a real failure or
• It will become impossible to find the cause of as a problem with the method of operation,
the failure. etc.
It will also cause a waste of manhours, parts, or ★ When operating the machine to reenact
oil or grease, and at the same time, will also lose the troubleshooting symptoms, do not
the confidence of the user or operator. carry out any investigation or measure-
For this reason, when carrying out troubleshoot- ment that may make the problem worse.
ing, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in 5. Troubleshooting
accordance with the fixed procedure. • Use the results of the investigation and in-
spection in Items 2 – 4 to narrow down the
2. Points to ask user or operator causes of failure, then use the troubleshoot-
1) Have any other problems occurred apart ing flowchart to locate the position of the fail-
from the problem that has been reported? ure exactly.
2) Was there anything strange about the ★ The basic procedure for troubleshooting
machine before the failure occurred? is as follows.
3) Did the failure occur suddenly, or were there 1) Start from the simple points.
problems with the machine condition before 2) Start from the most likely points.
this? 3) Investigate other related parts or
4) Under what conditions did the failure occur? information.
5) Had any repairs been carried out before the
failure? 6. Measures to remove root cause of failure
When were these repairs carried out? • Even if the failure is repaired, if the root
6) Has the same kind of failure occurred cause of the failure is not repaired, the same
before? failure will occur again.
To prevent this, always investigate why the
3. Check before troubleshooting problem occurred. Then, remove the root
1) Check the oil level cause.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
4) Check the stroke of the control valve spool.
20-202 D31/37EX,PX-21
TESTING AND ADJUSTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
Step 1
Examination, confirmation of symptoms
1) When a request for repairs is
received, first ask the following
points.
Name of customer
Type, serial number of machine
Details of jobsite, etc.
2) Ask questions to gain an outline of the
problem.
Condition of failure
Work being carried out at the time of the failure
Operating environment
Past history, details of maintenance, etc.
Step 2
Determining probable location of cause
1) Look at the troubleshooting section of
the shop manual to find locations of
possible causes.
Step 3
Preparation of troubleshooting tools
1) Look at the table of troubleshooting
tools in the shop manual and prepare Step 7
the necessary tools. Pinpoint locations of failure
T-adapter (carry out troubleshooting)
Hydraulic pressure gauge kit, etc. Decide action to take
2) Look in the parts book and prepare
1) Before starting troubleshooting,
the necessary replacement parts.
locate and repair simple failures.
Check before starting items
Other check items
2) See the Troubleshooting Section of
the shop manual, select a
troubleshooting flowchart that matches
the symptoms, and carry out troubleshooting.
Step 6
Re-enacting failure
Drive and operate the machine to confirm
the condition and judge if there is really a
failure.
Step 7
Step 4 Ask operator questions to confirm
Go to jobsite details of failure.
Was there anything strange about
the machine before the failure occurred?
Did the failure occur suddenly?
Had any repairs been carried out
before the failure?
D31/37EX,PX-21 20-203
TESTING AND ADJUSTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
20-204 D31/37EX,PX-21
TESTING AND ADJUSTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the solder-
ing may be damaged, or the wiring may be
broken.
D31/37EX,PX-21 20-205
TESTING AND ADJUSTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
• Disconnecting connectors
1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold
the connectors and not the wires. For con-
nectors held by a screw, loosen the screw
fully, then hold the male and female connec-
tors in each hand and pull apart. For con-
nectors which have a lock stopper, press
down the stopper with your thumb and pull
the connectors apart.
★ Never pull with one hand.
20-206 D31/37EX,PX-21
TESTING AND ADJUSTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
• Connecting connectors
1) Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation,
defective contact, corrosion, or damage
to the connector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
★ If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth.
If any water has got inside the connec-
tor, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
★ If there is any damage or breakage, re-
place the connector.
D31/37EX,PX-21 20-207
TESTING AND ADJUSTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
20-208 D31/37EX,PX-21
TESTING AND ADJUSTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
D31/37EX,PX-21 20-209
TESTING AND ADJUSTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from enter-
ing. If the opening is left open or is blocked with
a rag, there is danger of dirt entering or of the
surrounding area being made dirty by leaking oil
so never do this.
Do not simply drain oil out on to the ground, col-
lect it and ask the customer to dispose of it, or
take it back with you for disposal.
20-210 D31/37EX,PX-21
TESTING AND ADJUSTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump,
c o n tr o l v a lv e , e t c .) o r wh e n r u n ni n g t he
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3µ) particles that the filter
built into the hydraulic equipment cannot
remove, so it is an extremely effective device.
D31/37EX,PX-21 20-211
TESTING AND ADJUSTING CHECKS BEFORE TROUBLESHOOTING
Judgement
Item Action
value
1. Check fuel level, type of fuel — Add fuel
2. Check for impurities in fuel — Clean, drain
Lubricating oil,
4. Check engine oil level (oil pan oil level), type of oil — Add oil
5. Check coolant level — Add water
6. Check dust indicator for clogging — Clean or replace
7. Check hydraulic filter and charge filter — Replace
8. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace
mechanical equipment
Hydraulic, Electrical
20-212 D31/37EX,PX-21
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING CHARTS
D31/37EX,PX-21 20-213
TESTING AND ADJUSTING TYPES AND LOCATIONS OF CONNECTORS
CN1 DT 2 Intermediate connector B-4 CN62 KES 2 Rear washer (Cab specification) J-1
CN2 DT 4 Intermediate connector B-3 CN63 KES 2 Front washer (Cab specification) I-1
CN3 DT 4 Intermediate connector B-3 CN64 KES 6 Rear wiper switch (Cab specification) G-9
CN4 DT 2 Safety relay D-5 CN65 KES 6 Front wiper switch (Cab specification) G-9
CN5 DT 6 Intermediate connector D-5 CN66 KES 2 Breaker switch (Cab specification) G-9
CN6 DT 4 Intermediate connector (Starting switch) C-5 CN68 SWP 6 Front wiper motor (Cab specification) I-8
CN7 SWP 12 Intermediate connectori (Panel) C-4 CN69 SWP 4 Rear wiper motor (Cab specification) I-8
CN9 DT 4 Intermediate connector D-5 CN70 KES 2 Rear speaker (Left) (Cab specification) J-8
CN10 DT 12 Intermediate connector D-5 CN71 KES 2 Rear speaker (Right) (Cab specification) I-9
CN11 Relay 6 Relay (Backup alarm) F-9 CN72 KES 2 Room lamp (Cab specification) I-9
CN12 DT 2 HST oil temperature sensor J-1 CN73 DT 2 Rear lamp (Cab specification) H-9
CN13 DT 2 Fuel level sensor J-4 CN74 DT 2 Headlamp (Left) (Cab specification) J-7
CN14 DT 3 Intermediate connector J-3 CN75 DT 2 Headlamp (Right) (Cab specification) E-9
CN15 DT 2 Air bleed pump for fuel system J-2 CN76 040 12 Control panel (Cab specification) J-8
CN17 DTHD 1 Auxiliary power supply C-4 CN77 040 16 Control panel (Cab specification) J-8
CN18 DTHD 1 For backup B-4 CN78 — 1 Cigarette lighter (Cab specification) J-5
CN20 DT 2 Engine coolant sensor E-1 CN79 — 1 Cigarette lighter (Cab specification) J-4
CN21 090II 2 Horn B-1 CN80 SWP 16 Air conditioner unit (Cab specification) J-4
CN22 DT 2 Intermediate connector (Horn) B-3 CN81 DT 4 Air conditioner unit (Cab specification) J-3
CN23 X 1 Air conditioner compressor B-2 CN90 KES 4 Car heater (Machine with ROPS) D-7
CN25 DT 3 Brake pedal limit switch G-1 CN92 DT 2 Heater switch (Machine with ROPS) J-5
CN26 DT 3 Neutral safety parking brake I-1 CNT1 Terminal 1 Starting motor terminal B C-1
CN27 DT 6 Intermediate connector (Shift switch) I-1 CNT2 Terminal 1 Starting motor terminal C B-1
CN28 DT 2 Gear shifting solenoid H-1 CNT3 Terminal 1 Safety relay terminal B C-4
CN29 DT 2 Gear shifting solenoid G-1 CNT4 Terminal 1 Safety relay terminal C C-4
CN31 DT 2 Parking brake solenoid G-1 CNT5 Terminal 1 Heater relay terminal S B-2
CN32 DT 12 Gear shift controller H-1 CNT6 Terminal 1 Heater relay terminal L B-2
CN33 DT 4 Intermediate connector J-6 CNT7 Terminal 1 Battery relay terminal B I-1
CN34 Y 2 For power supply of cab J-6 CNT8 Terminal 1 Battery relay terminal M J-4
CN38 C03 3 Gear shift switch J-2 CNT9 Terminal 1 Battery relay terminal (–) J-5
CN39 C03 3 Gear shift switch J-2 CNT11 Terminal 1 Starting motor terminal B C-1
CN40 CN(A) 2 Panel D-7 CNT12 Terminal 1 Heater relay terminal B E-1
CN41 040 16 Panel E-8 CNT13 Terminal 1 Battery relay terminal (+) J-5
CN42 DT 4 Panel (Travel speed indicator lamp) D-8 CNT15 Terminal 1 Alternator terminal B B-3
CN43 KES 3 Lamp switch D-6 CNT16 Terminal 1 Alternator terminal R B-2
CN45 DT 8 Tele-management system D-5 CNT17 Terminal 1 Engine stop solenoid (+) D-1
CN51 DT 2 Headlamp (Right) A-8 CNT18 Terminal 1 Engine stop solenoid (–) E-1
CN52 DT 2 Headlamp (Left) B-5 CNT19 Terminal 1 Engine oil pressure switch E-1
CN53 DT 2 Rear lamp C-9 CNT25 Terminal 1 Starting switch terminal B D-7
CN54 Relay 6 Relay (Headlamp) E-8 CNT26 Terminal 1 Starting switch terminal BR D-7
CN56 DT 2 Backup alarm proximity switch J-1 CNT27 Terminal 1 Starting switch terminal ACC D-7
CN57 Relay 6 Relay (Backup alarm) J-3 CNT28 Terminal 1 Starting switch terminal C D-7
CN58 DT 2 Backup alarm buzzer (Japan) J-4 CNT29 Terminal 1 Starting switch terminal R D-7
CN60 PA 9 Radio (Cab specification) J-7 CNT36 Terminal 1 HST charge filter J-2
CN61 PA 9 Cassette player (Cab specification) J-7 CNT37 Terminal 1 Horn switch F-9
20-214 D31/37EX,PX-21
TESTING AND ADJUSTING TYPES AND LOCATIONS OF CONNECTORS
Con- Num-
Add-
nector Type ber of Location ress
No. pins
D31/37EX,PX-21 20-215
TESTING AND ADJUSTING CONNECTOR ARRANGEMENT DIAGRAM
20-216 D31/37EX,PX-21
TESTING AND ADJUSTING CONNECTOR ARRANGEMENT DIAGRAM
D31/37EX,PX-21 20-217
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
X type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
1 Part No.: 08055-00181 Part No.: 08055-00191 799-601-7010
2 799-601-7020
3 799-601-7030
4 799-601-7040
20-218 D31/37EX,PX-21
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
6 799-601-7050
8 799-601-7060
12 799-601-7310
14 799-601-7070
D31/37EX,PX-21 20-219
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
16 799-601-7320
20-220 D31/37EX,PX-21
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
M type connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080
2 799-601-7090
3 799-601-7110
4 799-601-7120
6 799-601-7130
8 799-601-7390
D31/37EX,PX-21 20-221
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
S type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
8 799-601-7140
10
799-601-7150
(White)
12
799-601-7350
(White)
16
799-601-7330
(White)
20-222 D31/37EX,PX-21
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
S type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
10
—
(Blue)
— —
12
799-601-7160
(Blue)
16
799-601-7170
(Blue)
D31/37EX,PX-21 20-223
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
5 799-601-2710
Body part No.: 79A-222-2620 (Q’ty: 5) Body part No.: 79A-222-2610 (Q’ty: 5)
9 799-601-2950
Body part No.: 79A-222-2660 (Q’ty: 5) Body part No.: 79A-222-2650 (Q’ty: 5)
13 799-601-2720
Body part No.: 79A-222-2710 (Q’ty: 2) Body part No.: 79A-222-2690 (Q’ty: 2)
20-224 D31/37EX,PX-21
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
17 799-601-2730
Body part No.: 79A-222-2730 (Q’ty: 2) Body part No.: 9A-222-2720 (Q’ty: 2)
21 799-601-2740
Body part No.: 79A-222-2750 (Q’ty: 2) Body part No.: 79A-222-2740 (Q’ty: 2)
Terminal part No.: 79A-222-2770 Terminal part No.: 79A-222-2760
—
(Q’ty: 50) (Q’ty: 50)
D31/37EX,PX-21 20-225
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
8 799-601-7180
12 799-601-7190
16 799-601-7210
20 799-601-7220
20-226 D31/37EX,PX-21
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
10 799-601-7510
12 799-601-7520
14 799-601-7530
18 799-601-7540
20 799-601-7550
D31/37EX,PX-21 20-227
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
L type connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
2 —
— —
Connector for PA
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
9 —
— —
Bendix MS connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
10 799-601-3460
— —
20-228 D31/37EX,PX-21
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
2 —
Part No.: 08027-10210 (Natural color) Part No.: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
4 —
Part No.: 08027-10410 (Natural color) Part No.: 08027-10460 (Natural color)
08027-10420 (Black) 08027-10470 (Black)
6 —
Part No.: 08027-10610 (Natural color) Part No.: 08027-10660 (Natural color)
08027-10620 (Black) 08027-10670 (Black)
D31/37EX,PX-21 20-229
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
8 —
Part No.: 08027-10810 (Natural color) Part No.: 08027-10860 (Natural color)
08027-10820 (Black) 08027-10870 (Black)
5 799-601-7360
— —
6 799-601-7370
— —
20-230 D31/37EX,PX-21
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
F type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
4 —
— —
D31/37EX,PX-21 20-231
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9210
799-601-9210
799-601-9220
799-601-9230
20-232 D31/37EX,PX-21
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9230
799-601-9230
799-601-9240
799-601-9240
D31/37EX,PX-21 20-233
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9250
799-601-9250
799-601-9260
799-601-9260
20-234 D31/37EX,PX-21
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9270
799-601-9270
799-601-9280
799-601-9280
D31/37EX,PX-21 20-235
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9290
799-601-9290
20-236 D31/37EX,PX-21
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
DT Series connector
No.of
pins Body (receptacle) T-adapter
Body (plug)
Part No.
2 799-601-9020
Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
Part No.: 08192-13200 (normal type) Part No.: 08192-13100 (normal type)
08192-23200 (fine wire type) 08192-23100 (fine wire type)
4 799-601-9040
Part No.: 08192-14200 (normal type) Part No.: 08192-14100 (normal type)
08192-24200 (fine wire type) 08192-24100 (fine wire type)
6 799-601-9050
Part No.: 08192-16200 (normal type) Part No.: 08192-16100 (normal type)
08192-26200 (fine wire type) 08192-26100 (fine wire type)
D31/37EX,PX-21 20-237
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
8GR: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8BR: 799-601-9090
Part No.: 08192-1820
(normal type) Part No.: 08192-1810
(normal type)
08192-2820
(fine wire type) 08192-2810
(fine wire type)
12GR: 799-601-9110
12B: 799-601-9120
10
12G: 799-601-9130
12BR: 799-601-9140
Part No.: 08192-1920
(normal type) Part No.: 08192-1910
(normal type)
08192-2920
(fine wire type) 08192-2910
(fine wire type)
20-238 D31/37EX,PX-21
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9010
2
[The pin No. is also marked on the connector (electric wire insertion end)]
2 —
Part No.: 08192-31200 (Contact size#12) Part No.: 08192-31100 (Contact size#12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
D31/37EX,PX-21 20-239
TROUBLESHOOTING FOR
ELECTRICAL SYSTEM (E-MODE)
★ Before carrying out the troubleshooting, check that all the related connectors are properly connected.
★ Always connect any disconnected connectors before going on to the next step.
D31/37EX,PX-21 20-301
TESTING AND ADJUSTING TABLE OF FAILURE MODES AND CAUSES (ELECTRICAL SYSTEM)
20-302 D31/37EX,PX-21
TESTING AND ADJUSTING TABLE OF FAILURE MODES AND CAUSES (ELECTRICAL SYSTEM)
D31/37EX,PX-21 20-303
TESTING AND ADJUSTING ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM
20-304 D31/37EX,PX-21
TESTING AND ADJUSTING ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM
D31/37EX,PX-21 20-305
TESTING AND ADJUSTING E-1
E-1. When starting switch is turned on, starting motor does not rotate
★ Before carrying out the troubleshooting, check that fuses FB1 No. 3 and FB2 No. 5 and fusible links CNH1
and H2 are normal.
20-306 D31/37EX,PX-21
TESTING AND ADJUSTING E-1
Note 1) This may be checked by testing if the lamp lights up or if the horn sounds normally.
D31/37EX,PX-21 20-307
TESTING AND ADJUSTING E-2
E-2. Engine does not start (Engine stop solenoid does not operate normally)
★ Carry out the following troubleshooting when the starting motor rotates normally.
★ Before carrying out the troubleshooting, check that fuse FB1 No. 5 is normal.
20-308 D31/37EX,PX-21
TESTING AND ADJUSTING E-3
★ Carry out the following troubleshooting when breakage of the bulb, etc. is not detected by visual inspection.
(If breakage of the bulb is detected, replace the bulb.)
★ Before carrying out the troubleshooting, check that fusible link CNH2 and fuse FB1 No. 1 are normal.
D31/37EX,PX-21 20-309
TESTING AND ADJUSTING E-3
20-310 D31/37EX,PX-21
TESTING AND ADJUSTING E-4
E-4. When starting switch is turned to HEAT position, engine is not heated
★ Before carrying out the troubleshooting, check that fusible link H1 and fuse FB2 No. 5 are normal.
D31/37EX,PX-21 20-311
TESTING AND ADJUSTING E-5
Note 1) If the circuit of the lamp (headlamp or rear lamp) or horn is normal, this may be checked by testing if the
lamp lights up or if the horn sounds normally.
Note 2) This troubleshooting is explained by using the rear wiper as an example. For the connector Nos. corre-
sponding to the front wiper, see Table 1.
20-312 D31/37EX,PX-21
TESTING AND ADJUSTING E-5
Table 1
Wiper name Rear wiper Front wiper
CN64 CN65
Connector No.
CN69 CN68
D31/37EX,PX-21 20-313
TESTING AND ADJUSTING E-6
Note 1) If the circuit of the lamp (headlamp or rear lamp) or horn is normal, this may be checked by testing if the
lamp lights up or if the horn sounds normally.
Note 2) This troubleshooting is explained by using the left washer as an example. For the connector Nos. cor-
responding to CN11 on the cab side of another washer, see below.
20-314 D31/37EX,PX-21
TESTING AND ADJUSTING E-6
D31/37EX,PX-21 20-315
TESTING AND ADJUSTING E-7
★ Carry out the following troubleshooting when the battery and battery relay are normal.
★ Before carrying out the troubleshooting, check that fuse (FB2) No. 3 is normal.
20-316 D31/37EX,PX-21
TESTING AND ADJUSTING E-7
D31/37EX,PX-21 20-317
TESTING AND ADJUSTING E-7
20-318 D31/37EX,PX-21
TESTING AND ADJUSTING E-7
D31/37EX,PX-21 20-319
TESTING AND ADJUSTING E-7
20-320 D31/37EX,PX-21
TESTING AND ADJUSTING E-7
Operating procedure
D31/37EX,PX-21 20-321
TESTING AND ADJUSTING E-7
20-322 D31/37EX,PX-21
TESTING AND ADJUSTING E-8
E-8. Parking brake cannot be released (Parking brake solenoid does not operate)
★ Before carrying out the troubleshooting, check that fusible link H2 and fuse FB1 No. 3 are normal.
D31/37EX,PX-21 20-323
TESTING AND ADJUSTING E-9
★ Before carrying out the troubleshooting, check that fusible link H2 and fuse FB1 No. 3 are normal.
★ If only display of the gear speed on the monitor panel is abnormal, go to M-10.
a) When gear shift switch is pressed, gear speed does not change or gear speed changes by itself
(Gear shift switch or controller is abnormal)
Connector Shift-up switch Shift-down switch Connector on shift Connector on shift con-
and pin No. Push Release Push Release switch side and pin No. troller side and pin No.
20-324 D31/37EX,PX-21
TESTING AND ADJUSTING E-9
b) Gear speed cannot be selected normally (Travel speed changeover solenoid is abnormal)
Table 1
1st gear 2nd gear 3rd gear
Between CN28 (1) – Chassis ground Max. 1 V 20V – 30V Max. 1 V
Between CN29 (1) – Chassis ground Max. 1 V Max. 1 V 20V – 30V
D31/37EX,PX-21 20-325
TESTING AND ADJUSTING E-9
20-326 D31/37EX,PX-21
TESTING AND ADJUSTING E-10
★ Before carrying out the troubleshooting, check that fusible link H2 and fuse FB2 No. 2 are normal.
★ Before carrying out the troubleshooting, adjust the proximity switch (See TESTING AND ADJUSTING).
D31/37EX,PX-21 20-327
TESTING AND ADJUSTING E-10
20-328 D31/37EX,PX-21
TESTING AND ADJUSTING E-11
★ Before carrying out the troubleshooting, check that fusible link H2 and fuse FB1 No. 4 are normal.
D31/37EX,PX-21 20-329
TROUBLESHOOTING FOR
HYDRAULIC AND MECHANICAL
SYSTEM (H-MODE)
Table of failure modes and causes (Hydraulic and mechanical systems) ...................................................20-402
H-1. Machine does not travel in either direction or it stops suddenly ..........................................................20-404
H-2. Machine does not travel in one direction .............................................................................................20-405
H-3. Machine travels while travel lever is in neutral ....................................................................................20-405
H-5. Machine deviates while travel lever is in partial position .....................................................................20-405
H-7. Machine swings momentarily when it starts on flat ground .................................................................20-405
H-11. Turning time lag is large.....................................................................................................................20-405
H-12. When operator intends to turn gradually, machine turns sharply.......................................................20-405
H-13. Machine does not return quickly to straight travel position ................................................................20-405
H-14. Machine is not decelerated smoothly or travel speed cannot be controlled on downhill ground .......20-405
H-15. Machine deviates when it is decelerated ...........................................................................................20-405
H-4. Machine deviates when travel lever is moved to stroke end ...............................................................20-406
H-6. Machine moves back when operator starts on uphill ground...............................................................20-406
H-8. Machine starts sharply.........................................................................................................................20-406
H-10. Starting time lag is large ....................................................................................................................20-408
H-16. Maximum travel speed is low or output power is insufficient or acceleration is low...........................20-409
H-17. Engine stalls ......................................................................................................................................20-410
H-18. HST noise is large .............................................................................................................................20- 411
H-19. HST oil temperature rises too high ....................................................................................................20-412
H-20. Gear speed does not change ............................................................................................................20-412
H-21. Abnormal sound is heard from around work equipment pump or HST pump....................................20-413
H-22. Any work equipment does not move..................................................................................................20-413
H-23. Speed or power of each work equipment is low ................................................................................20-414
H-24. Speed or power of blade lift of blade tilt cylinder is low .....................................................................20-414
H-25. Speed or power of blade angle cylinder is low ..................................................................................20-415
H-26. Hydraulic drift of blade lift cylinder is large ........................................................................................20-416
H-27. Hydraulic drift of blade tilt cylinder is large ........................................................................................20-416
H-28. Hydraulic drift of blade angle cylinder is large ...................................................................................20-417
D31/37EX,PX-21 20-401
TABLE OF FAILURE MODES AND CAUSES
TESTING AND ADJUSTING (HYDRAULIC AND MECHANICAL SYSTEMS)
20-402 D31/37EX,PX-21
TABLE OF FAILURE MODES AND CAUSES
TESTING AND ADJUSTING (HYDRAULIC AND MECHANICAL SYSTEMS)
D31/37EX,PX-21 20-403
TESTING AND ADJUSTING H-1
★ Before carrying out the troubleshooting, check the oil level in the hydraulic tank.
★ Check the electric system first. If it is normal, carry out the following troubleshooting.
Table 1 AS pressure
Operation of brake Oil pressure
Engine speed (rpm)
pedal MPa {kg/cm2}
1,100 Released 0.29 – 0.78 {3.0 – 8.0}
1,800 Released 1.76 – 2.40 {18 – 24.5}
Full Pressed Max. 0.49 {Max. 5.0}
20-404 D31/37EX,PX-21
TESTING AND ADJUSTING H-2, 3, 5, 7, 11, 12, 13, 14, 15
★ Before carrying out the troubleshooting, check the oil level in the hydraulic tank.
★ Before carrying out the troubleshooting, check the oil level in the hydraulic tank.
D31/37EX,PX-21 20-405
TESTING AND ADJUSTING H-4, H-6, H-8
★ Before carrying out the troubleshooting, check the oil level in the hydraulic tank.
★ Before carrying out the troubleshooting, check the oil level in the hydraulic tank.
★ Check the electric system first. If it is normal, carry out the following troubleshooting.
20-406 D31/37EX,PX-21
TESTING AND ADJUSTING H-9
★ Before carrying out the troubleshooting, check the oil level in the hydraulic tank.
★ Check the electric system first. If it is normal, carry out the following troubleshooting.
D31/37EX,PX-21 20-407
TESTING AND ADJUSTING H-10
★ Before carrying out the troubleshooting, check the oil level in the hydraulic tank.
★ Check the electric system first. If it is normal, carry out the following troubleshooting.
Table 1 AS pressure
Engine speed (rpm) Operation of brake pedal Oil pressure MPa {kg/cm2}
1,100 Released 0.29 – 0.78 {3.0 – 8.0}
1,800 Released 1.76 – 2.40 {18 – 24.5}
Full Pressed Max. 0.49 {Max. 5.0}
20-408 D31/37EX,PX-21
TESTING AND ADJUSTING H-16
★ Before carrying out the troubleshooting, check the oil level in the hydraulic tank.
★ Check the electric system first. If it is normal, carry out the following troubleshooting.
Table 1 AS pressure
Engine speed (rpm) Operation of brake pedal Oil pressure MPa {kg/cm2}
1,100 Released 0.29 – 0.78 {3.0 – 8.0}
1,800 Released 1.76 – 2.40 {18 – 24.5}
Full Pressed Max. 0.49 {Max. 5.0}
D31/37EX,PX-21 20-409
TESTING AND ADJUSTING H-17
★ Before carrying out the troubleshooting, check the oil level in the hydraulic tank.
Table 1 AS pressure
Engine speed (rpm) Operation of brake pedal Oil pressure MPa {kg/cm2}
1,100 Released 0.29 – 0.78 {3.0 – 8.0}
1,800 Released 1.76 – 2.40 {18 – 24.5}
Full Pressed Max. 0.49 {Max. 5.0}
20-410 D31/37EX,PX-21
TESTING AND ADJUSTING H-18
★ Before carrying out the troubleshooting, check the oil level in the hydraulic tank.
D31/37EX,PX-21 20-411
TESTING AND ADJUSTING H-19, H-20
★ Before carrying out the troubleshooting, check the oil level in the hydraulic tank.
★ Check the electric system first. If it is normal, carry out the following troubleshooting.
20-412 D31/37EX,PX-21
TESTING AND ADJUSTING H-21, H-22
H-21. Abnormal sound is heard from around work equipment pump or HST pump
★ Before carrying out the troubleshooting, check the oil level in the hydraulic tank.
★ Before carrying out the troubleshooting, check the oil level in the hydraulic tank.
D31/37EX,PX-21 20-413
TESTING AND ADJUSTING H-23, H-24
★ Before carrying out the troubleshooting, check the oil level in the hydraulic tank.
★ Before carrying out the troubleshooting, check the oil level in the hydraulic tank.
★ Check the blade to see if it has been modified.
★ Carry out the following troubleshooting when the angle cylinder is normal.
20-414 D31/37EX,PX-21
TESTING AND ADJUSTING H-25
★ Before carrying out the troubleshooting, check the oil level in the hydraulic tank.
★ Check the blade to see if it has been modified.
★ Carry out the following troubleshooting when the boom and tilt cylinders are normal.
D31/37EX,PX-21 20-415
TESTING AND ADJUSTING H-26, H-27
20-416 D31/37EX,PX-21
TESTING AND ADJUSTING H-28
D31/37EX,PX-21 20-417
TROUBLESHOOTING FOR
MACHINE MONITOR SYSTEM
(M-MODE)
★ Before carrying out troubleshooting, check that all the related connectors are properly inserted.
★ Always connect any disconnected connectors before going on to the next step.
D31/37EX,PX-21 20-501
TABLE OF FAILURE MODES AND CAUSES
TESTING AND ADJUSTING (MACHINE MONITOR SYSTEM)
20-502 D31/37EX,PX-21
TESTING AND ADJUSTING ELECTRIC CIRCUIT DIAGRAM FOR EACH SYSTEM
20-504 D31/37EX,PX-21
TESTING AND ADJUSTING ELECTRIC CIRCUIT DIAGRAM FOR EACH SYSTEM
D31/37EX,PX-21 20-505
TESTING AND ADJUSTING M-1
M-1. When starting switch is turned ON, monitor panel is not turned on
★ Carry out the following troubleshooting when the battery and battery relay are normal.
★ Before carrying out the following troubleshooting, check that fuse FB1 No. 2 and fusible link H2 are normal.
(If any of them is broken, check for short circuit with chassis ground in wiring harness between CN41 (1) –
CN7 (1) – fuse FB1 No. 2 – fusible link H2.)
★ Check the bulb visually for breakage. (If it is broken, replace it.)
20-506 D31/37EX,PX-21
TESTING AND ADJUSTING M-2
★ Carry out the following troubleshooting when the battery and battery relay are normal.
★ Before carrying out the following troubleshooting, check that fuse FB2 No. 5 and fusible link H1 are normal.
(If any of them is broken, check for short circuit with chassis ground in wiring harness between heater relay
terminal T5 (+) – CN2 (3) – CN6 (4) – starting switch terminal R1 and between starting switch terminal B –
CN5 (1) – fuse FB2 No. 5 – fusible link H2.)
D31/37EX,PX-21 20-507
TESTING AND ADJUSTING M-3
If the result of the continuity check of the engine oil pressure sensor is as follows, the sensor is normal.
Engine oil pressure: Min. 49 kPa {0.5 kg/cm2} There is not continuity
Engine oil pressure sensor
Engine oil pressure: Max. 49 kPa {0.5 kg/cm2} There is continuity
Differential pressure between before and after filter:
There is continuity
Min. 200 kPa {2 kg/cm2}
HST filter clogging sensor
Differential pressure between before and after filter:
There is not continuity
Max. 200 kPa {2 kg/cm2}
20-508 D31/37EX,PX-21
TESTING AND ADJUSTING M-3
c) HST filter clogging caution lamp lights up (while filter is not clogged)
D31/37EX,PX-21 20-509
TESTING AND ADJUSTING M-4
★ Before carrying out the following troubleshooting, check that the engine oil pressure caution lamp and charge
caution lamp light up when the starting switch is turned on.
20-510 D31/37EX,PX-21
TESTING AND ADJUSTING M-4
D31/37EX,PX-21 20-511
TESTING AND ADJUSTING M-5
★ Before carrying out the following troubleshooting, check that the engine oil pressure caution lamp and charge
caution lamp light up when the starting switch is turned on.
20-512 D31/37EX,PX-21
TESTING AND ADJUSTING M-5
D31/37EX,PX-21 20-513
TESTING AND ADJUSTING M-6
★ Before carrying out the following troubleshooting, check that the engine oil pressure caution lamp and charge
caution lamp light up when the starting switch is turned on.
20-514 D31/37EX,PX-21
TESTING AND ADJUSTING M-6
D31/37EX,PX-21 20-515
TESTING AND ADJUSTING M-7
20-516 D31/37EX,PX-21
TESTING AND ADJUSTING M-8
M-8. Monitor panel lamp does not light up (while headlamp is normal)
(Carry out the following troubleshooting when the headlamp lights up normally. If the headlamp does
not light up, execute "E-3" first.)
★ Check the bulb visually for breakage. (If it is broken, replace it.)
D31/37EX,PX-21 20-517
TESTING AND ADJUSTING M-9
M-9. Trouble in display of travel speed (while actual travel speed is normal)
★ Check the bulb visually for breakage. (If it is broken, replace it.)
★ Before carrying out the following troubleshooting, check that fuse FB1 No. 3 and fusible link H2 are normal.
Table 1 Table 2
Connector CN42 1st 2nd 3rd Travel speed
Circuit
Between (1) – (4) 20 –30V Max. 1 V Max. 1 V lamp
Between (2) – (4) Max. 1 V 20 –30V Max. 1 V Between CN42 (female) (1) –
1st
CN32 (female) (8)
Between (3) – (4) Max. 1 V Max. 1 V 20 –30V
Between CN42 (female) (2) –
2nd
CN32 (female) (9)
* When starting switch is turned on (1st gear speed
is selected at first) Between CN42 (female) (3) –
3rd
CN32 (female) (10)
20-518 D31/37EX,PX-21
TESTING AND ADJUSTING M-9
D31/37EX,PX-21 20-519
30 DISASSEMBLY AND
ASSEMBLY
D31/37EX,PX-21 30-1
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
(Example)
REMOVAL OF ASSEMBLY .........................Title of operation
k ................................................................................Precautions related to safety when carrying out the
operation
1. X X X X (1) ..............................................................Step in operation
★ .............................................................................Technique or important point to remember when
removing XXXX (1).
2. (2):.......................................................... Indicates that a technique is listed for use dur-
ing installation
3. assembly (3)
2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given
together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions
when carrying out the operation.
30-2 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
Nominal number Flange (hose end) Sleeve head (tube end) Split flange
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Dimensions
Nominal number Part Number
D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
D31/37EX,PX-21 30-3
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
★ When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hy-
draulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idling.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cyl-
inder 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.
30-4 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
★ Tools marked in the Sketch column are tools introduced in the sketches of the special tools (See SKETCH-
ES OF SPECIAL TOOLS).
New/Remodel
Necessity
Symbol
Sketch
Nature of work,
Q'ty
Component Part No. Part Name
remarks
D31/37EX,PX-21 30-5
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
New/Remodel
Necessity
Symbol
Sketch
Nature of work,
Q'ty
Component Part No. Part Name
remarks
30-6 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
L1 Push tool
L3 Push tool
D31/37EX,PX-21 30-7
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP ASSEMBLY
30-8 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP ASSEMBLY
12. Remove cap (14). 16. Remove 4 mounting bolts (18) and fuel injection
pump assembly (19).
13. Remove injection pump nut (15).
★ Remove with a filter wrench, etc.
★ Take care not to drop the nut in the case.
D31/37EX,PX-21 30-9
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP ASSEMBLY
30-10 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP ASSEMBLY
4) Install fuel injection pump assembly (19) 7) Remove plug (21) and install timing pin (22)
and tighten nut (18). in the reversed fitting position, then install
3 Nut: 43 ± 6 Nm {4.38 ± 0.61 kgm} the plug to the fuel injection pump.
3 Plug: 14.7 Nm {1.5 kgm}
D31/37EX,PX-21 30-11
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
6 Radiator: Approx. 20 l
30-12 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
8. Disconnect air cleaner hose (7). 15. Disconnect wiring harness clamp (16).
D31/37EX,PX-21 30-13
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
18. Disconnect charge air cooler hose (20). 22. Remove reservoir tank (26).
19. Disconnect oil filler tube (21) and oil filler hose 23. Disconnect radiator hose (27).
(22).
24. Disconnect heater hose (28).
4 Muffler assembly:
40 kg (Including bracket)
30-14 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
33. Remove air tube (38). 40. Remove turbocharger assembly (49) and
exhaust manifold (50).
34. Remove bracket (39) and spill tube (40).
D31/37EX,PX-21 30-15
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
43. Remove 4 nozzle holder assemblies (55). 45. Remove push rod (57).
★ If the nozzle holder is difficult to remove, use 46. Lift off cylinder head assembly (58).
tool A3.
★ Take care that dirt and foreign matter will not 4 Cylinder head assembly: 40 kg
enter the mounting part of the nozzle holder.
47. Remove cylinder head gasket (59).
30-16 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
3 Band: 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm} ★ When connecting the hose, apply spray
grease to the mating part (tube).
3 Charge air cooler hose clamp:
★ Install the air cleaner cover with the top mark 5.9 ± 0.5 Nm {0.6 ± 0.05 kgm}
up.
★ Use a new clamp. • Install the rocker arm assembly and cylinder
3 Clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} head assembly according to the following
procedure.
★ Check that there is not dirt or foreign
★ Pass the reservoir tank drain hose through matter on the mating face of the cylinder
the guide pipe of the shroud. head and in the cylinders.
1) Set cylinder head gasket (59) to the cylinder
block.
3 Radiator hose clamp: ★ Check that the gasket is matched to the
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} holes of the block.
2) Sling cylinder head assembly (58) and set it
to the cylinder block.
3 Tension pulley bolt: 3) Install push rod (57).
43 ± 6 Nm {4.38 ± 0.61 kgm} 4) Install rocker arm assembly (56) and tighten
the bolt with your fingers.
★ Check that the adjustment screw ball is
3 Bracket mounting bolt:
fitted to the socket of the push rod.
24 ± 4 Nm {2.45 ± 0.41 kgm}
D31/37EX,PX-21 30-17
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
5) Tighten the cylinder head mounting bolts in ii) When not using tool A4
the order shown in the following figure. • Make marks on the bolts and
2 Apply engine oil (SAE15W-40) to head with a marker pen, then
the threads and seats of the tighten each bolt by 90 ± 5º.
mounting bolts.
3 Cylinder head mounting bolt:
1st time: Tighten to 90 ± 5 Nm
{9.18 ± 0.51 kgm} in the
order of – .
• Bleeding air
★ Bleed air from the fuel circuit. For details,
see TESTING AND ADJUSTING, Bleeding
air from fuel circuit.
30-18 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
1. Remove the radiator guard assembly. For 5. Remove 27 mounting bolts (6) and cover (7).
details, see REMOVAL OF RADIATOR GUARD
ASSEMBLY.
D31/37EX,PX-21 30-19
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
30-20 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
D31/37EX,PX-21 30-21
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
30-22 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY RADIATOR GUARD ASSEMBLY
6 Radiator: Approx. 15 l
5. Remove both engine covers (5).
D31/37EX,PX-21 30-23
DISASSEMBLY AND ASSEMBLY RADIATOR GUARD ASSEMBLY
11. Disconnect oil cooler outlet hose (12). 15. Sling radiator guard assembly (17) temporarily
★ Prepare a blind plug before disconnecting and remove 8 mounting bolts (16) from both
the hose. sides and 2 from the underside.
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
30-24 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY RADIATOR GUARD ASSEMBLY
D31/37EX,PX-21 30-25
RADIATOR, OIL COOLER, AND CHARGE
DISASSEMBLY AND ASSEMBLY AIR COOLER ASSEMBLIES
30-26 D31/37EX,PX-21
RADIATOR, OIL COOLER, AND CHARGE
DISASSEMBLY AND ASSEMBLY AIR COOLER ASSEMBLIES
3) Lift off oil cooler assembly (12). 2) Remove right cleaning and inspection cover
(15).
4 Oil cooler: 35 kg ★ If the mounting bolt of the cleaning and
inspection cover is loosened with an im-
pact wrench, it is loosened too much and
the bolt pin is broken. Accordingly, loos-
en it with a wrench by hand.
★ If the oil cooler assembly is removed
without removing the cleaning and in-
spection 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).
4 Radiator: 80 kg
D31/37EX,PX-21 30-27
RADIATOR, OIL COOLER, AND CHARGE
DISASSEMBLY AND ASSEMBLY AIR COOLER ASSEMBLIES
4 Radiator: 80 kg
4 Oil cooler: 35 kg
30-28 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY RADIATOR, OIL COOLER, AND CHARGE AIR COOLER ASSEMBLIES
2) Install left cleaning and inspection cover 3. Charge air cooler assembly
(11). 1) Install charge air cooler assembly (8).
★ If the mounting bolt of the cleaning and
inspection cover is tightened with an im-
pact wrench, it is tightened too much and
the bolt pin is broken. Accordingly, tight-
en it with a wrench by hand.
D31/37EX,PX-21 30-29
DISASSEMBLY AND ASSEMBLY ENGINE ASSEMBLY
30-30 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY ENGINE ASSEMBLY
10. Remove the 3 mounting bolts and cover (19). 15. Disconnect 3 starting motor wiring harnesses
(28).
• (CNT1): Starting motor terminal B
• (CNT2): Starting motor terminal C
4 Front bracket: 65 kg
13. Disconnect the following 3 fuel hoses. 19. Sling engine assembly (33).
• (22): Fuel outlet
• (23): Fuel inlet 4 Engine assembly:
• (24): Fuel outlet 650 kg (Including HST pump assembly)
D31/37EX,PX-21 30-31
DISASSEMBLY AND ASSEMBLY ENGINE ASSEMBLY
3 Hose clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
30-32 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY DAMPER
3. Remove 12 cover mounting bolts (1). ★ 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}
D31/37EX,PX-21 30-33
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY
30-34 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY
D31/37EX,PX-21 30-35
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY
2. Cover
1) Remove 12 mounting bolts (1).
30-36 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY
3) Disassemble No. 1 planetary carrier assem- 7. No. 2 planetary carrier assembly (Travel
bly according to the following procedure. motor case)
i) Drive pin (7) into shaft (8). 1) Remove mounting bolts (15).
★ 3 sets ★ 3 sets
ii) Remove shaft (8) from No. 1 planetary
carrier assembly.
★ After removing the shaft, remove pin
(7) from shaft (8).
★ 3 sets
iii) Remove 2 thrust washers (9), gear (10),
and bearing (11).
★ 3 sets.
D31/37EX,PX-21 30-37
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY
30-38 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY
D31/37EX,PX-21 30-39
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY
30-40 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY
★ Tighten the nuts and adjust the pre-load on the 4) Using push-pull scale , tighten the nut so
bearing according to the following procedure. that the rotating force of the hub will be as
1) Using push tool , press the inner race on follows to adjust the pre-load on the bearing.
the bearing on the nut side with a press. 3 Nut: 245 – 490 Nm {25 – 50 kgm}
★ Pressing force on inner race: ★ Rotating force: 127 – 206 N {13 – 21 kg}
8.8 – 12.7 kN {0.9 – 1.3 tons}
★ After installing hub assembly (24), re-
volve the hub by 2 – 3 turns against the
travel motor case.
D31/37EX,PX-21 30-41
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY
★ If the lock plate is turned over, it deviates 3) Install 2 inner race bearings (19) to gear
by 1/2 notch. Accordingly, install it so (18).
that its claw will be fitted to a notch of the ★ 3 sets
nut. 4) Install gear (18) to No. 2 planetary carrier
2 Threads of mounting bolt: assembly.
Adhesive (LT-2) ★ 3 sets
3 Mounting bolt: 5) Install shaft (16) and ball (17) to No. 2 plan-
58.8 – 73.5 Nm {6 – 7.5 kgm} etary carrier assembly.
★ Install the shaft by expansion fit.
★ Match the hole of the shaft to that of the
carrier and install the shaft by hitting it
lightly with a plastic hammer, etc.
★ 3 sets
30-42 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY
D31/37EX,PX-21 30-43
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY
8. Cover
1) Using 2 through bolts , 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}
30-44 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY IDLER AND RECOIL SPRING ASSEMBLY
4 Idler: 100 kg
D31/37EX,PX-21 30-45
DISASSEMBLY AND ASSEMBLY RECOIL SPRING ASSEMBLY
1. Remove the mounting bolts and lock plate (1). 3) Remove 2 lock plates (7) and nut (6).
★ Compress the spring until the nut be-
2. Remove valve (3) comes loose.
★ Release the hydraulic pressure slowly to
3. Remove rod assembly (5) from recoil spring lower the tension of the spring to zero.
assembly (4). 4) Remove pilot (9) and cylinder (10) from
spring (8).
4. Disassembly of recoil spring assembly 5) Remove snap ring (11), spacer (12), dust
1) Set recoil spring assembly (4) to tool M. seal (13), and bushing (14) from cylinder
kSince the installed load of the spring is (10).
large and dangerous, set it securely.
★ Installed load of spring: 5. Disassembly of rod assembly
71.54 kN {7,300 kg} 1) Remove wear ring (16) from rod assembly
(5).
2) Remove snap ring (17) and U-packing (18).
30-46 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY RECOIL SPRING ASSEMBLY
1. Assembly of rod assembly 3) Using push tool , install spacer (12) and
1) Install U-packing (18) to rod assembly (5) secure it with snap ring (11).
and secure it with snap ring (17).
2) Install wear ring (16).
D31/37EX,PX-21 30-47
DISASSEMBLY AND ASSEMBLY RECOIL SPRING ASSEMBLY
30-48 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY IDLER ASSEMBLY
D31/37EX,PX-21 30-49
DISASSEMBLY AND ASSEMBLY IDLER ASSEMBLY
30-50 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY IDLER ASSEMBLY
5. Using tool L2, install floating seal (9) to support 8. Using tool L2, install floating seal (6) to support
(10). (5).
★ For precautions for installing the floating ★ For precautions for installing the floating
seal, see ★ in step 4 above. seal, see ★in step 4 above.
6. Install idler (7) to the shaft and support assem- 9. Fit the O-ring to shaft (8).
bly.
10. Supply oil through the hole of shaft (8) and
7. Using tool L2, install floating seal (6) to idler (7). tighten the plug.
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}
D31/37EX,PX-21 30-51
DISASSEMBLY AND ASSEMBLY IDLER ASSEMBLY
6 Track roller: Approx. 150 cc 7. Remove bushing (9) and (10) from roller (6).
2. Set roller assembly (2) to block . 8. Remove ring (11), then remove collar (12) from
shaft (13).
3. Push collar (3) and pull out ring (4), then remove
collar (3).
4. Remove floating seal (5) from collar (3). 10. Remove O-rings (15) from shaft (13).
30-52 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY IDLER ASSEMBLY
★ Precautions when assembling floating seal. 4. Install floating seal (8) to roller (6).
1) When assembling the floating seal, ★ For details of the precautions when installing
degrease and dry the parts indicated the floating seals, see Step 2, ★ Precautions
with thick line A (O-ring and mating face when assembling floating seal.
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
of the floating seal is within a range
of 7 – 11 mm.
D31/37EX,PX-21 30-53
DISASSEMBLY AND ASSEMBLY IDLER ASSEMBLY
5. Set shaft (13) and collar (12) assembly on block 8. Install floating seal (5) to collar (3).
, then assemble roller (6). ★ For details of the precautions when installing
★ Coat the sliding surface of the floating seal the floating seals, see Step 2, ★ Precaution
with engine oil, and make sure that no dirt or when assembling floating seal.
dust sticks to the surface. ★ Coat the sliding surface of the floating seal
★ When assembling the roller, coat the shaft or with engine oil, and make sure that no dirt or
bushing with engine oil. dust sticks to the surface.
6. Refilling with oil 9. Fit roller (2) to collar (3), then install ring (4).
Pour oil through clearance between shaft (13)
and roller (6).
30-54 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY IDLER ASSEMBLY
11. If oil was not added in Step 6, use tool L5, to fill
track roller assembly with oil.
D31/37EX,PX-21 30-55
DISASSEMBLY AND ASSEMBLY IDLER ASSEMBLY
30-56 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY IDLER ASSEMBLY
D31/37EX,PX-21 30-57
DISASSEMBLY AND ASSEMBLY IDLER ASSEMBLY
30-58 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY TRACK SHOE ASSEMBLY
D31/37EX,PX-21 30-59
DISASSEMBLY AND ASSEMBLY HST PUMP ASSEMBLY
• (4) : From charge filter 6. Lift off HST pump assembly (10).
• (5) : To drain hole
4 HST pump assembly: 140 kg
• (6) : To charge filter
• (7) : From hydraulic tank
• (8) : To upper travel motor, R.H. reverse
(Hose color band: Blue)
: To lower travel motor, L.H. forward
(Hose color band: Yellow)
• (9) : To upper travel motor, R.H. forward
(Hose color band: Green)
: To lower travel motor, L.H. reverse
(Hose color band: Orange)
★ The photograph shows the D39-21, but in
the case of the D31 and D37-21, there is a
branch hose, so disconnect the branch hose
also.
30-60 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY HST PUMP ASSEMBLY
3 Flange bolt:
98 – 123 Nm {10 – 12.5 kgm}
• Bleeding air
1) Before starting the engine, loosen bleeder
(13) and check that oil is oozing out through
the bleeder.
★ Bleed air while the engine is stopped.
2) When oil containing no bubbles flows out,
tighten the bleeder.
3 Bleeder:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
D31/37EX,PX-21 30-61
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE ASSEMBLY
2. Remove the 4 mounting bolts and charge pump 4. Disconnect 2 heater hoses (11).
oil filter bracket (2).
★ Move the bracket aside so that it will not be 5. Remove the 2 mounting bolts and seat belt (12).
an obstacle to the work to disconnect the
equipment hoses. 6. Remove mounting bolts (13).
30-62 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE ASSEMBLY
8. Disconnect the following 10 main control valve • Bleeding air (HST circuit)
main hoses. ★ Bleed air from the HST pump circuit. For de-
• (15): Angle left tails, see INSTALLATION OF HST PUMP
• (16): Angle right ASSEMBLY.
• (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)
D31/37EX,PX-21 30-63
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE ASSEMBLY
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).
★ Do not remove the spool, seal, and LS
selector valve.
8. Plugs
Remove 2 plugs (23), plug (24), plug (25), and 2
plugs (26).
30-64 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE ASSEMBLY
D31/37EX,PX-21 30-65
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE ASSEMBLY
30-66 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE ASSEMBLY
D31/37EX,PX-21 30-67
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE ASSEMBLY
★ Apply engine oil to the sliding surfaces before as- 3. Angle control valve
sembling. 1) Fit the O-ring to case (31).
★ As a result of disassembly, if the spool or block 2) Install case (31) to the block with the mount-
has any defect, replace the assembly. ing bolts.
★ Degrease the plug and female screw of the spool 3 Bolt:
with DRYSOL, etc. and dry them completely be- 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
fore tightening. Do not apply pressure on them 3) Install retainer (30) and spring (29) to the
for at least 2 hours after they are tightened. block with bolt (28).
3 Bolt: 6.9 – 9.8 Nm {0.7 – 1.0 kgm}
1. Lift control valve 4) Fit the O-ring to case (27).
1) Install retainer (50), spring (49), retainer 5) Install case (27) to the block with the mount-
(48), and spring (47) to the spool. ing bolts.
2) Tighten bolt (46) in the spool. 3 Bolt:
★ Apply 1 drip (approx. 0.02 g) of LOC- 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
TITE (No. 638) to the bolt.
★ 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}
30-68 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE ASSEMBLY
D31/37EX,PX-21 30-69
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE ASSEMBLY
5. Suction valve
Fit the O-ring and screw suction valve (14) into
the block.
★ 3 sets
3 Suction valve:
39.2 – 49 Nm {4 – 5 kgm}
30-70 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE ASSEMBLY
D31/37EX,PX-21 30-71
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER ASSEMBLIES
30-72 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER ASSEMBLIES
★ Apply engine oil to the sliding surfaces of each 2) Disassembly of piston assembly
part and take care not to damage the rod, pack- i) Set piston ring (8) to tool U4.
ing, dust seal, and O-ring. ii) Rotate the handle by 8 – 10 turns to
expand the piston ring.
1. Head assembly and piston assembly iii) Remove piston ring (8) from tool U4.
1) Assembly of head assembly iv) Install piston ring (8) to piston assembly
i) Press fit bushing (13) with tool U6. (5).
v) Using tool U5, reduce piston ring (8).
D31/37EX,PX-21 30-73
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER ASSEMBLIES
30-74 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY BLADE ASSEMBLY
D31/37EX,PX-21 30-75
DISASSEMBLY AND ASSEMBLY BLADE ASSEMBLY
30-76 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY OPERATOR’S SEAT FRAME ASSEMBLY
6 Hydraulic tank: 47 l
6 Radiator: Approx. 15 l
D31/37EX,PX-21 30-77
DISASSEMBLY AND ASSEMBLY OPERATOR’S SEAT FRAME ASSEMBLY
8. Remove the 2 mounting bolts and seat belt (8). 11. Remove the mounting bolts and cover (11).
30-78 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY OPERATOR’S SEAT FRAME ASSEMBLY
15. Remove the mounting bolts and lift off floor 19. Disconnect drain collecting block hose (29).
cover (19). ★ The photograph shows the D39-21, but in
the case of the D31 and D37-21, there is a
4 Floor cover: 35kg branch hose, so disconnect the branch hose
also.
D31/37EX,PX-21 30-79
DISASSEMBLY AND ASSEMBLY OPERATOR’S SEAT FRAME ASSEMBLY
30-80 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY FUEL TANK ASSEMBLY
INSTALLATION OF FUEL
TANK ASSEMBLY
• Carry out installation in the reverse order to
removal.
D31/37EX,PX-21 30-81
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK ASSEMBLY
30-82 D31/37EX,PX-21
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK ASSEMBLY
D31/37EX,PX-21 30-83
90 OTHERS
D31/37EX,PX-21 90-3
(5)
HYDRAULIC CIRCUIT DIAGRAM (1/2)
D31EX-21 Serial No. 50098 and up, D37EX-21 Serial No. 5105 and up
D31PX-21 Serial No. 50182 and up, D37PX-21 Serial No. 5091 and up
D31/37EX,PX-21 90-3-2
(5)
OTHERS HYDRAURIC CIRCUIT DIAGRAM
D31/37EX,PX-21 90-5-2
(5)
ELECTRICAL CIRCUIT DIAGRAM (1/2)
D31/37EX,PX-21 90-7
(7)
ELECTRICAL CIRCUIT DIAGRAM (2/2)
D31/37EX,PX-21 90-9
(7)
ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER
D31/37EX,PX-21 90-11
(7)