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SEBMOOI 007
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Manual
D31E,P,Pl,l’ll=~o
D31BOA
D31&ho
D37E=!i,D37p=sr
BULLDOZERS
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or
disciosed except in accordance with written authorization from Komatsu America lntemational Company.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or add improvements at any time wlthout Incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication.
It is recommended that customers contact their distributor for information on the latest revision.
May 1997 Copyright 1997 Komatsu America International Company
oo&
CONTENTS
01
10
20
30
40
90
No. of page
GENERAL ......~................................................................. 01-l
STRUCTURE AND FUNCTION ...................................... 10-I
TESTING AND ADJUSTING .......................................... 20-I
DISASSEMBLY AND ASSEMBLY ..............*.........*m....... 30-I
MAINTENANCE STANDARD ....................n....m.........m..... 40-I
%
OTHERS ........................................................................... 90-I
:
0
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT 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 A is used to mark safety precautions in this
manual. The cautions accompanying these symbols should always be followed care-
fully. If any dangerous situation arises or may possibly arise, first consider safety, and
take the necessary actions to deal with the situation.
Mistakes in operation are extremely dangerous.
Read the Operation and Maintenance Manual
carefully BEFORE operating the machine.
1.
2.
Before carrying out any greasing or repairs,
read all the precautions given on the decals
which are fixed to the machine.
When carrying out any operation, always
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons
missing.
. Always wear safety glasses when hitting
parts with a hammer.
6. Decide a place in the repair workshop to
keep tools and removed parts. Always keep
the tools and parts in their correct places.
Always keep the work area clean and make
sure that there is no dirt or oil on the floor.
Smoke only in the areas provided for smok-
ing. Never smoke while working.
PREPARATIONS FOR WORK
GENERAL PRECAUTIONS
7.
. Always wear safety glasses when grind-
ing parts with a grinder, etc.
%.
3. If welding repairs are needed, always have a
trained, experienced welder carry out the
work. When carrying out welding work, al-
ways wear welding gloves, apron, hand
shield, cap and other clothes suited for weld-
Before adding oil or making any repairs,
park the machine on hard, level ground, and
block the wheels or tracks to prevent the
machine from moving.
Before starting work, lower blade, ripper,
bucket or any other work equipment to the
ground. If this is not possible, insert the
safety pin or use blocks to prevent the work
equipment from falling. In addition, be sure
to lock all the control levers and hang warn-
ing signs on them.
ing work.
4. When carrying out any operation with two
or more workers, always agree on the oper-
ating procedure before starting. Always in-
form your fellow workers before starting any
step of the operation. Before starting work,
hang UNDER REPAIR signs on the controls
in the operator’s compartment.
5. Keep all tools in good condition and learn
the correct way to use them.
9. When disassembling or assembling, support
the machine with blocks, jacks or stands
IO.
before starting work.
Remove all mud and oil from the steps or
other places used to get on and off the ma-
chine. Always use the handrails, ladders or
steps when getting on or off the machine.
Never jump on or off the machine. If it is
impossible to use the handrails, ladders or
steps, use a stand to provide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK
11 When removing the oil filler cap, drain plug
or hydraulic pressure measuring plugs,
loosen them slowly to prevent the oil from
spurting out.
Before disconnecting or removing compo-
nents of the oil, water or air circuits, first
remove the pressure completely from the
circuit.
12. The water and oil in the circuits are hot
when the engine is stopped, so be careful
not to get burned.
Wait for the oil and water to cool before
carrying out any work on the oil or water
circuits.
13. Before starting work, remove the leads from
the battery. Always remove the lead from
the negative (-1 terminal first.
14.
15.
16.
17.
18.
When raising heavy components, use a hoist
or crane.
Check that the wire rope, chains and hooks
are free from damage.
Always use lifting equipment which has
ample capacity.
Install the lifting equipment at the correct
places. Use a hoist or crane and operate
slowly to prevent the component from hit-
ting any other part. Do not work with any
part still raised by the hoist or crane.
When removing covers which are under in-
ternal pressure or under pressure from a
spring, always leave two bolts in position
on opposite sides. Slowly release the pres-
sure, then slowly loosen the bolts to remove.
When removing components, be careful not
to break or damage the wiring. Damaged
wiring may cause electrical fires.
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.
As a general rule, do not use gasoline to
wash parts. In particular, use only the mini-
mum of gasoline when washing electrical
parts.
19.
20.
21
Be sure to assemble all parts again in their
original places.
Replace any damaged parts with new parts.
. When installing hoses and wires, be sure
that they will not be damaged by contact
with other parts when the machine is be-
ing operated.
When installing high pressure hoses, make
sure that they are not twisted. Damaged
tubes are dangerous, so be extremely care-
ful when installing tubes for high pressure
circuits. Also, check that connecting parts
are correctly installed.
22. When aligning two holes, never insert your
When assembling or installing parts, always
use the specified tightening torques. When
installing protective parts such as guards,
or parts which vibrate violently or rotate at
high speed, be particularly careful to check
that they are installed correctly.
fingers or hand. Be careful not to get your
fingers caught in a hole.
23. When measuring hydraulic pressure, check
that the measuring tool is correctly assem-
bled before taking any measurements.
24. Take care when removing or installing the
tracks of track-type machines.
When removing the track, the track sepa-
rates suddenly, so never let anyone stand at
either end of the track.
00-4
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
REMOVAL OF STARTING
MOTOR ASSEMBLY
D31E-20 Serial No.: 42001 - 42713
D31P, PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660
ADisconnect the cable from the negative (-) terminal
1.
2.
3.
4.
5.
of the battery.
Remove cover of engine left side.
Disconnect fuel control cable (1). m
Disconnect engine stop motor cable (2) together
with bracket (3). a
Disconnect starting motor wiring (4) and (5).
Remove starting motor assembly (6).
-4 /Il4FO2105
INSTALLATION OF STARTING
MOTOR ASSEMBLY
D3 1E-20 Serial No.: 42001 - 42713
D3lP, PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D3lS, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660
l Carrv out installation in the reverse order to removal.
p?iJ
*
m
*
Adjust the control cable. For details, see TEST-
ING AND ADJUSTING, ADJUSTING FUEL CON-
TROL LEVER.
Adjust the cable. For details, see TESTING AND
ADJUSTING, ADJUSTING ENGINE STOP MOTOR
CABLE.
30-6
a
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
REMOVAL OF STARTING
MOTOR ASSEMBLY
D31E-20 Serial No.: 42714 and up
D31P, PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up
A
1.
2.
3.
4.
$rr
5
0
Disconnect the cable from the negative (-) ter-
minal of the battery.
Remove right engine side cover.
Remove adiabatic plate (I).
Disconnect terminal B (STB) (2) and terminal C
(l-pin connector) (3). 0
Remove starting motor assembly (4). m
INSTALLATION OF STARTING
MOTOR ASSEMBLY
D31E-20 Serial No.: 42714 and up
D31P, PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up
. Carry out installation in the reverse order to
removal.
w Terminal B mounting nut:
17.64 2 1.96 Nm Il.8
CLPO2024
+ 0.2 kgmj
w Starting motor assembly mounting bolt:
42.95 t 5.98 Nm {4.38 f 0.61 kgm)
* Coat the whole circumference with 1.0 mm
of gasket sealant (LG-4) at a point 4 mm
from the inside of the starting motor gasket.
30-7
a
DISASSEMBLY AND ASSEMBLY ALTERNATOR
REMOVAL OF ALTERNATOR
ASSEMBLY
D31 E-20 Serial No.: 42001 - 42713
D31P. PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660
ADisconnect the cable from the negative (-) terminal of
the battery.
Remove cover of engine right side.
Disconnect wiring (1) from alternator.
Remove mounting bolt (2) of adjustment plate, then
loosen mounting bolt (3) and nut, and remove fan belt
(4). j
Remove mounting bolt and nut, then remove alterna-
tor assembly (5).
%
6
INSTALLATION OF
ALTERNATOR ASSEMBLY
D31E-20 Serial No.: 42001 - 42713
D31P, PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660
l Carry out installation in the reverse order to removal.
* Adjust the fan belt tension. For details, see
STANDARD VALUE TABLE FOR ENGINE RE-
LATED PARTS.
30-7-l
0
DISASSEMBLY AND ASSEMBLY ALTERNATOR
REMOVAL OF ALTERNATOR
ASSEMBLY
D31 E-20 Serial No.: 42714 and up
D31P, PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up
a Disconnect the cable from the negative (-) ter-
1.
2.
3.
4.
%
z
0
5.
minal of the battery.
Remove right engine side cover.
Loosen locknut (I) and remove bolt (2). (Revers-
ible fan specification) m
Using ratchet handle @(insertion angle: 9.5 mm),
raise tensioner (3) and remove fan belt (4).
g Be extremely careful not to get your fingers
caught between the tensioner and pulley
when removing the fan belt.
Remove terminal R (AIR) (5) and terminal B (ALB)
(6).
* The wiring at the R terminal is yellow.
Remove alternator assembly (7). a
* There are spacers installed to the mounting
bolts, so be careful not to lose them.
INSTALLATION OF
ALTERNATOR ASSEMBLY
D31E-20 Serial No.: 42714 and up
D31P. PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up
. Carry out installation in the reverse order to
removal.
Put the fan belt under tension from tensioner
(31, adjust bolt (2) so that clearance a between
bolt (2) and tensioner (3) is 0, then secure with
locknut (I).
m
w Alternator assembly mounting bolt:
42.95 + 5.98 Nm I4.38 + 0.61 kgm}
* Use a straight edge and check that the end
face of the alternator pulley is level with the
end face of the other pulleys.
~2
I’
I ' CEO02251
--u-Ji J- / CEtl02252
30-7-2
a
DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER CORE
REMOVAL OF ENGINE OIL
COOLER CORE ASSEMBLY
D31E-20 Serial No.: 42714 and up
D31P, PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up
1.
2.
3.
4.
5.
Remove alternator assembly.
For details, see REMOVAL OF ALTERNATOR AS-
SEMBLY.
Disconnect turbocharger lubrication hose (I).
Ir Disconnect at the engine oil cooler end.
Remove oil filter (2). a
Remove cooler cover assembly (3). a
Remove cooler core (4) from oil cooler cover
assembly.
INSTALLATION OF ENGINE OIL
COOLER CORE ASSEMBLY
D31E-20 Serial No.: 42714 and up
D31P, PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up
l Carry out installation in the reverse order to
removal.
w Oil filter:
13.04 z 1.96 Nm {I.33 2 0.2 kgm}
w Oil cooler assembly mounting bolt:
24.03 f 4.02 Nm (2.45 = 0.41 kgm}
30-7-3
a
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
REMOVAL OF FUEL INJECTION
PUMP ASSEMBLY
D31E-20 Serial No.: 42001 - 42713
D31P, PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660
1. Remove cover of engine left side.
2. Disconnect fuel control cable (1) and engine stop
motor cable (2). m
3. Disconnect fuel supply hose (3) and fuel hoses (4).
* Fit a blind plug in supply hose (3) to prevent
fuel from leaking out.
4. Remove lubrication tube (5).
5. Disconnect 6 fuel injection pipes (6). m
6. Remove bracket (7), then remove fuel injection
pump assembly (8). m
I Il4FO2108
30-8
0
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY
D31 E-20 Serial No.: 42001 - 42713
D31 P, PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S. Q-20 Serial No.: 41001 - 41183
D31 P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660
. Carry out installation in the reverse order to removal.
m
* Adjust the cables. For details, see TESTING AND
ADJUSTING, ADJUSTING FUEL CONTROL LEVER
and ADJUSTING ENGINE STOP MOTOR CABLE.
m Sleeve nut:
22.06 z 2.45 Nm (2.25 = 0.25 kgm)
m
. Install the fuel injection pump as follows.
1) Set No. 1 cylinder at compression top dead center.
+ Rotate the crankshaft in the normal direction
and align the pointer with the 1.6 TOP line
on the crankshaft pulley. If the match mark
on the idler gear cannot be seen, rotate the
crankshaft one more turn.
2) Replace with bolt @ and fix drive gear (11) in
position.
3) Injection pump assembly
+ Insert pin @ (0 4.0 - 4.5 mm, length = approx.
100 mm) through cover mounting bolt hole
a, and check that the pin enters the casting
hole in the drive gear smoothly.
4) Remove bolt 0, and replace it with a standard
bolt.
. Adjust the fuel injection timing and bleed the air from
the fuel system.
For details, see TESTING AND ADJUSTING.
014OF107
I I4FO2 109
il4FO21 IO
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
REMOVAL OF FUEL INJECTION
PUMP ASSEMBLY
D3 1E-20 Serial No.: 42714 and up
D31P, PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up
1.
2.
3.
4.
5.
Drain fuel from fuel tank.
Remove engine left cover.
Remove hydraulic pump assembly.
For details, see REMOVAL OF HYDRAULIC PUMP
ASSEMBLY.
Disconnect rod (1) of engine stop solenoid.
* Disconnect at the fuel injection pump end.
Disconnect 2 wires (2) and remove engine stop
solenoid (3). a
* Be careful not to drop the spacer.
6. Remove delivery tubes (4).
7. Disconnect fuel tubes (5), (61, and (7), fuel hose
(8), and lubrication tube (9). a
30-9-1
0
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
8.
9.
10.
Remove cap (IO). a
* Use a filter wrench to remove.
Remove nut (11) and washer (12). m
* Be careful not to drop the nut or washer
inside the case.
Using tool AZ, disconnect shaft and drive gear
of fuel injection pump.
11. Remove sound absorbing material (13).
12.
13.
Remove fuel injection pump mount bracket (14).
m
Remove 4 nuts (151, then remove fuel injection
pump assembly (16). m
CED02259
CED02260
CED02262
30-9-2
a
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY
D31E-20 Serial No.: 42714 and up
D31P, PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up
l Carry out installation in the reverse order to
removal.
* Adjust the engine stop solenoid.
For details, see TESTING AND ADJUSTING,
Adjusting engine stop solenoid linkage.
Delivery tube sleeve nut:
24 + 4 Nm 12.45 + 0.41 kgm}
Fuel tube l-joint:
24 f 4 Nm 12.45 + 0.41 kgm}
Lubrication tube l-joint:
12 + 2 Nm Il.2 + 0.2 kgm}
Ir Turn the cap 180” to tighten it.
Ifmm
. Install the fuel injection pump assembly as
follows.
1) Loosen bolt, move plate (22) to the side,
then remove cap (23).
2) Using tool Al, crank the engine slowly in
the normal direction, and push No. 1 cylin-
der compression top dead center position-
ing pin (17) into the gear.
30-9-3
a
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
3)
4)
5) Align fuel injection
gear and install fuel
bly (16).
pump shaft with drive
injection pump assem-
6) Tighten nut (15).
m Nut: 43 c 6 Nm (4.38 + 0.61 kgm}
* Refer to the following and push posi-
tioning pin (17) securely into the gear.
. Dimension a when free: 24 mm
. Dimension b when there is gear con-
tact: 20 mm
. Dimension c when pushed into gear
hole:16 mm
* When the positioning pin is pushed in,
stop barring the engine immediately (oth-
erwise, the positioning pin will break).
Remove plug (19), then remove timing pin
(20).
Reverse the position of timing pin (19) 180”,
align the timing pin groove with pointer (21)
inside the pump, then temporarily tighten
plug (19).
* If the tooth of pointer (21) cannot be
aligned with the timing pin hole, rotate
the shaft of the fuel injection pump to
align the pointer tooth.
ET-lCED02263
CEP05301
ii
CEP05302
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
7)
8)
9)
IO)
Install washer (121, and tighten nut (II).
-k Be extremely careful not to drop the nut
or washer inside the case when install-
ing.
w Nut: 12.5 t 2.5 Nm Il.27 + 0.25 kgm}
* This is not the final torque value.
* To prevent damage to the No. 1 cylinder
compression top dead center position-
ing pin, be careful not to tighten the nut
to more than the above tightening
torque.
Remove meshing of No. 1 cylinder compres-
sion top dead center positioning pin (17).
Remove plug (191, reverse mounting posi-
tion of timing pin (20), then assemble and
install plug to fuel injection pump.
m Plug: 14.7 Nm (1.5 kgm}
Tighten drive gear mounting nut (I I) of fuel
injection pump fully.
w Nut: 95 + 10 Nm (9.7 + 1.02 kgm}
11) Carry out the rest of the installation in the
reverse order to removal.
* Adjust fuel injection timing.
For details, see TESTING AND ADJUSTING,
Adjusting fuel injection timing.
CED02259
CLPO2075
CEP0530
. Bleeding air
Sr Bleed the air from the fuel line.
For details, see TESTING AND ADJUSTING,
Bleeding air from fuel circuit.
30-9-5
a
DISASSEMBLY AND ASSEMBLY WATER PUMP
REMOVAL OF WATER PUMP
ASSEMBLY
D31 E-20 Serial No.: 42001 - 42713
D31P, PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660
1.
2.
3.
4.
5.
Loosen radiator drain valve and drain cooling water.
Remove exhaust pipe (1) and left and right engine
side covers (2), disconnect reserve tank hose, then
remove engine hood (3).
& kg Engine hood assembly: 40 kg
Remove fan guard (4) and shroud (5).
Disconnect radiator hoses (6), (7) and wire (8) of
water temperature gauge sensor.
Loosen mounting bolt of adjustment plate, then
mounting bolt and nut, and remove fan belt (9) and
fan (IO).
6. Remove fan pulley (11). @J
7. Remove water pump assembly (12).
INSTALLATION OF WATER
PUMP ASSEMBLY
D31 E-20 Serial No.: 42001 - 42713
D31P, PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660
l Carry out installation in the reverse order to removal.
m
* Adjust the fan belt tension. For details, see
STANDARD VALUE TABLE FOR ENGINE RELA-
TED PARTS.
l Refilling with water
* Add water to the specified level from filler port,
and run the engine to circulate the water
through the system. Then check the water level
again.
%
6
30-10
0
DISASSEMBLY AND ASSEMBLY WATER PUMP
REMOVAL OF WATER PUMP
ASSEMBLY
D3 1E-20 Serial No.: 42714 and up
D31P. PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S. Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up
1. Drain coolant.
2. Remove alternator assembly.
For details, see REMOVAL OF ALTERNATOR AS-
SEMBLY.
3. Remove water pump assembly (I). m
INSTALLATION OF WATER
PUMP ASSEMBLY
D31E-20 Serial No.: 42714 and up
D31P, PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up
. Carry out installation in the reverse order to
removal.
w Water pump assembly mounting bolt:
24.03 + 4.02 Nm 12.45 2 0.41 kgm}
. Refilling with water
Add water through the water filler to the speci-
fied level.
Run the engine to circulate the water through
the system. Then check the water level again.
30-l o-1
a
DISASSEMBLY AND ASSEMBLY THERMOSTAT
REMOVAL OF THERMOSTAT
D31 E-20 Serial No.: 42001 - 42713
D31P, PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660
1. Loosen radiatqr drain valve and drain cooling water.
2. Remove cover of engine right side.
3. Disconnect hose (I), and remove connector (2).
4. Remove thermostat (3).
INSTALLATION OF
THERMOSTAT
D31E-20 Serial No.: 42001 - 42713
D31P. PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660
l Carry out installation in the reverse order to removal.
l Refilling with water
* Add water to the specified level from filler port,
and run the engine to circulate the water
through the system. Then check the water level
again.
30-1o-2
a
DISASSEMBLY AND ASSEMBLY THERMOSTAT
REMOVAL OF THERMOSTAT
ASSEMBLY
D3 1E-20 Serial No.: 42714 and up
D31 P, PL-20 Serial No.: 47617 and up
D31 PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31 P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up
1.
2.
%
7.
z
0
Drain coolant.
Remove alternator assembly.
For details, see REMOVAL OF ALTERNATOR
ASSEMBLY.
Disconnect hose (I I.
Disconnect radiator inlet port hose (2).
Remove alternator bracket (3).
Remove thermostat housing (4).
Remove thermostat (5).
INSTALLATION OF
THERMOSTAT ASSEMBLY
D3 1E-20 Serial No.: 42714 and up
D31P, PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S. Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up
l Carry out installation in the reverse order to
removal.
m Alternator bracket mounting bolt:
24.03 2 4.02 Nm I2.45 + 0.41 kgm}
w Thermostat housing mounting bolt:
24.03 f 4.02 Nm I2.45 = 0.41 kgm}
CEDO2280
. Refilling with water
* Add water through the water filler to the
specified level.
Run the engine to circulate the water through
the system. Then check the water level again.
30-l 1
a
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER
REMOVAL OF NOZZLE
HOLDER ASSEMBLY
D31 E-20 Serial No.: 42001 - 42713
D31P, PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660
1. Remove clamp (l), then disconnet fuel injection pipe
(2). m
2. Disconnect spill hose (3).
3. Remove the bolt, then remove nozzle holder assem-
bly (4). 133f
* When removing the nozzle holder assembly,
clean around the nozzle holder assembly and fit
a blind plug to prevent dust or dirt from enter-
ing.
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY
D31 E-20 Serial No.: 42001 - 42713
D31P, PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660
. Carry out installation in the reverse order to removal.
F07 I27
/I
w Sleeve nut:
22.06 t 2.45 Nm i2.25 + 0.25 kgml
/izJ
* When installing the nozzle holder assembly, check
the nozzle holder mount, and clean before install-
ing.
w Nozzle holder mounting bolt:
44.13 + 4.90 Nm (4.5 + 0.5 kgm}
30-12
0
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER
REMOVAL OF NOZZLE
HOLDER ASSEMBLY
D31 E-20 Serial No.: 42714 and up
D31P. PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up
1. Remove left engine side cover.
2.
3.
4.
Remove air cleaner mounting bolts (2) and (3).
* Support the air cleaner with block 0.
Disconnect wiring (AS1 and AS2) (4).
Loosen 2 clamps (5), remove air duct (6) at air
cleaner end, then remove air cleaner assembly.
5. Remove air supply connector (8).
+ When removing the No. 3 nozzle holder as-
sem bly
6. Remove muffler bracket (9).
* When removing the No. 4 nozzle holder as-
sem bly
7.
8.
Remove 4 delivery tubes (IO). m
Remove spill tube (II). m
- CED02270
Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER
9. Loosen nut (12) and remove nozzle holder as-
sembly (13). m
* If it is difficult to remove the nozzle holder
assembly, use tool J to remove it.
* Be careful not to let dirt or dust get into the
nozzle holder assembly mount.
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY
D3 1E-20 Serial No.: 42714 and up
D31P, PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up
l Carry out installation in the reverse order to
removal.
w Fuel injection tube sleeve nut (nozzle
holder end):
30.01 +. 5.00 Nm I3.06 z 0.51 kgm}
w Fuel injection tube sleeve nut (fuel injec-
tion pump end):
24.03 z 4.02 Nm 12.45 + 0.41 kgm)
m Mounting bolt of fuel injection tube in-
termediate clamp:
24.03 2 4.02 Nm 12.45 +. 0.41 kgm}
w Spill tube joint bolt: 8.04 Nm IO.82 kgm}
w Nozzle holder mounting bolt:
60.02 + 8.92 Nm 16.12 + 0.91 kgm}
* When assembling the nozzle holder, clean
the nozzle holder mount, and check that there
is no dirt or dust inside the sleeve before
assembling.
30-l 3-l
a
DISASSEMBLY AND ASSEMBLY TURBOCHARGER
REMOVAL OF
TURBOCHARGER ASSEMBLY
D31E-20 Serial No.: 42714 and up
D31P, PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up
1. Remove left and right engine side covers.
2. Remove exhaust pipe (I).
3. Remove air cleaner mounting bolts (2) and
(3).
* Support the air cleaner with block 0.
4. Lift off engine hood (4).
Engine hood: 30 kg
5. Disconnect wiring (AS1 and AS2) (5).
30- 13-2
a
DISASSEMBLY AND ASSEMBLY TURBOCHARGER
6. Remove clamps (6) and (71, then remove air
cleaner assembly (8) together with intake hose.
7. Remove adiabatic plate (9).
8.
9.
IO.
11.
12.
13.
Sling muffler assembly (IO).
Loosen clamp (II).
Remove muffler assembly together with exhaust
connector (12).
&I kg Muffler assembly: 35 kg
Loosen clamp and move hose (13) towards in-
take connector. a
Disconnect lubrication inlet hose (14). a
Disconnect lubrication outlet tube (15). 113
30-13-3
0

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Komatsu d31 p 20 dozer bulldozer service repair manual

  • 1. SEBMOOI 007 Shop Manual D31E,P,Pl,l’ll=~o D31BOA D31&ho D37E=!i,D37p=sr BULLDOZERS This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or disciosed except in accordance with written authorization from Komatsu America lntemational Company. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time wlthout Incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision. May 1997 Copyright 1997 Komatsu America International Company oo&
  • 2. CONTENTS 01 10 20 30 40 90 No. of page GENERAL ......~................................................................. 01-l STRUCTURE AND FUNCTION ...................................... 10-I TESTING AND ADJUSTING .......................................... 20-I DISASSEMBLY AND ASSEMBLY ..............*.........*m....... 30-I MAINTENANCE STANDARD ....................n....m.........m..... 40-I % OTHERS ........................................................................... 90-I : 0
  • 3. SAFETY SAFETY NOTICE SAFETY SAFETY NOTICE IMPORTANT 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 A is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed care- fully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. 2. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. . Always wear safety glasses when hitting parts with a hammer. 6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smok- ing. Never smoke while working. PREPARATIONS FOR WORK GENERAL PRECAUTIONS 7. . Always wear safety glasses when grind- ing parts with a grinder, etc. %. 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, al- ways wear welding gloves, apron, hand shield, cap and other clothes suited for weld- Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warn- ing signs on them. ing work. 4. When carrying out any operation with two or more workers, always agree on the oper- ating procedure before starting. Always in- form your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment. 5. Keep all tools in good condition and learn the correct way to use them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands IO. before starting work. Remove all mud and oil from the steps or other places used to get on and off the ma- chine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. 00-3
  • 4. SAFETY SAFETY NOTICE PRECAUTIONS DURING WORK 11 When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing compo- nents of the oil, water or air circuits, first remove the pressure completely from the circuit. 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (-1 terminal first. 14. 15. 16. 17. 18. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hit- ting any other part. Do not work with any part still raised by the hoist or crane. When removing covers which are under in- ternal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pres- sure, then slowly loosen the bolts to remove. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 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. As a general rule, do not use gasoline to wash parts. In particular, use only the mini- mum of gasoline when washing electrical parts. 19. 20. 21 Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. . When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is be- ing operated. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely care- ful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 22. When aligning two holes, never insert your When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. fingers or hand. Be careful not to get your fingers caught in a hole. 23. When measuring hydraulic pressure, check that the measuring tool is correctly assem- bled before taking any measurements. 24. Take care when removing or installing the tracks of track-type machines. When removing the track, the track sepa- rates suddenly, so never let anyone stand at either end of the track. 00-4
  • 5. DISASSEMBLY AND ASSEMBLY STARTING MOTOR REMOVAL OF STARTING MOTOR ASSEMBLY D31E-20 Serial No.: 42001 - 42713 D31P, PL-20 Serial No.: 45001 - 47616 D31PLL-20 Serial No.: 45001 - 47652 D31S, Q-20 Serial No.: 41001 - 41183 D31P-20A Serial No.: 45001 - 47616 D37E-5 Serial No.: 3001 - 3730 D37P-5A Serial No.: 3001 - 3660 ADisconnect the cable from the negative (-) terminal 1. 2. 3. 4. 5. of the battery. Remove cover of engine left side. Disconnect fuel control cable (1). m Disconnect engine stop motor cable (2) together with bracket (3). a Disconnect starting motor wiring (4) and (5). Remove starting motor assembly (6). -4 /Il4FO2105 INSTALLATION OF STARTING MOTOR ASSEMBLY D3 1E-20 Serial No.: 42001 - 42713 D3lP, PL-20 Serial No.: 45001 - 47616 D31PLL-20 Serial No.: 45001 - 47652 D3lS, Q-20 Serial No.: 41001 - 41183 D31P-20A Serial No.: 45001 - 47616 D37E-5 Serial No.: 3001 - 3730 D37P-5A Serial No.: 3001 - 3660 l Carrv out installation in the reverse order to removal. p?iJ * m * Adjust the control cable. For details, see TEST- ING AND ADJUSTING, ADJUSTING FUEL CON- TROL LEVER. Adjust the cable. For details, see TESTING AND ADJUSTING, ADJUSTING ENGINE STOP MOTOR CABLE. 30-6 a
  • 6. DISASSEMBLY AND ASSEMBLY STARTING MOTOR REMOVAL OF STARTING MOTOR ASSEMBLY D31E-20 Serial No.: 42714 and up D31P, PL-20 Serial No.: 47617 and up D31PLL-20 Serial No.: 47653 and up D31S, Q-20 Serial No.: 41184 and up D31P-20A Serial No.: 47617 and up D37E-5 Serial No.: 3731 and up D37P-5A Serial No.: 3661 and up A 1. 2. 3. 4. $rr 5 0 Disconnect the cable from the negative (-) ter- minal of the battery. Remove right engine side cover. Remove adiabatic plate (I). Disconnect terminal B (STB) (2) and terminal C (l-pin connector) (3). 0 Remove starting motor assembly (4). m INSTALLATION OF STARTING MOTOR ASSEMBLY D31E-20 Serial No.: 42714 and up D31P, PL-20 Serial No.: 47617 and up D31PLL-20 Serial No.: 47653 and up D31S, Q-20 Serial No.: 41184 and up D31P-20A Serial No.: 47617 and up D37E-5 Serial No.: 3731 and up D37P-5A Serial No.: 3661 and up . Carry out installation in the reverse order to removal. w Terminal B mounting nut: 17.64 2 1.96 Nm Il.8 CLPO2024 + 0.2 kgmj w Starting motor assembly mounting bolt: 42.95 t 5.98 Nm {4.38 f 0.61 kgm) * Coat the whole circumference with 1.0 mm of gasket sealant (LG-4) at a point 4 mm from the inside of the starting motor gasket. 30-7 a
  • 7. DISASSEMBLY AND ASSEMBLY ALTERNATOR REMOVAL OF ALTERNATOR ASSEMBLY D31 E-20 Serial No.: 42001 - 42713 D31P. PL-20 Serial No.: 45001 - 47616 D31PLL-20 Serial No.: 45001 - 47652 D31S, Q-20 Serial No.: 41001 - 41183 D31P-20A Serial No.: 45001 - 47616 D37E-5 Serial No.: 3001 - 3730 D37P-5A Serial No.: 3001 - 3660 ADisconnect the cable from the negative (-) terminal of the battery. Remove cover of engine right side. Disconnect wiring (1) from alternator. Remove mounting bolt (2) of adjustment plate, then loosen mounting bolt (3) and nut, and remove fan belt (4). j Remove mounting bolt and nut, then remove alterna- tor assembly (5). % 6 INSTALLATION OF ALTERNATOR ASSEMBLY D31E-20 Serial No.: 42001 - 42713 D31P, PL-20 Serial No.: 45001 - 47616 D31PLL-20 Serial No.: 45001 - 47652 D31S, Q-20 Serial No.: 41001 - 41183 D31P-20A Serial No.: 45001 - 47616 D37E-5 Serial No.: 3001 - 3730 D37P-5A Serial No.: 3001 - 3660 l Carry out installation in the reverse order to removal. * Adjust the fan belt tension. For details, see STANDARD VALUE TABLE FOR ENGINE RE- LATED PARTS. 30-7-l 0
  • 8. DISASSEMBLY AND ASSEMBLY ALTERNATOR REMOVAL OF ALTERNATOR ASSEMBLY D31 E-20 Serial No.: 42714 and up D31P, PL-20 Serial No.: 47617 and up D31PLL-20 Serial No.: 47653 and up D31S, Q-20 Serial No.: 41184 and up D31P-20A Serial No.: 47617 and up D37E-5 Serial No.: 3731 and up D37P-5A Serial No.: 3661 and up a Disconnect the cable from the negative (-) ter- 1. 2. 3. 4. % z 0 5. minal of the battery. Remove right engine side cover. Loosen locknut (I) and remove bolt (2). (Revers- ible fan specification) m Using ratchet handle @(insertion angle: 9.5 mm), raise tensioner (3) and remove fan belt (4). g Be extremely careful not to get your fingers caught between the tensioner and pulley when removing the fan belt. Remove terminal R (AIR) (5) and terminal B (ALB) (6). * The wiring at the R terminal is yellow. Remove alternator assembly (7). a * There are spacers installed to the mounting bolts, so be careful not to lose them. INSTALLATION OF ALTERNATOR ASSEMBLY D31E-20 Serial No.: 42714 and up D31P. PL-20 Serial No.: 47617 and up D31PLL-20 Serial No.: 47653 and up D31S, Q-20 Serial No.: 41184 and up D31P-20A Serial No.: 47617 and up D37E-5 Serial No.: 3731 and up D37P-5A Serial No.: 3661 and up . Carry out installation in the reverse order to removal. Put the fan belt under tension from tensioner (31, adjust bolt (2) so that clearance a between bolt (2) and tensioner (3) is 0, then secure with locknut (I). m w Alternator assembly mounting bolt: 42.95 + 5.98 Nm I4.38 + 0.61 kgm} * Use a straight edge and check that the end face of the alternator pulley is level with the end face of the other pulleys. ~2 I’ I ' CEO02251 --u-Ji J- / CEtl02252 30-7-2 a
  • 9. DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER CORE REMOVAL OF ENGINE OIL COOLER CORE ASSEMBLY D31E-20 Serial No.: 42714 and up D31P, PL-20 Serial No.: 47617 and up D31PLL-20 Serial No.: 47653 and up D31S, Q-20 Serial No.: 41184 and up D31P-20A Serial No.: 47617 and up D37E-5 Serial No.: 3731 and up D37P-5A Serial No.: 3661 and up 1. 2. 3. 4. 5. Remove alternator assembly. For details, see REMOVAL OF ALTERNATOR AS- SEMBLY. Disconnect turbocharger lubrication hose (I). Ir Disconnect at the engine oil cooler end. Remove oil filter (2). a Remove cooler cover assembly (3). a Remove cooler core (4) from oil cooler cover assembly. INSTALLATION OF ENGINE OIL COOLER CORE ASSEMBLY D31E-20 Serial No.: 42714 and up D31P, PL-20 Serial No.: 47617 and up D31PLL-20 Serial No.: 47653 and up D31S, Q-20 Serial No.: 41184 and up D31P-20A Serial No.: 47617 and up D37E-5 Serial No.: 3731 and up D37P-5A Serial No.: 3661 and up l Carry out installation in the reverse order to removal. w Oil filter: 13.04 z 1.96 Nm {I.33 2 0.2 kgm} w Oil cooler assembly mounting bolt: 24.03 f 4.02 Nm (2.45 = 0.41 kgm} 30-7-3 a
  • 10. DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP REMOVAL OF FUEL INJECTION PUMP ASSEMBLY D31E-20 Serial No.: 42001 - 42713 D31P, PL-20 Serial No.: 45001 - 47616 D31PLL-20 Serial No.: 45001 - 47652 D31S, Q-20 Serial No.: 41001 - 41183 D31P-20A Serial No.: 45001 - 47616 D37E-5 Serial No.: 3001 - 3730 D37P-5A Serial No.: 3001 - 3660 1. Remove cover of engine left side. 2. Disconnect fuel control cable (1) and engine stop motor cable (2). m 3. Disconnect fuel supply hose (3) and fuel hoses (4). * Fit a blind plug in supply hose (3) to prevent fuel from leaking out. 4. Remove lubrication tube (5). 5. Disconnect 6 fuel injection pipes (6). m 6. Remove bracket (7), then remove fuel injection pump assembly (8). m I Il4FO2108 30-8 0
  • 11. DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY D31 E-20 Serial No.: 42001 - 42713 D31 P, PL-20 Serial No.: 45001 - 47616 D31PLL-20 Serial No.: 45001 - 47652 D31S. Q-20 Serial No.: 41001 - 41183 D31 P-20A Serial No.: 45001 - 47616 D37E-5 Serial No.: 3001 - 3730 D37P-5A Serial No.: 3001 - 3660 . Carry out installation in the reverse order to removal. m * Adjust the cables. For details, see TESTING AND ADJUSTING, ADJUSTING FUEL CONTROL LEVER and ADJUSTING ENGINE STOP MOTOR CABLE. m Sleeve nut: 22.06 z 2.45 Nm (2.25 = 0.25 kgm) m . Install the fuel injection pump as follows. 1) Set No. 1 cylinder at compression top dead center. + Rotate the crankshaft in the normal direction and align the pointer with the 1.6 TOP line on the crankshaft pulley. If the match mark on the idler gear cannot be seen, rotate the crankshaft one more turn. 2) Replace with bolt @ and fix drive gear (11) in position. 3) Injection pump assembly + Insert pin @ (0 4.0 - 4.5 mm, length = approx. 100 mm) through cover mounting bolt hole a, and check that the pin enters the casting hole in the drive gear smoothly. 4) Remove bolt 0, and replace it with a standard bolt. . Adjust the fuel injection timing and bleed the air from the fuel system. For details, see TESTING AND ADJUSTING. 014OF107 I I4FO2 109 il4FO21 IO
  • 12. DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP REMOVAL OF FUEL INJECTION PUMP ASSEMBLY D3 1E-20 Serial No.: 42714 and up D31P, PL-20 Serial No.: 47617 and up D31PLL-20 Serial No.: 47653 and up D31S, Q-20 Serial No.: 41184 and up D31P-20A Serial No.: 47617 and up D37E-5 Serial No.: 3731 and up D37P-5A Serial No.: 3661 and up 1. 2. 3. 4. 5. Drain fuel from fuel tank. Remove engine left cover. Remove hydraulic pump assembly. For details, see REMOVAL OF HYDRAULIC PUMP ASSEMBLY. Disconnect rod (1) of engine stop solenoid. * Disconnect at the fuel injection pump end. Disconnect 2 wires (2) and remove engine stop solenoid (3). a * Be careful not to drop the spacer. 6. Remove delivery tubes (4). 7. Disconnect fuel tubes (5), (61, and (7), fuel hose (8), and lubrication tube (9). a 30-9-1 0
  • 13. DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP 8. 9. 10. Remove cap (IO). a * Use a filter wrench to remove. Remove nut (11) and washer (12). m * Be careful not to drop the nut or washer inside the case. Using tool AZ, disconnect shaft and drive gear of fuel injection pump. 11. Remove sound absorbing material (13). 12. 13. Remove fuel injection pump mount bracket (14). m Remove 4 nuts (151, then remove fuel injection pump assembly (16). m CED02259 CED02260 CED02262 30-9-2 a
  • 14. DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY D31E-20 Serial No.: 42714 and up D31P, PL-20 Serial No.: 47617 and up D31PLL-20 Serial No.: 47653 and up D31S, Q-20 Serial No.: 41184 and up D31P-20A Serial No.: 47617 and up D37E-5 Serial No.: 3731 and up D37P-5A Serial No.: 3661 and up l Carry out installation in the reverse order to removal. * Adjust the engine stop solenoid. For details, see TESTING AND ADJUSTING, Adjusting engine stop solenoid linkage. Delivery tube sleeve nut: 24 + 4 Nm 12.45 + 0.41 kgm} Fuel tube l-joint: 24 f 4 Nm 12.45 + 0.41 kgm} Lubrication tube l-joint: 12 + 2 Nm Il.2 + 0.2 kgm} Ir Turn the cap 180” to tighten it. Ifmm . Install the fuel injection pump assembly as follows. 1) Loosen bolt, move plate (22) to the side, then remove cap (23). 2) Using tool Al, crank the engine slowly in the normal direction, and push No. 1 cylin- der compression top dead center position- ing pin (17) into the gear. 30-9-3 a
  • 15. DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP 3) 4) 5) Align fuel injection gear and install fuel bly (16). pump shaft with drive injection pump assem- 6) Tighten nut (15). m Nut: 43 c 6 Nm (4.38 + 0.61 kgm} * Refer to the following and push posi- tioning pin (17) securely into the gear. . Dimension a when free: 24 mm . Dimension b when there is gear con- tact: 20 mm . Dimension c when pushed into gear hole:16 mm * When the positioning pin is pushed in, stop barring the engine immediately (oth- erwise, the positioning pin will break). Remove plug (19), then remove timing pin (20). Reverse the position of timing pin (19) 180”, align the timing pin groove with pointer (21) inside the pump, then temporarily tighten plug (19). * If the tooth of pointer (21) cannot be aligned with the timing pin hole, rotate the shaft of the fuel injection pump to align the pointer tooth. ET-lCED02263 CEP05301 ii CEP05302
  • 16. DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP 7) 8) 9) IO) Install washer (121, and tighten nut (II). -k Be extremely careful not to drop the nut or washer inside the case when install- ing. w Nut: 12.5 t 2.5 Nm Il.27 + 0.25 kgm} * This is not the final torque value. * To prevent damage to the No. 1 cylinder compression top dead center position- ing pin, be careful not to tighten the nut to more than the above tightening torque. Remove meshing of No. 1 cylinder compres- sion top dead center positioning pin (17). Remove plug (191, reverse mounting posi- tion of timing pin (20), then assemble and install plug to fuel injection pump. m Plug: 14.7 Nm (1.5 kgm} Tighten drive gear mounting nut (I I) of fuel injection pump fully. w Nut: 95 + 10 Nm (9.7 + 1.02 kgm} 11) Carry out the rest of the installation in the reverse order to removal. * Adjust fuel injection timing. For details, see TESTING AND ADJUSTING, Adjusting fuel injection timing. CED02259 CLPO2075 CEP0530 . Bleeding air Sr Bleed the air from the fuel line. For details, see TESTING AND ADJUSTING, Bleeding air from fuel circuit. 30-9-5 a
  • 17. DISASSEMBLY AND ASSEMBLY WATER PUMP REMOVAL OF WATER PUMP ASSEMBLY D31 E-20 Serial No.: 42001 - 42713 D31P, PL-20 Serial No.: 45001 - 47616 D31PLL-20 Serial No.: 45001 - 47652 D31S, Q-20 Serial No.: 41001 - 41183 D31P-20A Serial No.: 45001 - 47616 D37E-5 Serial No.: 3001 - 3730 D37P-5A Serial No.: 3001 - 3660 1. 2. 3. 4. 5. Loosen radiator drain valve and drain cooling water. Remove exhaust pipe (1) and left and right engine side covers (2), disconnect reserve tank hose, then remove engine hood (3). & kg Engine hood assembly: 40 kg Remove fan guard (4) and shroud (5). Disconnect radiator hoses (6), (7) and wire (8) of water temperature gauge sensor. Loosen mounting bolt of adjustment plate, then mounting bolt and nut, and remove fan belt (9) and fan (IO). 6. Remove fan pulley (11). @J 7. Remove water pump assembly (12). INSTALLATION OF WATER PUMP ASSEMBLY D31 E-20 Serial No.: 42001 - 42713 D31P, PL-20 Serial No.: 45001 - 47616 D31PLL-20 Serial No.: 45001 - 47652 D31S, Q-20 Serial No.: 41001 - 41183 D31P-20A Serial No.: 45001 - 47616 D37E-5 Serial No.: 3001 - 3730 D37P-5A Serial No.: 3001 - 3660 l Carry out installation in the reverse order to removal. m * Adjust the fan belt tension. For details, see STANDARD VALUE TABLE FOR ENGINE RELA- TED PARTS. l Refilling with water * Add water to the specified level from filler port, and run the engine to circulate the water through the system. Then check the water level again. % 6 30-10 0
  • 18. DISASSEMBLY AND ASSEMBLY WATER PUMP REMOVAL OF WATER PUMP ASSEMBLY D3 1E-20 Serial No.: 42714 and up D31P. PL-20 Serial No.: 47617 and up D31PLL-20 Serial No.: 47653 and up D31S. Q-20 Serial No.: 41184 and up D31P-20A Serial No.: 47617 and up D37E-5 Serial No.: 3731 and up D37P-5A Serial No.: 3661 and up 1. Drain coolant. 2. Remove alternator assembly. For details, see REMOVAL OF ALTERNATOR AS- SEMBLY. 3. Remove water pump assembly (I). m INSTALLATION OF WATER PUMP ASSEMBLY D31E-20 Serial No.: 42714 and up D31P, PL-20 Serial No.: 47617 and up D31PLL-20 Serial No.: 47653 and up D31S, Q-20 Serial No.: 41184 and up D31P-20A Serial No.: 47617 and up D37E-5 Serial No.: 3731 and up D37P-5A Serial No.: 3661 and up . Carry out installation in the reverse order to removal. w Water pump assembly mounting bolt: 24.03 + 4.02 Nm 12.45 2 0.41 kgm} . Refilling with water Add water through the water filler to the speci- fied level. Run the engine to circulate the water through the system. Then check the water level again. 30-l o-1 a
  • 19. DISASSEMBLY AND ASSEMBLY THERMOSTAT REMOVAL OF THERMOSTAT D31 E-20 Serial No.: 42001 - 42713 D31P, PL-20 Serial No.: 45001 - 47616 D31PLL-20 Serial No.: 45001 - 47652 D31S, Q-20 Serial No.: 41001 - 41183 D31P-20A Serial No.: 45001 - 47616 D37E-5 Serial No.: 3001 - 3730 D37P-5A Serial No.: 3001 - 3660 1. Loosen radiatqr drain valve and drain cooling water. 2. Remove cover of engine right side. 3. Disconnect hose (I), and remove connector (2). 4. Remove thermostat (3). INSTALLATION OF THERMOSTAT D31E-20 Serial No.: 42001 - 42713 D31P. PL-20 Serial No.: 45001 - 47616 D31PLL-20 Serial No.: 45001 - 47652 D31S, Q-20 Serial No.: 41001 - 41183 D31P-20A Serial No.: 45001 - 47616 D37E-5 Serial No.: 3001 - 3730 D37P-5A Serial No.: 3001 - 3660 l Carry out installation in the reverse order to removal. l Refilling with water * Add water to the specified level from filler port, and run the engine to circulate the water through the system. Then check the water level again. 30-1o-2 a
  • 20. DISASSEMBLY AND ASSEMBLY THERMOSTAT REMOVAL OF THERMOSTAT ASSEMBLY D3 1E-20 Serial No.: 42714 and up D31 P, PL-20 Serial No.: 47617 and up D31 PLL-20 Serial No.: 47653 and up D31S, Q-20 Serial No.: 41184 and up D31 P-20A Serial No.: 47617 and up D37E-5 Serial No.: 3731 and up D37P-5A Serial No.: 3661 and up 1. 2. % 7. z 0 Drain coolant. Remove alternator assembly. For details, see REMOVAL OF ALTERNATOR ASSEMBLY. Disconnect hose (I I. Disconnect radiator inlet port hose (2). Remove alternator bracket (3). Remove thermostat housing (4). Remove thermostat (5). INSTALLATION OF THERMOSTAT ASSEMBLY D3 1E-20 Serial No.: 42714 and up D31P, PL-20 Serial No.: 47617 and up D31PLL-20 Serial No.: 47653 and up D31S. Q-20 Serial No.: 41184 and up D31P-20A Serial No.: 47617 and up D37E-5 Serial No.: 3731 and up D37P-5A Serial No.: 3661 and up l Carry out installation in the reverse order to removal. m Alternator bracket mounting bolt: 24.03 2 4.02 Nm I2.45 + 0.41 kgm} w Thermostat housing mounting bolt: 24.03 f 4.02 Nm I2.45 = 0.41 kgm} CEDO2280 . Refilling with water * Add water through the water filler to the specified level. Run the engine to circulate the water through the system. Then check the water level again. 30-l 1 a
  • 21. DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER REMOVAL OF NOZZLE HOLDER ASSEMBLY D31 E-20 Serial No.: 42001 - 42713 D31P, PL-20 Serial No.: 45001 - 47616 D31PLL-20 Serial No.: 45001 - 47652 D31S, Q-20 Serial No.: 41001 - 41183 D31P-20A Serial No.: 45001 - 47616 D37E-5 Serial No.: 3001 - 3730 D37P-5A Serial No.: 3001 - 3660 1. Remove clamp (l), then disconnet fuel injection pipe (2). m 2. Disconnect spill hose (3). 3. Remove the bolt, then remove nozzle holder assem- bly (4). 133f * When removing the nozzle holder assembly, clean around the nozzle holder assembly and fit a blind plug to prevent dust or dirt from enter- ing. INSTALLATION OF NOZZLE HOLDER ASSEMBLY D31 E-20 Serial No.: 42001 - 42713 D31P, PL-20 Serial No.: 45001 - 47616 D31PLL-20 Serial No.: 45001 - 47652 D31S, Q-20 Serial No.: 41001 - 41183 D31P-20A Serial No.: 45001 - 47616 D37E-5 Serial No.: 3001 - 3730 D37P-5A Serial No.: 3001 - 3660 . Carry out installation in the reverse order to removal. F07 I27 /I w Sleeve nut: 22.06 t 2.45 Nm i2.25 + 0.25 kgml /izJ * When installing the nozzle holder assembly, check the nozzle holder mount, and clean before install- ing. w Nozzle holder mounting bolt: 44.13 + 4.90 Nm (4.5 + 0.5 kgm} 30-12 0
  • 22. DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER REMOVAL OF NOZZLE HOLDER ASSEMBLY D31 E-20 Serial No.: 42714 and up D31P. PL-20 Serial No.: 47617 and up D31PLL-20 Serial No.: 47653 and up D31S, Q-20 Serial No.: 41184 and up D31P-20A Serial No.: 47617 and up D37E-5 Serial No.: 3731 and up D37P-5A Serial No.: 3661 and up 1. Remove left engine side cover. 2. 3. 4. Remove air cleaner mounting bolts (2) and (3). * Support the air cleaner with block 0. Disconnect wiring (AS1 and AS2) (4). Loosen 2 clamps (5), remove air duct (6) at air cleaner end, then remove air cleaner assembly. 5. Remove air supply connector (8). + When removing the No. 3 nozzle holder as- sem bly 6. Remove muffler bracket (9). * When removing the No. 4 nozzle holder as- sem bly 7. 8. Remove 4 delivery tubes (IO). m Remove spill tube (II). m - CED02270
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  • 24. DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER 9. Loosen nut (12) and remove nozzle holder as- sembly (13). m * If it is difficult to remove the nozzle holder assembly, use tool J to remove it. * Be careful not to let dirt or dust get into the nozzle holder assembly mount. INSTALLATION OF NOZZLE HOLDER ASSEMBLY D3 1E-20 Serial No.: 42714 and up D31P, PL-20 Serial No.: 47617 and up D31PLL-20 Serial No.: 47653 and up D31S, Q-20 Serial No.: 41184 and up D31P-20A Serial No.: 47617 and up D37E-5 Serial No.: 3731 and up D37P-5A Serial No.: 3661 and up l Carry out installation in the reverse order to removal. w Fuel injection tube sleeve nut (nozzle holder end): 30.01 +. 5.00 Nm I3.06 z 0.51 kgm} w Fuel injection tube sleeve nut (fuel injec- tion pump end): 24.03 z 4.02 Nm 12.45 + 0.41 kgm) m Mounting bolt of fuel injection tube in- termediate clamp: 24.03 2 4.02 Nm 12.45 +. 0.41 kgm} w Spill tube joint bolt: 8.04 Nm IO.82 kgm} w Nozzle holder mounting bolt: 60.02 + 8.92 Nm 16.12 + 0.91 kgm} * When assembling the nozzle holder, clean the nozzle holder mount, and check that there is no dirt or dust inside the sleeve before assembling. 30-l 3-l a
  • 25. DISASSEMBLY AND ASSEMBLY TURBOCHARGER REMOVAL OF TURBOCHARGER ASSEMBLY D31E-20 Serial No.: 42714 and up D31P, PL-20 Serial No.: 47617 and up D31PLL-20 Serial No.: 47653 and up D31S, Q-20 Serial No.: 41184 and up D31P-20A Serial No.: 47617 and up D37E-5 Serial No.: 3731 and up D37P-5A Serial No.: 3661 and up 1. Remove left and right engine side covers. 2. Remove exhaust pipe (I). 3. Remove air cleaner mounting bolts (2) and (3). * Support the air cleaner with block 0. 4. Lift off engine hood (4). Engine hood: 30 kg 5. Disconnect wiring (AS1 and AS2) (5). 30- 13-2 a
  • 26. DISASSEMBLY AND ASSEMBLY TURBOCHARGER 6. Remove clamps (6) and (71, then remove air cleaner assembly (8) together with intake hose. 7. Remove adiabatic plate (9). 8. 9. IO. 11. 12. 13. Sling muffler assembly (IO). Loosen clamp (II). Remove muffler assembly together with exhaust connector (12). &I kg Muffler assembly: 35 kg Loosen clamp and move hose (13) towards in- take connector. a Disconnect lubrication inlet hose (14). a Disconnect lubrication outlet tube (15). 113 30-13-3 0