SM D31ex, PX-22 - Sen04343-09 PDF

SEN04343-09
BULLDOZER D31EX -22

D31PX -22
D37EX -22
D37PX -22
SERIAL NUMBERS 60001 and up
SEN04352-09
BULLDOZER
D31EX-22
D31PX-22
D37EX-22
D37PX-22
Machine model Serial number
D31EX-22 60001 and up
D31PX-22 60001 and up
D37EX-22 60001 and up
D37PX-22 60001 and up
00 Index and foreword 00
100 Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 4
D31/37-22 00-100 1
100 Index
SEN04352-09 Composition of shop manual
Composition of shop manual 1
The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
q Place a divider on the top of each section in the file after matching the Tub No. with No. indi-
cated next to each Section Name shown in the table below:
q File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs ..................................................................... SEN04343-09
00 Index and foreword .................................................................................................................... SEN04344-09

100 Index .................................................................................................................................. SEN04352-09 q
200 Foreword and general information ..................................................................................... SEN04353-02
01 General ...................................................................................................................................... SEN04345-00

100 Specification and technical data......................................................................................... SEN04354-00
10 Structure, function and maintenance standard........................................................................... SEN04346-01

100 Engine and cooling system ................................................................................................ SEN04484-00
200 Power train......................................................................................................................... SEN04485-00
300 Undercarriage and frame ................................................................................................... SEN04486-00
410 Hydraulic system, Part 1 .................................................................................................... SEN04487-00
420 Hydraulic system, Part 2 .................................................................................................... SEN04488-00
500 Work equipment................................................................................................................. SEN04489-00
600 Cab and its attachments .................................................................................................... SEN04490-00
700 Electrical system ................................................................................................................ SEN04491-01 q
20 Standard value table................................................................................................................... SEN04347-02

100 Standard service value table.............................................................................................. SEN04501-02
30 Testing and adjusting ................................................................................................................. SEN04348-03

110 Testing and adjusting, Part 1.............................................................................................. SEN04502-02
120 Testing and adjusting, Part 2.............................................................................................. SEN04503-01
130 Testing and adjusting, Part 3.............................................................................................. SEN04504-02 q
40 Troubleshooting.......................................................................................................................... SEN04349-02
100 Failure code table and fuse locations ................................................................................ SEN04505-01 q
200 General information on troubleshooting............................................................................. SEN04506-01
310 Troubleshooting by failure code (Display of code), Part 1 ................................................. SEN04507-01
320 Troubleshooting by failure code (Display of code), Part 2 ................................................. SEN04508-02 q
400 Troubleshooting of electrical system (E-mode).................................................................. SEN04512-01 q
500 Troubleshooting of hydraulic and mechanical system (H-mode) ....................................... SEN04513-00
600 Troubleshooting of engine (S-mode).................................................................................. SEN04514-01
00-100 2 D31/37-22
100 Index
Composition of shop manual SEN04352-09
50 Disassembly and assembly ........................................................................................................SEN04350-01

100 General information on disassembly and assembly...........................................................SEN04724-01
200 Engine and cooling system ................................................................................................SEN04725-01
300 Power train .........................................................................................................................SEN04726-01
400 Undercarriage and frame ...................................................................................................SEN04727-01
500 Hydraulic system ................................................................................................................SEN04728-00
600 Work equipment .................................................................................................................SEN04729-00
700 Cab and its attachments.....................................................................................................SEN04730-00
800 Electrical system ................................................................................................................SEN04731-00
90 Diagrams and drawings..............................................................................................................SEN04351-04

100 Hydraulic diagrams and drawings ......................................................................................SEN04355-02
200 Electrical diagrams and drawings.......................................................................................SEN04356-02 q
D31/37-22 00-100 3
100 Index
SEN04352-09 Table of contents
Table of contents 1
00 Index and foreword

100 Index ..........................................................................................................................................SEN04352-09
Composition of shop manual......................................................................................................................... 2
Table of contents ........................................................................................................................................... 4
200 Foreword and general information .............................................................................................SEN04353-02
Safety notice ................................................................................................................................................. 2
How to read the shop manual ....................................................................................................................... 7
Explanation of terms for maintenance standard............................................................................................ 9
Handling of electric equipment and hydraulic component............................................................................. 11
Handling of connectors newly used for engines............................................................................................ 20
How to read electric wire code ...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
01 General
100 Specification and technical data.................................................................................................SEN04354-00
Specification dimensional drawing ................................................................................................................ 2
Specifications ................................................................................................................................................ 4
Weight table .................................................................................................................................................. 12
Table of fuel, coolant and lubricants.............................................................................................................. 16
10 Structure, function and maintenance standard

100 Engine and cooling system ........................................................................................................SEN04484-00
Engine system parts...................................................................................................................................... 2
Cooling system.............................................................................................................................................. 3
Cooling fan pump .......................................................................................................................................... 4
Cooling fan motor.......................................................................................................................................... 5
Oil cooler bypass valve ................................................................................................................................. 10
200 Power train.................................................................................................................................SEN04485-00
Power train .................................................................................................................................................... 2
Power train system........................................................................................................................................ 3
Damper ......................................................................................................................................................... 4
HST hydraulic equipment arrangement diagram .......................................................................................... 5
Steering and brake control ............................................................................................................................ 6
Solenoid valve............................................................................................................................................... 8
Final drive...................................................................................................................................................... 15
HST pump ..................................................................................................................................................... 18
HST motor..................................................................................................................................................... 30
Charge pump ................................................................................................................................................ 40
300 Undercarriage and frame ...........................................................................................................SEN04486-00
Main frame .................................................................................................................................................... 2
Track frame and idler cushion....................................................................................................................... 4
Idler ............................................................................................................................................................... 6
Track roller .................................................................................................................................................... 8
Carrier roller .................................................................................................................................................. 10
Sprocket ........................................................................................................................................................ 12
Track shoe..................................................................................................................................................... 14
410 Hydraulic system, Part 1 ............................................................................................................SEN04487-00
Arrangement of hydraulic equipment for work equipment............................................................................. 2
Work equipment control ................................................................................................................................ 4
Hydraulic tank and filter................................................................................................................................. 6
Work equipment and fan pump ..................................................................................................................... 8
Control valve ................................................................................................................................................. 16
00-100 4 D31/37-22
100 Index
Table of contents SEN04352-09
CLSS ............................................................................................................................................................. 28
Functions and operation of each valve.......................................................................................................... 31
420 Hydraulic system, Part 2 ........................................................................................................... SEN04488-00
Blade PPC valve............................................................................................................................................ 2
Accumulator................................................................................................................................................... 11
500 Work equipment ........................................................................................................................ SEN04489-00
Work equipment ............................................................................................................................................ 2
Cutting edge and end bit ............................................................................................................................... 6
Ripper ............................................................................................................................................................ 7
Work equipment cylinder ............................................................................................................................... 8
Piston valve ................................................................................................................................................... 11
600 Cab and its attachments............................................................................................................ SEN04490-00
ROPS cab...................................................................................................................................................... 2
Cab mount ..................................................................................................................................................... 3
Canopy mount ............................................................................................................................................... 4
Air conditioner................................................................................................................................................ 5
700 Electrical system ....................................................................................................................... SEN04491-01
Monitor system .............................................................................................................................................. 2
Engine control................................................................................................................................................ 4
Engine control system ................................................................................................................................... 5
Cooling control system .................................................................................................................................. 6
HST control system ....................................................................................................................................... 8
Parking brake control system ........................................................................................................................ 14
KOMTRAX system ........................................................................................................................................ 16
Component equipment of system.................................................................................................................. 18
PCCS lever (for steering) .............................................................................................................................. 27
Sensor ........................................................................................................................................................... 30
20 Standard value table

100 Standard service value table ..................................................................................................... SEN04501-02
Standard service value table for engine ........................................................................................................ 2
Standard service value table for chassis ....................................................................................................... 4
30 Testing and adjusting

110 Testing and adjusting, Part 1 ..................................................................................................... SEN04502-02
Tools for testing, adjusting, and troubleshooting ........................................................................................... 3
Measuring engine speed ............................................................................................................................... 7
Measuring intake air pressure (boost pressure) ............................................................................................ 8
Testing exhaust temperature ......................................................................................................................... 10
Measuring exhaust gas color (boost pressure) ............................................................................................. 11
Adjusting valve clearance.............................................................................................................................. 12
Testing compression pressure....................................................................................................................... 14
Measuring blow-by pressure ......................................................................................................................... 16
Testing oil pressure........................................................................................................................................ 18
Handling fuel system equipment ................................................................................................................... 19
Releasing residual pressure in fuel system ................................................................................................... 19
Bleeding air from fuel circuit .......................................................................................................................... 20
Testing fuel pressure ..................................................................................................................................... 23
Testing leakage from pressure limiter and return rate from injector .............................................................. 24
Testing leakage in fuel system....................................................................................................................... 27
Measuring fan circuit pressure and fan speed............................................................................................... 28
Adjustment of fan speed sensor .................................................................................................................... 29
Handling reduced cylinder mode operation ................................................................................................... 30
Handling no-injection cranking operation ...................................................................................................... 30
Check of muffler and muffler stack for looseness and damage..................................................................... 31
Check of muffler function............................................................................................................................... 31
Check of installed condition of cylinder head and manifolds ......................................................................... 32
D31/37-22 00-100 5
100 Index
Check of engine piping for damage and looseness ...................................................................................... 32

Testing and adjusting alternator belt tension................................................................................................. 33
Testing and adjusting air conditioner compressor belt tension...................................................................... 34
120 Testing and adjusting, Part 2......................................................................................................SEN04503-01
Adjusting decelerator pedal........................................................................................................................... 2
Testing and adjusting HST oil pressure......................................................................................................... 4
Measuring solenoid valve output oil pressure ............................................................................................... 9
Testing travel deviation.................................................................................................................................. 12
Adjusting parking brake lever........................................................................................................................ 13
Simple brake performance test procedure .................................................................................................... 15
Adjusting brake pedal.................................................................................................................................... 16
Method of releasing parking brake (Procedure for emergency escape) ....................................................... 18
Testing and adjusting idler clearance ............................................................................................................ 20
Testing and adjusting track shoe tension ...................................................................................................... 21
Testing work equipment oil pressure............................................................................................................. 22
Testing work equipment PPC valve output oil pressure ................................................................................ 24
Adjusting play of work equipment PPC valve................................................................................................ 26
Adjusting work equipment lock lever............................................................................................................. 27
Testing internal leakage of work equipment cylinder..................................................................................... 28
Releasing residual pressure in hydraulic circuit ............................................................................................ 30
Bleeding air from hydraulic circuit ................................................................................................................. 31
Adjusting play of blade center ball ................................................................................................................ 32
Procedure for testing diodes ......................................................................................................................... 33
Preparation work for troubleshooting for electrical system ........................................................................... 34
How to start operation of KOMTRAX terminal .............................................................................................. 38
Lamp display of KOMTRAX terminal ............................................................................................................ 41
130 Testing and adjusting, Part 3......................................................................................................SEN04504-02
Special functions of monitor panel (EMMS) .................................................................................................. 2
Items to be adjusted when electric/hydraulic devices are adjusted/replaced................................................ 62
Adjustment procedure after replacement of HST controller .......................................................................... 63
Adjustment procedure after replacement of monitor panel ........................................................................... 65
Pm-clinic service (D31EX-22, D31PX-22)..................................................................................................... 67
Pm-clinic service (D37EX-22, D37PX-22)..................................................................................................... 75
40 Troubleshooting
100 Failure code table and fuse locations ........................................................................................SEN04505-01
Failure code table.......................................................................................................................................... 2
Before carrying out troubleshooting for electrical system (E-mode) ............................................................. 8
200 General information on troubleshooting.....................................................................................SEN04506-01
Points to remember when troubleshooting.................................................................................................... 2
Sequence of events in troubleshooting ......................................................................................................... 3
Testing before troubleshooting ...................................................................................................................... 4
Classification and procedures of troubleshooting ......................................................................................... 5
Information contained in troubleshooting table ............................................................................................. 8
Connection table for connector pin numbers ................................................................................................ 10
T- branch box and T- branch adapter table ................................................................................................... 46
310 Troubleshooting by failure code (Display of code), Part 1 .........................................................SEN04507-01
Failure code [6091NX] HST charge filter element: Clogging ........................................................................ 3
Failure code [AA10NX] Air cleaner: Clogging ............................................................................................... 4
Failure code [AB00MA] Alternator: Malfunction ............................................................................................ 6
Failure code [B@BAZG] Engine oil: Lowering of oil pressure....................................................................... 7
Failure code [B@BCNS] Coolant: Overheat ................................................................................................. 8
Failure code [B@CRNS] HST oil: Overheating............................................................................................. 9
Failure code [B@CRZG] HST oil: Lowering of oil pressure .......................................................................... 10
Failure code [CA111] Engine controller: Abnormality in controller ................................................................ 11
Failure code [CA115] Abnormal engine Ne and Bkup speed sensors: Abnormal speed sensor signal........ 14
Failure code [CA122] Charge pressure sensor tool high: Excessively high voltage detected ...................... 15
00-100 6 D31/37-22
100 Index
Failure code [CA123] Charge pressure sensor too low: Excessively low voltage detected .......................... 17
Failure code [CA131] Decelerator pedal sensor tool high: Excessively high voltage detected ..................... 18
Failure code [CA132] Decelerator pedal sensor too low: Excessively low voltage detected......................... 20
Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected ................. 22
Failure code [CA145] Coolant temperature sensor too low: Excessively low voltage detected .................... 24
Failure code [CA153] Charge air temperature sensor too high: Excessively high voltage detected ............. 26
Failure code [CA154] Charge temperature sensor too low: Excessively low voltage detected..................... 28
Failure code [CA187] Sensor power source 2 too low: Excessively low voltage detected ............................ 29
Failure code [CA221] Atmospheric pressure sensor too high: Excessively high voltage detected ............... 30
Failure code [CA222] Atmospheric pressure sensor too low: Excessively low voltage detected .................. 32
Failure code [CA227] Sensor power source 2 too high: Excessively high voltage detected ......................... 34
Failure code [CA234] Engine over speed: Excessively high speed .............................................................. 36
Failure code [CA238] Abnormal power source for Ne speed sensor: Excessively low voltage detected...... 38
Failure code [CA271] IMV/PCV1 short circuit: Short circuit........................................................................... 40
Failure code [CA272] IMV/PCV1 disconnection: Disconnection ................................................................... 42
320 Troubleshooting by failure code (Display of code), Part 2......................................................... SEN04508-02
Failure code [CA322] Injector No. 1 system disconnection or short circuit: disconnection, short circuit ....... 4
Failure code [CA351] Injector drive circuit abnormality: Abnormal circuit ..................................................... 12
Failure code [CA352] Sensor power source 1 too low: Excessively low voltage detected ............................ 14
Failure code [CA386] Sensor power source 1 too high: Excessively high voltage detected ......................... 16
Failure code [CA428] Water in fuel sensor too high: Excessively high voltage detected .............................. 18
Failure code [CA429] Water in fuel sensor too low: Excessively low voltage detected ................................. 20
Failure code [CA435] Abnormal engine oil pressure switch: Abnormal signal circuit .................................... 22
Failure code [CA441] Power source voltage too low: Excessively low voltage detected .............................. 23
Failure code [CA442] Power source voltage too high:
Excessively high voltage has occurred in the controller power source circuit ......................................... 24
Failure code [CA449] Common rail pressure too high (2): Excessively high pressure trouble occurred....... 25
Failure code [CA451] Common rail pressure sensor too high: Excessively high voltage detected............... 26
Failure code [CA452] Common rail pressure sensor too low: Excessively low voltage detected.................. 28
Failure code [CA553] Common rail pressure too high (1): Excessively high pressure detected................... 29
Failure code [CA559] Loss of pressure feed from supply pump (1): Loss of pressure feed detected........... 30
Failure code [CA689] Abnormal engine Ne speed sensor: Abnormal signal................................................. 34
Failure code [CA731] Abnormal engine Bkup speed sensor phase: Abnormal phase.................................. 36
Failure code [CA757] Loss of all engine controller data: Loss of all data ...................................................... 37
Failure code [CA778] Abnormal engine Bkup speed sensor: Abnormal Bkup signal.................................... 38
Failure code [CA1633] Abnormal KOMNET: Abnormal communication........................................................ 40
Failure code [CA2185] Decelerator pedal sensor power source too high:
Excessively high voltage detected........................................................................................................... 42
Failure code [CA2186] Decelerator pedal sensor power source too low:
Excessively low voltage detected ............................................................................................................ 44
Failure code [CA2249] Loss of pressure feed from supply pump (2): Loss of pressure feed detected......... 45
Failure code [CA2311] Abnormal IMV solenoid: Abnormal resistance .......................................................... 46
Failure code [CA2555] Air intake heater relay disconnection: Disconnection ............................................... 48
Failure code [CA2556] Air intake heater relay short circuit: Short circuit ...................................................... 50
330 Troubleshooting by failure code (Display of code), Part 3......................................................... SEN04509-00
Failure code [D130KA] Neutral safety relay: Disconnection.......................................................................... 4
Failure code [D130KB] Neutral safety relay: Short circuit ............................................................................. 6
Failure code [DAFRKR] CAN communication (Monitor panel ? HST controller):
Defective communication (Abnormality in objective component system)................................................ 8
Failure code [DAFRMC] CAN communication (Monitor panel ? ENGINE controller):
Defective communication (Abnormality in objective component system)................................................ 11
Failure code [DAJ000] HST controller: Memory error ................................................................................... 14
Failure code [DAJ0KK] HST controller: Lowing of source voltage ................................................................ 16
Failure code [DAJ0KQ] HST controller: Machine code error......................................................................... 18
Failure code [DAJ0KT] HST controller: Memory error................................................................................... 19
D31/37-22 00-100 7
100 Index
Failure code [DAJ5KK] HST controller sensor 5 V power supply No.1: Lowing of source voltage/Input ...... 20
Failure code [DAJRKR] CAN communication (HST controller ? Monitor panel):
Defective communication (Abnormality in objective component system) ............................................... 24
Failure code [DB2RKR] CAN communication (HST controller ? Engine controller):
Defective communication (Abnormality in objective component system) ............................................... 27
Failure code [DD12KA] Shift up switch: Disconnection................................................................................. 30
Failure code [DD12KB] Shift up switch: Short circuit .................................................................................... 32
Failure code [DD13KA] Shift down switch: Disconnection ............................................................................ 34
Failure code [DD13KB] Shift down switch: Short circuit................................................................................ 36
Failure code [DD14KB] Travel lock limit switch 1: Short circuit..................................................................... 38
Failure code [DD1NL4] Fan rotation selector switch: Disagreement of ON, OFF Signals ............................ 40
Failure code [DDDCKB] Reverse travel speed switch: Short circuit ............................................................. 42
Failure code [DDP6KA] Brake oil pressure sensor: Disconnection............................................................... 44
Failure code [DDP6KB] Brake oil pressure sensor: Short circuit .................................................................. 46
Failure code [DDP6MA] Brake oil pressure sensor: Malfunction .................................................................. 48
Failure code [DDQ2KA] Travel lock limit switch 1: Disconnection ................................................................ 50
Failure code [DDT0L4] Shift mode switch: Disagreement of ON/ OFF Signals ............................................ 52
Failure code [DDU1FS] Travel lock limit switches 1 and 2: Fixing................................................................ 54
Failure code [DDU1KA] Travel lock limit switch 2: Disconnection................................................................. 56
Failure code [DDU1KY] Travel lock limit switch 2: Short circuit with power supply line ................................ 58
Failure code [DGS1KA] HST oil temperature sensor: Disconnection ........................................................... 60
Failure code [DGS1KX] HST oil temperature sensor: Out of Input signal range .......................................... 62
Failure code [DHH5KA] Left HST pump pressure sensor: Disconnection .................................................... 4
Failure code [DHH5KB] Left HST pump pressure sensor: Short circuit........................................................ 6
Failure code [DHH6KA] Right HST pump pressure sensor: Disconnection.................................................. 8
Failure code [DHH6KB] Right HST pump pressure sensor: Short circuit ..................................................... 10
Failure code [DK10KA] Fuel dial sensor: Disconnection............................................................................... 12
Failure code [DK10KB] Fuel dial sensor: Short circuit .................................................................................. 14
Failure code [DK30KA] Steering angle sensor 1: Disconnection .................................................................. 16
Failure code [DK30KB] Steering angle sensor 1: Short circuit...................................................................... 18
Failure code [DK30KX] Steering angle sensor: Out of input signal range..................................................... 20
Failure code [DK30KZ] Steering angle sensor: Disconnection or short circuit.............................................. 21
Failure code [DK30L8] Steering angle sensor: Disagreement of analog signals .......................................... 22
Failure code [DK40KA] Brake pedal sensor: Disconnection ......................................................................... 28
Failure code [DK40KB] Brake pedal sensor: Short circuit............................................................................. 30
Failure code [DK55KX] Directional potentiometer: Out of input signal range ............................................... 32
Failure code [DK55KZ] Directional potentiometer: Disconnection or short circuit......................................... 33
Failure code [DK55L8] Directional potentiometer: Disagreement of analog signals ..................................... 34
Failure code [DK56KA] Directional potentiometer 1: Disconnection ............................................................. 36
Failure code [DK56KB] Directional potentiometer 1: Short circuit................................................................. 38
Failure code [DLM0KX] HST motor speed sensors: Out of input signal range ............................................. 44
Failure code [DLM1KA] Left HST motor speed sensor: Disconnection ........................................................ 46
Failure code [DLM1KB] Left HST motor speed sensor: Short circuit ............................................................ 48
Failure code [DLM1MA] Left HST motor speed sensor: Malfunction ............................................................ 50
Failure code [DLM2KA] Right HST motor speed sensor: Disconnection ...................................................... 52
Failure code [DLM2KB] Right HST motor speed sensor: Short circuit.......................................................... 54
Failure code [DLM2MA] Right HST motor speed sensor: Malfunction.......................................................... 56
Failure code [DLM3KA] Fan speed sensor: Disconnection........................................................................... 58
Failure code [DLM3KB] Fan speed sensor: Short circuit .............................................................................. 60
Failure code [DN21FS] Brake pedal and proximity switch: Fixing ................................................................ 4
Failure code [DV00KB] Caution buzzer: Short circuit ................................................................................... 6
00-100 8 D31/37-22
100 Index
Failure code [DV20KB] Back alarm buzzer: Short circuit .............................................................................. 7

Failure code [DW4BKA] Parking brake solenoid valve: Disconnection ......................................................... 8
Failure code [DW4BKB] Parking brake solenoid valve: Short circuit............................................................. 10
Failure code [DW4BKY] Parking brake solenoid valve: Short circuit with power supply line ........................ 12
Failure code [DW7BKA] Fan reverse solenoid valve: Disconnection ............................................................ 14
Failure code [DW7BKB] Fan reverse solenoid valve: Short circuit................................................................ 16
Failure code [DW7BKY] Fan reverse solenoid valve: Short circuit with power supply line ........................... 17
Failure code [DW7EKA] Slow brake solenoid valve: Disconnection ............................................................. 18
Failure code [DW7EKB] Slow brake solenoid valve: Short circuit ................................................................. 22
Failure code [DW7EKY] Slow brake solenoid valve: Short circuit with power supply line............................. 24
Failure code [DWN5KA] Fan EPC solenoid valve: Disconnection ................................................................ 26
Failure code [DWN5KB] Fan EPC solenoid valve: Short circuit .................................................................... 28
Failure code [DWN5KY] Fan EPC solenoid valve: Short circuit with power supply line................................ 30
Failure code [DXA4KA] LF HST pump EPC solenoid valve: Disconnection ................................................. 32
Failure code [DXA4KB] LF HST pump EPC solenoid valve: Short circuit ..................................................... 34
Failure code [DXA4KY] LF HST pump EPC solenoid valve: Short circuit with power supply line................. 36
Failure code [DXA5KA] LR HST pump EPC solenoid valve: Disconnection ................................................. 38
Failure code [DXA5KB] LR HST pump EPC solenoid valve: Short circuit..................................................... 40
Failure code [DXA5KY] LR HST pump EPC solenoid valve: Short circuit with power supply line ................ 42
Failure code [DXA6KA] RF HST pump EPC solenoid valve: Disconnection................................................. 44
Failure code [DXA6KB] RF HST pump EPC solenoid valve: Short circuit .................................................... 46
Failure code [DXA6KY] RF HST pump EPC solenoid valve: Short circuit with power supply line ................ 47
Failure code [DXA7KA] RR HST pump EPC solenoid valve: Disconnection ................................................ 48
Failure code [DXA7KB] RR HST pump EPC solenoid valve: Short circuit .................................................... 50
Failure code [DXA7KY] RR HST pump EPC solenoid valve: Short circuit with power supply line................ 52
Failure code [DXK1KA] Left HST motor EPC solenoid valve: Disconnection ............................................... 53
Failure code [DXK1KB] Left HST motor EPC solenoid valve: Short circuit ................................................... 54
Failure code [DXK1KY] Left HST motor EPC solenoid valve: Short circuit with power supply line............... 55
Failure code [DXK2KA] Right HST motor EPC solenoid valve: Disconnection ............................................. 56
Failure code [DXK2KB] Right HST motor EPC solenoid valve: Short circuit................................................. 57
Failure code [DXK2KY] Right HST motor EPC solenoid valve: Short circuit with power supply line ............ 58
400 Troubleshooting of electrical system (E-mode) ......................................................................... SEN04512-01
E-1 Engine does not start (Starting motor does not rotate) ........................................................................... 4
E-2 Engine is not preheated .......................................................................................................................... 7
E-3 When starting switch is turned ON, any item does not light up............................................................... 10
E-4 Charge level caution flashes while engine is running ............................................................................. 12
E-5 Emergency warning items flash while engine is running ........................................................................ 14
E-6 Preheating pilot lamp does not light up during preheating operation...................................................... 20
E-7 The coolant temperature gauge does not indicate correctly. .................................................................. 22
E-8 The HST oil temperature gauge does not indicate correctly. .................................................................. 23
E-9 Fuel level gauge does not indicate properly ........................................................................................... 24
E-10 Gear speed, set travel speed, and shift mode indicator does not display normally .............................. 26
E-11 Multi-information unit does not display normally ................................................................................... 26
E-12 Caution lamp does not flash or does not go off .................................................................................... 27
E-13 Caution buzzer does not sound or does not stop ................................................................................. 28
E-14 Reverse travel speed setting switch does not function ......................................................................... 30
E-15 Shift mode switch does not function ..................................................................................................... 32
E-16 Buzzer cancel switch does not function ................................................................................................ 34
E-17 Information switch does not function..................................................................................................... 36
E-18 The fan cleaning does not operate or cannot be reset ......................................................................... 38
E-19 Backup alarm does not sound .............................................................................................................. 40
E-20 The horn does not sound or does not stop ........................................................................................... 41
E-21 Work equipment does not move ........................................................................................................... 42
E-22 Headlamp or rear lamp does not light up.............................................................................................. 44
E-23 Foot heater does not operate................................................................................................................ 47
E-24 Air conditioner does not operate ........................................................................................................... 50
E-25 Windshield wiper and window washer do not operate .......................................................................... 55
E-26 KOMTRAX system does not operate normally ..................................................................................... 68
D31/37-22 00-100 9
100 Index
500 Troubleshooting of hydraulic and mechanical system (H-mode) ...............................................SEN04513-00

Information in troubleshooting table .............................................................................................................. 3
H-1 Right and left travel systems do not operate forward and in reverse (No travel systems operate) ........ 4
H-2 Right or left travel system does not operate forward and in reverse (Only right or left travel system
does not operate) ................................................................................................................................... 6
H-3 Right or left travel system does not operate forward or in reverse (Only 1 system does not operate)... 7
H-4 Speed or power of travel is low .............................................................................................................. 8
H-5 Gear is not shifted .................................................................................................................................. 9
H-6 Large shocks are made when machine starts and stops travel.............................................................. 10
H-7 Machine deviates largely during travel ................................................................................................... 11
H-8 Hydraulic drift of travel is large ............................................................................................................... 12
H-9 Engine stalls or engine speed lowers extremely during travel ............................................................... 13
H-10 Abnormal sound comes out from around HST pump and motor.......................................................... 14
H-11 Work equipment dose not operate at all............................................................................................... 15
H-12 Speed or power of whole work equipment is low ................................................................................. 16
H-13 Speed or power of lifting blade is low ................................................................................................... 17
H-14 Speed or power of tilting blade is low ................................................................................................... 18
H-15 Speed or power of angling blade is low................................................................................................ 19
H-16 Time lag in lifting blade is large ............................................................................................................ 20
H-17 Hydraulic drift of lifting blade is large.................................................................................................... 20
H-18 Hydraulic drift of tilting blade is large.................................................................................................... 20
H-19 Abnormal sound comes out from around work equipment pump and control valve............................. 21
H-20 HST oil temperature (Hydraulic oil temperature) rises too high ........................................................... 22
H-21 Fan speed is abnormal (High, low, or 0 rpm) ....................................................................................... 24
H-22 Abnormal sound is heard from around fan ........................................................................................... 25
600 Troubleshooting of engine (S-mode)..........................................................................................SEN04514-01
Method of using troubleshooting charts ........................................................................................................ 3
S-1 Starting performance is poor .................................................................................................................. 6
S-2 Engine does not start.............................................................................................................................. 7
S-3 Engine does not pick up smoothly.......................................................................................................... 10
S-4 Engine stops during operations .............................................................................................................. 11
S-5 Engine does not rotate smoothly ............................................................................................................ 12
S-6 Engine lacks output (or lacks power)...................................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion).................................................................................. 14
S-8 Oil consumption is excessive (or exhaust smoke is blue) ...................................................................... 15
S-9 Oil becomes contaminated quickly ......................................................................................................... 16
S-10 Fuel consumption is excessive............................................................................................................. 17
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 18
S-12 Oil pressure drops ................................................................................................................................ 19
S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 20
S-14 Coolant temperature becomes too high (overheating) ......................................................................... 21
S-15 Abnormal noise is made ....................................................................................................................... 22
S-16 Vibration is excessive ........................................................................................................................... 23
50 Disassembly and assembly

100 General information on disassembly and assembly ..................................................................SEN04724-01
How to read this manual ............................................................................................................................... 2
Coating materials list..................................................................................................................................... 4
Special tools list............................................................................................................................................. 7
Sketches of special tools............................................................................................................................... 10
200 Engine and cooling system ........................................................................................................SEN04725-01
Removal and installation of fuel supply pump assembly............................................................................... 2
Removal and installation of fuel injector assembly ....................................................................................... 5
Removal and installation of front seal assembly ........................................................................................... 8
Removal and installation of rear seal assembly............................................................................................ 10
Removal and installation of cylinder head assembly .................................................................................... 13
Removal and installation of engine and HST pump assembly...................................................................... 20
00-100 10 D31/37-22
100 Index
Removal and installation of front guard assembly......................................................................................... 24

Removal and installation of radiator assembly .............................................................................................. 26
Removal and installation of hydraulic oil cooler assembly ............................................................................ 28
Removal and installation of aftercooler assembly ......................................................................................... 30
Removal and installation of cooling fan and motor assembly........................................................................ 32
Removal and installation of cooling fan drive motor assembly...................................................................... 34
Removal and installation of fuel tank assembly............................................................................................. 36
300 Power train ................................................................................................................................ SEN04726-01
Removal and installation of HST pump assembly ......................................................................................... 2
Removal and installation of HST motor and final drive assembly ................................................................. 4
Disassembly and assembly of final drive assembly ...................................................................................... 6
400 Undercarriage and frame .......................................................................................................... SEN04727-01
Spreading and installation of track shoe assembly........................................................................................ 2
Removal and installation of idler and recoil spring assembly ........................................................................ 4
Disassembly and assembly of idler assembly ............................................................................................... 5
Disassembly and assembly of recoil spring assembly .................................................................................. 8
Disassembly and assembly of track roller assembly ..................................................................................... 12
Disassembly and assembly of carrier roller assembly................................................................................... 16
500 Hydraulic system ....................................................................................................................... SEN04728-00
Removal and installation of hydraulic tank assembly .................................................................................... 2
Removal and installation of control valve assembly ...................................................................................... 4
Disassembly and assembly of control valve assembly.................................................................................. 5
Disassembly and assembly of hydraulic cylinder assembly .......................................................................... 7
600 Work equipment ........................................................................................................................ SEN04729-00
Removal and installation of work equipment assembly................................................................................. 2
700 Cab and its attachments............................................................................................................ SEN04730-00
Removal and installation of ROPS canopy and operator seat frame assembly ............................................ 2
Removal and installation of ROPS cab and operator seat frame assembly.................................................. 5
Removal and installation of operator’s cab glass (Stuck glass)..................................................................... 9
800 Electrical system ....................................................................................................................... SEN04731-00
Removal and installation of HST controller assembly ................................................................................... 2
Removal and installation of KOMTRAX terminal assembly........................................................................... 3
90 Diagrams and drawings

100 Hydraulic diagrams and drawings ............................................................................................. SEN04355-02
Work equipment hydraulic circuit diagram..................................................................................................... 3
200 Electrical diagrams and drawings.............................................................................................. SEN04356-02
Electrical circuit diagram................................................................................................................................ 3
Cab electrical circuit diagram ........................................................................................................................ 17
Air conditioner circuit diagram ....................................................................................................................... 21
Connector list and stereogram ...................................................................................................................... 23
D31/37-22 00-100 11
SEN04352-09
D31/37-22 Bulldozer
Form No. SEN04352-09
©2014 KOMATSU
All Rights Reserved
Printed in Japan 02-14
00-100 12
SEN04353-02
BULLDOZER
D31EX-22
D31PX-22
D37EX-22
D37PX-22
D31EX-22 60001 and up
D31PX-22 60001 and up
D37EX-22 60001 and up
D37PX-22 60001 and up
00 Index and foreword 00
200 Foreword and general information

Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling of electric equipment and hydraulic component .............................................................................11
Handling of connectors newly used for engines ........................................................................................... 20
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
D31/37-22 00-200 1
SEN04353-02 Safety notice
Safety notice 1
Important safety notice

Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before w elding work, alw ays wear welding
operating the machine. In addition, gloves, apron, shielding goggles, cap and
read this manual and understand its other clothes suited for welding work.
contents before starting the work. 8) Before starting work, warm up your body
1) Before carrying out any greasing or thoroughly to start work under good condi-
repairs, read all the safety labels stuck to tion.
the machine. For the locations of the 9) Avoid continuing work for long hours and
safety labels and detailed explanation of take rests at proper intervals to keep your
precautions, see the Operation and Main- body in good condition. Take rests in
tenance Manual. specified safe places.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always Safety points
keep the tools and parts in their correct
places. Always keep the work area clean 1 Good arrangement
and make sure that there is no dirt, water, 2 Correct work clothes
or oil on the floor. Smoke only in the areas 3 Following work standard
provided for smoking. Never smoke while
working. 4 Making and checking signs
3) When carrying out any operation, always Prohibition of operation and handling by
5
wear safety shoes and helmet. Do not unlicensed workers
wear loose work clothes, or clothes with 6 Safety check before starting work
buttons missing.
Wearing protective goggles
q Always wear safety glasses when hit- 7
(for cleaning or grinding work)
ting parts with a hammer.
q Always wear safety glasses when Wearing shielding goggles and protectors
8
grinding parts with a grinder, etc. (for welding work)
4) When carrying out any operation with 2 or 9 Good physical condition and preparation
more workers, always agree on the oper- Precautions against work which you are
ating procedure before starting. Always 10
not used to or you are used to too much
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, fork-
lift, service car, etc.
00-200 2 D31/37-22
Safety notice SEN04353-02
2. Preparations for work

1) Before adding oil or making any repairs,
park the machine on a hard and level
ground, and apply the parking brake and
block the wheels or tracks to prevent the
machine from moving.
2) Before starting work, lower the work
equipment (blade, ripper, bucket, etc.) to
the ground. If this is not possible, insert
the lock pin or use blocks to prevent the
work equipment from falling. In addition,
be sure to lock all the control levers and
hang warning signs on them.
3) When disassembling or assembling, sup-
port the machine with blocks, jacks, or
stands before starting work. 5) When raising a heavy component (heavier
4) Remove all mud and oil from the steps or than 25 kg), use a hoist or crane. Before
other places used to get on and off the starting work, check that the slings (wire
machine. Always use the handrails, lad- ropes, chains, and hooks) are free from
ders or steps when getting on or off the damage. Always use slings which have
m a c h i n e . N e v e r j u m p o n o r o ff t h e ample capacity and install them to proper
machine. If it is impossible to use the places. Operate the hoist or crane slowly
handrails, ladders or steps, use a stand to to prevent the component from hitting any
provide safe footing. other part. Do not work with any part still
raised by the hoist or crane.
3. Precautions during work 6) When removing a cover which is under
1) Before disconnecting or removing compo- internal pressure or under pressure from a
nents of the oil, water, or air circuits, first spring, always leave 2 bolts in diagonal
release the pressure completely from the positions. Loosen those bolts gradually
circuit. When removing the oil filler cap, a and alternately to release the pressure,
drain plug, or an oil pressure pickup plug, and then remove the cover.
loosen it slowly to prevent the oil from 7) When removing components, be careful
spurting out. not to break or damage the electrical wir-
2) The coolant and oil in the circuits are hot ing. Damaged wiring may cause electrical
when the engine is stopped, so be careful fires.
not to get scalded. Wait for the oil and 8) When removing piping, stop the fuel or oil
coolant to cool before carrying out any from spilling out. If any fuel or oil drips
work on the oil or water circuits. onto the floor, wipe it up immediately. Fuel
3) Before starting work, stop the engine. or oil on the floor can cause you to slip
When working on or around a rotating and can even start fires.
part, in particular, stop the engine. When 9) As a general rule, do not use gasoline to
checking the machine without stopping wash parts. Do not use it to clean electri-
the engine (measuring oil pressure, cal parts, in particular.
revolving speed, temperature, etc.), take 10) Be sure to assemble all parts again in their
extreme care not to get rolled or caught in original places. Replace any damaged
rotating parts or moving parts. parts and parts which must not be reused
4) For the machine equipped with a bat- with new parts. When installing hoses and
tery disconnct switch, turn the battery wires, be sure that they will not be dam-
disconnect switch to the OFF (O) posi- aged by contact with other parts when the
tion and pull the switch key out, before machine is operated.
starting the work. For machines without 11) When installing high pressure hoses,
a battery disconnct switch, remove the make sure that they are not twisted. Dam-
cable from the battery , before starting the aged tubes are dangerous, so be
work. Always remove the cable from the extremely careful when installing tubes for
negative (-) terminal first. high pressure circuits. In addition, check
t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
installed.
D31/37-22 00-200 3
12) When assembling or installing parts, 7) Limit the hanging angle to 60°, as a rule.
always tighten them to the specified Do not sling a heavy load with ropes form-
torques. When installing protective parts ing a wide hanging angle from the hook.
such as guards, or parts which vibrate vio- When hoisting a load with 2 or more
lently or rotate at high speed, be particu- ropes, the force subjected to each rope
l ar l y c a r e f u l t o c h e c k t h a t t h e y a r e will increase with the hanging angle. The
installed correctly. table below shows the variation of allow-
13) When aligning 2 holes, never insert your able load in kN {kg} when hoisting is made
fingers or hand. Be careful not to get your with 2 ropes, each of which is allowed to
fingers caught in a hole. sling up to 9.8 kN {1,000 kg} vertically, at
14) When measuring hydraulic pressure, various hanging angles. When the 2 ropes
check that the measuring tools are cor- sling a load vertically, up to 19.6 kN {2,000
rectly assembled. kg} of total weight can be suspended.
15) Take care when removing or installing the This weight is reduced to 9.8 kN {1,000
tracks of track-type machines. When kg} when the 2 ropes make a hanging
removing the track, the track separates angle of 120°. If the 2 ropes sling a 19.6
suddenly, so never let anyone stand at kN {2,000 kg} load at a lifting angle of
either end of the track. 150°, each of them is subjected to a force
16) If the engine is operated for a long time in as large as 39.2 kN {4,000 kg}.
a place which is not ventilated well, you
may suffer from gas poisoning. Accord-
ingly, open the windows and doors to ven-
tilate well.
4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is well seen
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
8) When installing wire ropes to an angular
load and guide the operator safely.
load, apply pads to protect the wire ropes.
q Do not stand under the load.
If the load is slippery, apply proper mate-
q Do not step on the load.
rial to prevent the wire rope from slipping.
2) Check the slings before starting sling
9) Use the specified eyebolts and fix wire
work.
ropes, chains, etc. to them with shackles,
3) Keep putting on gloves during sling work.
etc.
(Put on leather gloves, if available.)
10) Apply wire ropes to the middle portion of
4) Measure the weight of the load by the eye
the hook.
and check its center of gravity.
q Slinging near the tip of the hook may
5) Use proper sling according to the weight
cause the rope to slip off the hook
of the load and method of slinging. If too
during hoisting. The hook has the
thick wire ropes are used to sling a light
maximum strength at the middle por-
load, the load may slip and fall.
tion.
6) Do not sling a load with 1 wire rope alone.
If it is slung so, it may rotate and may slip
out of the rope. Install 2 or more wire
ropes symmetrically.
k Slinging with 1 rope may cause
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
00-200 4 D31/37-22
Safety notice SEN04353-02
6. Precautions for using overhead hoist crane

k When raising a heavy part (heavier
than 25 kg), use a hoist, etc. In Disas-
sembly and assembly, the weight of a
part heavier than 25 kg is indicated
after the mark of 4.
1) Before starting work, inspect the wire
ropes, brake, clutch, controller, rails, over
wind stop device, electric shock preven-
tion earth leakage breaker, crane collision
prevention device, and power application
warning lamp, and check safety.
2) Observe the signs for sling work.
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east,
west, south, and north) and the directions
11) Do not use twisted or kinked wire ropes.
of the control buttons without fail.
12) When lifting up a load, observe the follow-
5) Do not sling a load slantingly. Do not move
ing.
the crane while the slung load is swinging.
q Wind in the crane slowly until wire
6) Do not raise or lower a load while the
ropes are stretched. When settling
crane is moving longitudinally or laterally.
the wire ropes with the hand, do not
7) Do not drag a sling.
grasp them but press them from
8) When lifting up a load, stop it just after it
above. If you grasp them, your fingers
leaves the ground and check safety, and
may be caught.
then lift it up.
q After the wire ropes are stretched,
9) Consider the travel route in advance and
stop the crane and check the condi-
lift up a load to a safe height.
tion of the slung load, wire ropes, and
10) Place the control switch on a position
pads.
where it will not be an obstacle to work
q If the load is unstable or the wire rope
and passage.
or chains are twisted, lower the load
11) After operating the hoist, do not swing the
and lift it up again.
control switch.
q Do not lift up the load slantingly.
12) Remember the position of the main switch
13) When lifting down a load, observe the fol-
so that you can turn off the power immedi-
lowing.
ately in an emergency.
q When lifting down a load, stop it tem-
13) If the hoist stops because of a power fail-
porarily at 30 cm above the floor, and
ure, turn the power switch OFF. When
then lower it slowly.
turning on a switch which was turned OFF
q Check that the load is stable, and
by the electric shock prevention earth
then remove the sling.
leakage breaker, check that the devices
q Remove kinks and dirt from the wire
related to that switch are not in operation
ropes and chains used for the sling
state.
work, and put them in the specified
14) If you find an obstacle around the hoist,
place.
stop the operation.
15) After finishing the work, stop the hoist at
5. Precautions for using mobile crane
the specified position and raise the hook
a Read the Operation and Maintenance
to at least 2 m above the floor. Do not
Manual of the crane carefully in advance
leave the sling installed to the hook.
and operate the crane safely.
D31/37-22 00-200 5
7. Selecting wire ropes 2) Connection

1) Select adequate ropes depending on the 1] When installing the air conditioner cir-
weight of parts to be hoisted, referring to cuit hoses and tubes, take care that
the table below. dirt, dust, water, etc. will not enter
them.
Wire ropes 2] When connecting the air conditioner
(Standard “Z” twist ropes without galvanizing) hoses and tubes, check that O-rings
(JIS G3525, No. 6, Type 6X37-A) (1) are fitted to their joints.
Nominal 3] Check that each O-ring is not dam-
Allowable load
diameter of rope aged or deteriorated.
mm kN ton 4] When connecting the refrigerant pip-
10 8.8 0.9 ing, apply compressor oil for refriger-
12 12.7 1.3 ant (R134a) (DENSO: ND-OIL8,
14 17.3 1.7 VA L E O T H E R M A L S Y S T E M S :
16 22.6 2.3 ZXL100PG (equivalent to PAG46))
18 28.6 2.9 to its O-rings.
20 35.3 3.6
a Example of O-ring (Fitted to every joint of
25 55.3 5.6
hoses and tubes)
30 79.6 8.1
40 141.6 14.4
50 221.6 22.6
60 318.3 32.4
a The allowable load is one-sixth of the

breaking strength of the rope used
(Safety coefficient: 6).
8. Precautions for disconnecting and con-

necting hoses and tubes in air conditioner
circuit
1) Disconnection
k For the environment, the air condi-
tioner of this machine uses the a For tightening torque, see the precautions for
refrigerant (air conditioner gas: installation in each section of "Disassembly
R134a) which has fewer factors of and assembly".
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting
and filling operation of refrigerant
(R134a).
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
00-200 6 D31/37-22
How to read the shop manual SEN04353-02
How to read the shop manual 1
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
1. Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword

This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard

This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.
20. Standard value table

This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting

This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
D31/37-22 00-200 7
SEN04353-02 How to read the shop manual
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 …)
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
00-200 8 D31/37-22
Explanation of terms for maintenance standard SEN04353-02
Explanation of terms for maintenance standard 1
The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the
machine maintenance work. The following terms are used to explain the criteria.
1. Standard size and tolerance

q To be accurate, the finishing size of parts
is a little different from one to another.
q To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the “standard size” and the range of differ-
ence from the standard size is called the
“tolerance”.
q The tolerance with the symbols of + or – is
indicated on the right side of the standard
size.
Example:
Standard size Tolerance
–0.022
120
–0.126
a The tolerance may be indicated in the text

and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
q Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
D31/37-22 00-200 9
SEN04353-02 Explanation of terms for maintenance standard
2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the “standard clear- between them is increased to a certain
ance“, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the “clearance limit”.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
“standard value“, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value “interference limit”.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and tol-
erance table is smaller than that of the
mating shaft, the difference between those
diameters is called the “interference”.
q The range (A – B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the “standard interference”.
q After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4. Repair limit and allowable value or allow-

able dimension
q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the “repair
limit”.
q If a part is worn to the repair limit, it must
be replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value which
the product can be used without causing a
problem is called the “allowable value” or
“allowable dimension”.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
00-200 10 D31/37-22
Handling of electric equipment and hydraulic component SEN04353-02
Handling of electric equipment and hydraulic component 1
To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and
“Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
Points to remember when handling electric

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness

1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
D31/37-22 00-200 11
SEN04353-02 Handling of electric equipment and hydraulic component
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 sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-cir-
cuited by the water, so if any water gets in,
immediately dry the connector or take
other appropriate action before passing
electricity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
00-200 12 D31/37-22
3. Removing, installing, and drying connec-

tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.
q When removing a connector from a

clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
3] Action to take after removing connec-

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
D31/37-22 00-200 13
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a 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 connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
00-200 14 D31/37-22
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
D31/37-22 00-200 15
4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oil and water from the com-
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
00-200 16 D31/37-22
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
D31/37-22 00-200 17
Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
1. Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2. Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.
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
entering. 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 onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4. Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
00-200 18 D31/37-22
5. Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
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 secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
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 ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
D31/37-22 00-200 19
SEN04353-02 Handling of connectors newly used for engines
Handling of connectors newly used for engines 1
a Mainly, following engines are object for follow- 2. Pull lock type (PACKARD-2)
ing connectors. q 95 – 170, 12V140 engines
q 95E-5 q Various temperature sensors
q 107E-1 Example)
q 114E-3 Intake air temperature sensor in
q 125E-5 intake manifold: TIM
q 140E-5 Fuel temperature sensor: TFUEL
q 170E-5 Oil temperature sensor: TOIL
q 12V140E-3 Coolant temperature sensor: TWTR,
etc.
1. Slide lock type Disconnect the connector by pulling lock
(FRAMATOME-3, FRAMATOME-2) (B) (on the wiring harness side) of connec-
q 95 – 170, 12V140 engines tor (2) outward.
q Various pressure sensors and NE
speed sensor
Examples)
Intake air pressure sensor in intake
manifold: PIM
(125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(95, 107, 114 engines)
Ne speed sensor of flywheel housing:
NE (95 – 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
Disconnect connector (1) according to the fol-

lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connec-
tor (1) toward you.
a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screw-
driver while press lock (L2), and then
pull out connector (1) toward you.
00-200 20 D31/37-22
Handling of connectors newly used for engines SEN04353-02
3. Push lock type

q 95, 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the fol-

lowing procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q 114 engine
q 107, 114 engines

Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)
3) While pressing lock (D), pull out connector

(4) in the direction of the arrow.
q 107 engine
a If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
D31/37-22 00-200 21
SEN04353-02 Handling of connectors newly used for engines
q 95, 125 – 170, 12V140 engines 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure sensor in common rail: 1) Disconnect connector (6) according to the
PFUEL etc. (AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
2) Connect the connector according to the

following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it “clicks”.
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
00-200 22 D31/37-22
How to read electric wire code SEN04353-02
How to read electric wire code 1
a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indi-
cated.)
1. Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
Insulator Soft polyvinyl chloride
automobile
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
D31/37-22 00-200 23
SEN04353-02 How to read electric wire code
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
00-200 24 D31/37-22
How to read electric wire code SEN04353-02
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
D31/37-22 00-200 25
SEN04353-02 Precautions when carrying out operation
Precautions when carrying out operation 1
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work

q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising components, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Sleeve nut (elbow end)
number
02 07376-70210 02789-20210
03 07376-70315 02789-20315
04 07376-70422 02789-20422
05 07376-70522 02789-20522
06 07376-70628 02789-20628
10 07376-71034 07221-21034
12 07376-71234 07221-21234
2) Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
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.
Nominal Dimensions
Part Number
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
00-200 26 D31/37-22
Precautions when carrying out operation SEN04353-02
2. Precautions when carrying out installation work

q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
q When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, “Bleeding air”.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see “Disassembly and assembly”.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
D31/37-22 00-200 27
SEN04353-02 Precautions when carrying out operation
4) Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly
and assembly”.
00-200 28 D31/37-22
Method of disassembling and connecting push-pull type coupler SEN04353-02
Method of disassembling and connecting push-pull type coupler 1
k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
D31/37-22 00-200 29
SEN04353-02 Method of disassembling and connecting push-pull type coupler
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
contacts contact surface (a) of the hexag-
00-200 30 D31/37-22
Method of disassembling and connecting push-pull type coupler SEN04353-02
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
D31/37-22 00-200 31
SEN04353-02 Standard tightening torque table
Standard tightening torque table 1
1. Table of tightening torques for bolts and nuts

a Unless there are special instructions, tighten metric nuts and bolts to the torque below.
a The following table applies to the bolts in Fig. A.
Thread diameter of bolt Width across flats Tightening torque

mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 157 – 196 16 – 20
16 24 245 – 309 25 – 31.5
18 27 343 – 427 35 – 43.5
20 30 490 – 608 50 – 62
22 32 662 – 829 67.5 – 84.5
24 36 824 – 1,030 84 – 105
27 41 1,180 – 1,470 120 – 150
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table applies to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
a Fig. A a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
00-200 32 D31/37-22
Standard tightening torque table SEN04353-02
2. Table of tightening torques for split flange bolts

a Unless there are special instructions, tighten split flange bolts to the torque below.

mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5
3. Table of tightening torques for O-ring boss piping joints

a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Thread diameter Width across flats Tightening torque Nm {kgm}

Nominal No.
mm mm Range Target
02 14 35 – 63 { 3.5 – 6.5} 44 { 4.5}
03,04 20 Varies depending 84 – 132 { 8.5 – 13.5} 103 {10.5}
05,06 24 on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0}
10,12 33 tor. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
D31/37-22 00-200 33
SEN04353-02 Standard tightening torque table
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. –
No. of across Thread
Thread size Number of
hose flats Range Target diameter (mm)
(mm) threads, type of
(Reference)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
6. Table of tightening torques for face seal joints

a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to
be used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).
Outer Width Tightening torque Nm {kgm} Face seal

diameter across Nominal No. – Thread diameter
of pipe flats Range Target Number of threads, (mm)
(mm) (mm) type of thread (Reference)
8 19 14 – 16 {1.4 – 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 – 27 {2.4 – 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 (27) 43 – 47 {4.4 – 4.8} 45 {4.6} 13/16-16UN 20.6
15 (16) 30 (32) 60 – 68 {6.1 – 6.8} 64 {6.5} 1-14UN 25.4
22 (20) 36 90 – 95 {9.2 – 9.7} 92.5 {9.4} 1-3/16-12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
00-200 34 D31/37-22
Standard tightening torque table SEN04353-02
8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size Tightening torque

mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
D31/37-22 00-200 35
SEN04353-02 Conversion table
Conversion table 1
Method of using the conversion table

The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a hori-
zontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
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
00-200 36 D31/37-22
Conversion table SEN04353-02
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
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
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
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
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
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
D31/37-22 00-200 37
Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
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
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
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
00-200 38 D31/37-22
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
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 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
D31/37-22 00-200 39
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-200 40 D31/37-22
D31/37-22 00-200 41
SEN04353-02
D31/37-22 Bulldozer
©2012 KOMATSU
All Rights Reserved
00-200 42
SEN04354-00
BULLDOZER
D31EX-22
D31PX-22
D37EX-22
D37PX-22
D31EX-22 60001 and up
D31PX-22 60001 and up
D37EX-22 60001 and up
D37PX-22 60001 and up
01 General 01
100 Specification and technical data

Specification dimensional drawing .................................................................................................................. 2
Specifications .................................................................................................................................................. 4
Weight table .................................................................................................................................................. 12
Table of fuel, coolant and lubricants.............................................................................................................. 16
D31/37-22 01-100 1
SEN04354-00 Specification dimensional drawing
Specification dimensional drawing 1
D31EX-22 power angle and power tiltdozer with ROPS cab

D31PX-22 power angle and power tiltdozer with ROPS cab
D31EX-22 D31PX-22
Item Unit 400 mm 600 mm
Single shoe Single shoe
Machine weight kg 8,190 8,540
Engine name — SAA4D95LE-5 Diesel engine
Engine rated output

• Net [ISO 9249/SAE J1349] (*1) kW{HP}/rpm 58 {78}/2,200
• Gross [SAE J1995] (*2) 59.6 {80}/2,200
A Overall length mm 4,175 4,155
Overall height (Excluding antenna) 2,755

B mm
Overall height (Including KOMTRAX antenna) 2,945
3,250
C Overall width mm 2,550
(2,875)
Forward
km/h 3.4/5.6/8.5
Travel speed (1st/2nd/3rd)
(Quick shift mode) Reverse
km/h 4.1/6.5/8.5
(1st/2nd/3rd)
Forward km/h 0.8 – 8.5

Travel speed
(Variable shift mode)
Reverse km/h 0.8 – 8.5
*1: Indicates the value at the lowest cooling fan speed.

*2: Indicates the value of the engine alone (without cooling fan.)
a The engine rated output is indicated in the net value and gross value. Gross denotes the rated output measured of an
independent engine. While, net denotes the value measured of an engine under the condition essentially the same
as that when it is installed on machine.
a Following shows the rated output (net) at the maximum cooling fan speed.
53 kW {71 HP}/2,200 rpm
Values in ( ) are of the narrow blade type.
01-100 2 D31/37-22
Specification dimensional drawing SEN04354-00

D37EX-22 D37PX-22
Item Unit 400 mm 600 mm
Machine weight kg 8,300 8,650
Engine name — SAA4D95LE-5 Diesel engine
Engine rated output

• Gross [SAE J1995] (*2) 67.7 {91}/2,200
A Overall length mm 4,190 4,175
Overall height (Excluding antenna) 2,755

B mm
Overall height (Including KOMTRAX antenna) 2,945
3,250
C Overall width mm 2,710
(2,875)
Forward
km/h 3.4/5.6/8.5
Travel speed (1st/2nd/3rd)
(Quick shift mode) Reverse
km/h 4.1/6.5/8.5
(1st/2nd/3rd)
Forward km/h 0.8 – 8.5

Travel speed
(Variable shift mode)
Reverse km/h 0.8 – 8.5

59 kW {79 HP}/2,200 rpm
D31/37-22 01-100 3
SEN04354-00 Specifications
Specifications 1

D31EX-22 D31PX-22
Machine model/type 400 mm 600 mm
Serial No. 60001 and up 60001 and up
Machine weight
• Tractor unit + ROPS cab 7,070 7,320
Weight
• Power angle and power tiltdozer

kg 8,190 8,540
+ ROPS cab
7,720 8,130
+ ROPS canopy
Min. turning radius m [Counter-rotation] [Counter-rotation]
Gradeability deg. 30 30
Stability (Front, rear, left, right) deg. 35 35
Quick shift mode
Forward (1st/2nd/3rd) km/h 3.4/5.6/8.5 3.4/5.6/8.5
Travel speed
Performance
Reverse (1st/2nd/3rd) 4.1/6.5/8.5 4.1/6.5/8.5

Variable shift mode
Forward km/h 0.8 – 8.5 0.8 – 8.5
Reverse 0.8 – 8.5 0.8 – 8.5
Tractor unit + ROPS cab 39.6 {0.40} 27.4 {0.28}
pressure
Ground
Power angle and power tiltdozer kPa 45.9 {0.47} 31.9 {0.33}
+ ROPS cab {kg/cm2}
Power angle and power tiltdozer
43.3 {0.44} 30.4 {0.31}
+ ROPS canopy
Overall Overall length
Tractor unit 3,195 3,195

mm 4,175 4,155
+ ROPS cab
4,175 4,155
+ ROPS canopy
width
mm
Power angle and power tiltdozer 2,550 3,250 (2,875)
With ROPS cab
2,755 2,755
(Excluding antenna)
Dimensions
With ROPS canopy

Overall height
2,765 2,765
(Excluding antenna)
With ROPS cab
mm 2,945 2,945
(Including KOMTRAX antenna)
With ROPS canopy
2,775 2,775
With ROPS cab
2,940 2,940
(Including radio antenna)
Track gauge 1,510 1,650
Length of track on ground 2,185 2,185
mm
Shoe width (Standard track shoe) 400 600
Min. ground clearance 315 315
01-100 4 D31/37-22
Specifications SEN04354-00
D31EX-22 D31PX-22
Model name — SAA4D95LE-5
4-cycle, water-cooled, in-line 4-cylinder, direct injection type
Type —
with turbocharger and air-cooled aftercooler
Number of cylinders – Bore x Stroke mm 4 – 95 x 115
Total displacement l {cc} 3.26 {3,260}
Rated output
• Gross [SAE J1995] (*2) 59.6 {80}/2,200
Performance
Engine
Max. torque Nm{kgm}/rpm 350 {35.7}/1,500

High idle speed under no load rpm 2,400
Low idle speed under no load rpm 975
Min. fuel consumption g/kWh{g/HPh} 235 {175}
Starting motor — 24 V, 4.5 kW
Alternator — 24 V, 35 A (Canopy specification) 60 A (Cab specification)
Battery (*3) — 12 V, 92 Ah x 2 pieces
Radiator core type — Aluminum corrugate, 8/2
Type, number of unit
(Main pump) — Variable displacement swash plate piston type x 2
(Charge pump) Fixed displacement gear type x 1
HST pump
Delivery
(Main pump) cm3/rev 63
(Charge pump) 36
Power train
Set pressure
(Main pump) MPa{kg/cm2} 41.2 {420}
(Charge pump) 3.23 {33}
Variable displacement bent axis piston type
Type, number of unit —
motor
HST
(with parking brake) x 2

Delivery cm3/rev 105
Final drive — Planetary gear, 2-stage reduction, splash lubrication type
Suspension type — Rigid type
Carrier roller — 1 piece on each side
Undercarriage
Track roller — 6 pieces on each side

Track shoe
Width: 400 mm Width: 600 mm
• Assembly-type single grouser — Each side: 40 pieces Each side: 40 pieces
Pitch: 154 mm Pitch: 154 mm
• Assembly-type special swamp shoe — — —
53 kW {71 HP}/2,200 rpm
*3: The battery capacity (Ah) is indicated in the 5-hour rate value.
D31/37-22 01-100 5
D31EX-22 D31PX-22
Type, number of unit — Variable displacement, swash plate, piston type x 1
Hydraulic
pump
3
Delivery cm /rev 45
Max. discharge pressure MPa{kg/cm2} 27.4 {280}
Control
Type, number of unit — 4-spool valve x 1

valve
Operation method — Hydraulic pilot type

Type — Double-acting piston type
Cylinder bore mm 75
Lift cylinder
Piston rod outside diameter mm 40

Piston stroke mm 352
Work equipment hydraulic system
Max. distance between pin

mm 984
centers
Min. distance between pin
mm 632
centers
Cylinder bore mm 90
Tilt cylinder

mm 640
centers
mm 504
centers
Cylinder bore mm 80
Angle cylinder

mm 1,117
centers
mm 730
centers
Hydraulic tank — Box type (Control valve external mount type)
Hydraulic oil filter — Return side of tank
Oil cooler — Air-cooled (Laminated aluminum, 10/2)
01-100 6 D31/37-22
D31EX-22 D31PX-22
Type — Hydraulic angle tiltdozer
Blade supporting system — Hydraulic cylinder type
Max. lifting height
mm 870 860
(Above ground)
Performance
Work equipment
Max. lowering depth

mm 390 380
(Below ground)
Max. tilt distance mm 350 440 (390)
Max. angle distance deg. 25 25
Dimensions
Blade width mm 2,545 3,250 (2,875)

Blade height mm 840 750 (790)
Blade angle deg. 57 57
D31/37-22 01-100 7

D37EX-22 D37PX-22
Machine weight
• Tractor unit + ROPS cab 7,160 7,440
Weight

kg 8,300 8,650
+ ROPS cab
7,890 8,240
+ ROPS canopy
Min. turning radius m [Counter-rotation] [Counter-rotation]
Gradeability deg. 30 30
Stability (Front, rear, left, right) deg. 35 35
Quick shift mode
Forward (1st/2nd/3rd) km/h 3.4/5.6/8.5 3.4/5.6/8.5
Travel speed
Performance
Reverse (1st/2nd/3rd) 4.1/6.5/8.5 4.1/6.5/8.5

Variable shift mode
Forward km/h 0.8 – 8.5 0.8 – 8.5
Reverse 0.8 – 8.5 0.8 – 8.5
Tractor unit + ROPS cab 40.1 {0.41} 27.1 {0.28}
pressure
Ground
Power angle and power tiltdozer kPa 46.5 {0.47} 31.5 {0.32}
+ ROPS cab {kg/cm2}
44.2 {0.45} 30.0 {0.31}
+ ROPS canopy
Overall Overall length

mm 4,190 4,175
+ ROPS cab
4,190 4,175
+ ROPS canopy
width
mm
Power angle and power tiltdozer 2,550 3,250 (2,875)
With ROPS cab
2,755 2,755
(Excluding antenna)
Dimensions
With ROPS canopy

Overall height
2,765 2,765
(Excluding antenna)
With ROPS cab
mm 2,945 2,945
With ROPS canopy
2,775 2,775
With ROPS cab
2,940 2,940
(Including radio antenna)
Track gauge 1,510 1,650
Length of track on ground 2,240 2,240
mm
Shoe width (Standard track shoe) 460 600
Min. ground clearance 315 315
01-100 8 D31/37-22
D37EX-22 D37PX-22
Model name — SAA4D95LE-5
4-cycle, water-cooled, in-line 4-cylinder, direct injection type
Type —
with turbocharger and air-cooled aftercooler
Number of cylinders – Bore x Stroke mm 4 – 95 x 115
Total displacement l {cc} 3.26 {3,260}
Rated output
• Gross [SAE J1995] (*2) 67.7 {91}/2,200
Performance
Engine
Max. torque Nm{kgm}/rpm 375.3 {38.3}/1,500

High idle speed under no load rpm 2,400
Low idle speed under no load rpm 975
Min. fuel consumption g/kWh{g/HPh} 234 {174}
Starting motor — 24 V, 4.5 kW
Alternator — 24 V, 35 A (Canopy specification) 60 A (Cab specification)
Battery (*3) — 12 V, 92 Ah x 2 pieces
Radiator core type — Aluminum corrugate, 8/2
Type, number of unit
(Main pump) — Variable displacement swash plate piston type x 2
(Charge pump) Fixed displacement gear type x 1
HST pump
Delivery
(Main pump) cm3/rev 63
(Charge pump) 36
Power train
Set pressure
(Main pump) MPa{kg/cm2} 41.2 {420}
(Charge pump) 3.23 {33}
Variable displacement bent axis piston type
Type, number of unit —
motor
HST
(with parking brake) x 2

Delivery cm3/rev 105
Final drive — Planetary gear, 2-stage reduction, splash lubrication type
Suspension type — Rigid type
Carrier roller — 1 piece on each side
Undercarriage
Track roller — 6 pieces on each side

Track shoe
Width: 400 mm Width: 600 mm
• Assembly-type single grouser — Each side: 41 pieces Each side: 41 pieces
Pitch: 154 mm Pitch: 154 mm
• Assembly-type special swamp shoe — — —
59 kW {79 HP}/2,200 rpm
*3: The battery capacity (Ah) is indicated in the 5-hour rate value.
D31/37-22 01-100 9
D37EX-22 D37PX-22
Type, number of unit — Variable displacement, swash plate, piston type x 1
Hydraulic
pump
3
Delivery cm /rev 45
Max. discharge pressure MPa{kg/cm2} 27.4 {280}
Control
Type, number of unit — 4-spool valve x 1

valve
Operation method — Hydraulic pilot type

Cylinder bore mm 75
Lift cylinder

Work equipment hydraulic system

mm 984
centers
mm 632
centers
Cylinder bore mm 90
Tilt cylinder

mm 640
centers
mm 504
centers
Cylinder bore mm 80
Angle cylinder

mm 1,117
centers
mm 730
centers
Hydraulic tank — Box type (Control valve external mount type)
Hydraulic oil filter — Return side of tank
Oil cooler — Air-cooled (Laminated aluminum, 10/2)
01-100 10 D31/37-22
D37EX-22 D37PX-22
Type — Hydraulic angle tiltdozer
Blade supporting system — Hydraulic cylinder type
Max. lifting height
mm 880 870
(Above ground)
Performance
Work equipment
Max. lowering depth

mm 400 390
(Below ground)
Max. tilt distance mm 370 440 (390)
Max. angle distance deg. 25 25
Dimensions
Blade width mm 2,710 3,250 (2,875)

Blade height mm 860 830
Blade angle deg. 57 57
D31/37-22 01-100 11
SEN04354-00 Weight table
Weight table 1
a This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
Machine model/type D31EX-22 D31PX-22
Engine and damper assembly (Excluding coolant and oil) 405 405
• Engine assembly
371 371
(Including mount bracket, starting motor, alternator, etc.)
• Damper assembly 34 34
Fan support bracket assembly
88 88
(Including fan, motor, guard, bracket, shroud and hinge)
Cooling core
• Radiator 9 9
• Oil cooler 25 25
• Charge air cooler 8 8
Fuel tank (Excluding fuel) 175 175
Hydraulic pump assembly (Including pump mounting parts) 172 172
• HST pump 138 138
• Work equipment pump 26 26
• Charge pump 7.3 7.3
Final drive assembly (Including motor and sprocket) 302 302
• HST motor (Each side) 125 125
• Sprocket (Each side) 26 26
Frame assembly (Including piping mount bracket) 2,230 2,240
• Main frame 1,470 1,480
• Underguard (Inspection cover)
Front 7 7
Rear 23 23
• Idler assembly (Each side) 93 93
• Recoil spring assembly (Each side) 64 64
• Track roller, single flange type (Each side) 27 x 4 27 x 4
• Track roller, double flange type (Each side) 30 x 2 30 x 2
• Carrier roller (Each side) 16 x 1 16 x 1
Track shoe assembly
• Single grouser shoe (400 mm) 530 x 2 —
• Single grouser shoe (600 mm) — 680 x 2
• Swamp shoe (600 mm) — 680 x 2
Hydraulic tank
169 169
(Excluding hydraulic oil) (Including washer tank)
Control valve
• 4-spool valve (Including accessories and mount plate) 23 23
• 5-spool valve (For machine with ripper)
26 —
(Including accessories and mount plate)
01-100 12 D31/37-22
Weight table SEN04354-00
Unit: kg
Power angle and power tiltdozer assembly
1,050 1,120
(Including center ball, pitch link and pin)
• Blade 560 630
• Dozer frame 400 400
• Tilt cylinder assembly 20 20
• Angle cylinder assembly 23 x 2 23 x 2
Lift cylinder assembly 20 x 2 20 x 2
Ripper assembly (Including ripper cylinder) 490 —
Ripper cylinder assembly 30 —
ROPS cab assembly
1,176 (2,590) 1,176 (2,590)
(Including floor, seat, and air conditioner)
ROPS canopy assembly (Including floor and seat mount) 800 800
Operator seat
• Standard seat 64 (141) 64 (141)
• High-back seat 67 (148) 67 (148)
• Air suspension seat 74 (163) 74 (163)
Rear mask assembly 33 33
Engine hood assembly
167 167
(Including door, pre-cleaner and air cleaner)
D31/37-22 01-100 13
SEN04354-00 Weight table
a This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
Engine and damper assembly (Excluding coolant and oil) 405 405
• Engine assembly
371 371
(Including mount bracket, starting motor, alternator, etc.)
• Damper assembly 34 34
Fan support bracket assembly
88 88
(Including fan, motor, guard, bracket, shroud and hinge)
Cooling core
• Radiator 9 9
• Oil cooler 25 25
• Charge air cooler 8 8
Fuel tank (Excluding fuel) 175 175
Hydraulic pump assembly (Including pump mounting parts) 172 172
• HST pump 138 138
• Work equipment pump 26 26
• Charge pump 7.3 7.3
Final drive assembly (Including motor and sprocket) 302 302
• HST motor (Each side) 125 125
• Sprocket (Each side) 26 26
Frame assembly (Including piping mount bracket) 2,240 2,250
• Main frame 1,480 1,490
• Underguard (Inspection cover)
Front 7 7
Rear 23 23
• Idler assembly (Each side) 93 93
• Recoil spring assembly (Each side) 64 64
• Track roller, single flange type (Each side) 27 x 4 27 x 4
• Track roller, double flange type (Each side) 30 x 2 30 x 2
• Carrier roller (Each side) 16 x 1 16 x 1
Track shoe assembly
• Single grouser shoe (600 mm) — 680 x 2
• Swamp shoe (600 mm) — 700 x 2
Hydraulic tank
169 169
(Excluding hydraulic oil) (Including washer tank)
Control valve
• 4-spool valve (Including accessories and mount plate) 23 23
• 5-spool valve (For machine with ripper)
26 —
(Including accessories and mount plate)
01-100 14 D31/37-22
Weight table SEN04354-00
Unit: kg
Power angle and power tiltdozer assembly
1,070 1,140
(Including center ball, pitch link and pin)
• Blade 580 650
• Dozer frame 400 400
• Tilt cylinder assembly 20 20
• Angle cylinder assembly 23 x 2 23 x 2
Lift cylinder assembly 20 x 2 20 x 2
Ripper assembly (Including ripper cylinder) 490 —
Ripper cylinder assembly 30 —
ROPS cab assembly
1,176 (2,590) 1,176 (2,590)
(Including floor, seat, and air conditioner)
ROPS canopy assembly (Including floor and seat mount) 800 800
Operator seat
• Standard seat 64 (141) 64 (141)
• High-back seat 67 (148) 67 (148)
• Air suspension seat 74 (163) 74 (163)
Rear mask assembly 33 33
Engine hood assembly
167 167
(Including door, pre-cleaner and air cleaner)
D31/37-22 01-100 15
SEN04354-00 Table of fuel, coolant and lubricants
Table of fuel, coolant and lubricants 1
a For details of the notes (Note. 1, Note. 2…) in the table, see the Operation and Maintenance Manual.
01-100 16 D31/37-22
Table of fuel, coolant and lubricants SEN04354-00
Reservoir Final drive case Idler Cooling system

Engine oil Hydraulic
(Each of right (Each of right Fuel tank (Including sub
pan system
Capacity and left) and left) tank)
Specified capacity (l) 12 3.5 110 0.16 195 18
Refill capacity (l) 11 3.5 60 0.16 — —
D31/37-22 01-100 17
SEN04354-00
D31/37-22 Bulldozer
©2008 KOMATSU
All Rights Reserved
Printed in Japan 04-08 (01)
01-100 18
SEN04484-00
BULLDOZER
D31EX-22
D31PX-22
D37EX-22
D37PX-22
D31EX-22 60001 and up
D31PX-22 60001 and up
D37EX-22 60001 and up
D37PX-22 60001 and up
10 Structure, function and

maintenance standard 10
100 Engine and cooling system

Engine system parts........................................................................................................................................ 2
Cooling system ............................................................................................................................................... 3
Cooling fan pump............................................................................................................................................ 4
Cooling fan motor............................................................................................................................................ 5
Oil cooler bypass valve ................................................................................................................................. 10
D31/37-22 10-100 1
SEN04484-00 Engine system parts
Engine system parts 1
1. Rear engine mount Outline

2. Front engine mount 1. The cooling core and fan are installed to the
3. Water pump rear end of the machine. The supplied air and
4. Alternator coolant are led through the piping to the rear
5. Air conditioner compressor section of the machine.
(for cab specification)
6. Turbocharger 2. The air conditioner compressor is installed to
7. Muffler the front section of the engine and driven with
8. Fuel pump the special belt.
9. Engine controller
10. Air cleaner 3. The air cleaner, pre-cleaner and exhaust pipe
11. Pre-cleaner are installed near the engine hood.
4. The engine controller and its mounting bracket

are rubber-mounted in the engine hood.
10-100 2 D31/37-22
Cooling system SEN04484-00
Cooling system 1
1. Radiator 9. Radiator inlet port hose

2. Radiator cap 10. Reservoir tank
3. Oil cooler 11. Aftercooler inlet port
4. Aftercooler 12. Radiator outlet port hose
5. Shroud 13. Oil cooler bypass valve
6. Fan 14. Cooling fan motor
7. Coolant drain valve (2 pieces) 15. Air breather
8. Aftercooler outlet port hose 16. Pickup sensor
Item Unit Radiator Oil cooler Aftercooler
Core type — Aluminum corrugate Aluminum laminate Aluminum corrugate
Fin pitch mm/2p 8.0 ± 1 10 ± 1 8.0 ± 1
Total heat dissipation area m2 16.23 19.71 6.56

Cracking pressure of kPa 90 ± 15
— —
pressure valve {kg/cm2} {0.9 ± 0.15}
Cracking pressure of vacuum kPa 0 – 4.8
— —
valve {kg/cm2} {0 – 0.05}
D31/37-22 10-100 3
SEN04484-00 Cooling fan pump
Cooling fan pump 1
a See Hydraulic system, Part 1, Work equipment and fan pump.
10-100 4 D31/37-22
Cooling fan motor SEN04484-00
Cooling fan motor 1
Type: LMF16
P: From fan pump

T: To tank via cooler
TC: To hydraulic tank
Specifications
Type: LMF16
Capacity: 16.0 cm3/rev
Rated speed: 1,800 rpm (D31EX, PX-22), 2,000 rpm (D37EX, PX-22)
Rated flow rate: 28.8 l/min (D31EX, PX-22), 32 l/min (D37EX, PX-22)
Check valve cracking pressure: 0.013 MPa {0.13 kg/cm2}
D31/37-22 10-100 5
SEN04484-00 Cooling fan motor
1. Output shaft 7. End cover

2. Case 8. Center spring
3. Thrust plate 9. Check valve
4. Piston assembly 10. Pilot valve
5. Cylinder block 11. Spool (for reversible valve)
6. Valve plate
Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
Free length x
Installed
Outside Installed load Free length Installed load
12 Spool return spring diameter length If damaged or
deformed, replace
58.8 N 47.1 N the spring
44.84 x 12 33 {6 kg} — {4.8 kg}
3.04 N 2.45 N
13 Check valve spring 29.27 x 6.5 19.1
{0.31 kg}
—
{0.25 kg}
10-100 6 D31/37-22
Hydraulic motor
Function
q This hydraulic motor is called a swash plate
axial piston motor. It converts the energy of the
pressurized oil sent from the hydraulic pump
into rotary motion.
Principle of operation
q The pressurized oil sent from the hydraulic
pump flows through valve plate (7) into cylin-
der block (5).
q This pressurized oil flows to the only one side
of the (Y - Y) line connecting the top dead cen-
ter and bottom dead center of the stroke of pis-
ton (4).
q The oil sent to one side of cylinder block (5)
presses respective pistons (4) [2 or 3 pieces],
and generates force (F1) [F1 = P x x D2/4].
q This force is applied to thrust plate (2). Since
thrust plate (2) is fixed at the specified angle of
(a) degrees to output shaft (1), the force is
divided into components (F2) and (F3).
q The radial component (F3) generates torque (T
= F3 x ri) against the (Y -Y) line connecting the
top dead center and bottom dead center.
q The result of this torque [T = s (F3 x ri)] rotates
cylinder block (5) through piston (4).
q Since this cylinder block (5) is splined to the
output shaft, the output shaft revolves to trans-
mit the torque.
D31/37-22 10-100 7
SEN04484-00 Cooling fan motor
Suction valve
Function 2. When pump is stopped

q If the pump stops, the pressurized oil does not q If the engine is stopped and the pump input
flow into the motor. However, since the motor shaft revolution turns to 0 rpm, the pressurized
continues revolution because of the force of oil from the pump is not supplied to port (P)
inertia, the pressure on the outlet side of the any more. As the pressurized oil is not sup-
motor rises. plied to (MA) side of the motor, the motor
q When the pressurized oil stops flowing in from speed lowers gradually to stop.
inlet port (P), the suction valve suctions the oil q If the motor shaft is revolved by the force of
on the outlet side and supplies sufficient oil to inertia while the oil flow to port (P) is gradually
the port (MA) to subsequently prevent cavita- reduced, the oil of the outlet side port (T) is
tion. supplied to (MA) side by suction valve (1) to
prevent cavitation.
Operation
1. When pump is started

q The pressurized oil from the pump is supplied
to port (P), increasing the (MA) side pressure
and generating the starting torque on the
motor. As the result, the motor starts revolu-
tion. The pressurized oil on outlet (MB) side of
the motor returns to the tank through port (T).
10-100 8 D31/37-22
Reversible valve
Operation
1. When ON-OFF solenoid for reversible 2. When ON-OFF solenoid for reversible
valve is de-energized valve is energized
q If ON/OFF solenoid (1) is "de-energized", the q If ON/OFF solenoid (1) is "energized", ON/OFF
pressurized oil from the pump is blocked by selector valve (2) is switched, allowing the
ON/OFF selector valve (2), and port (C) opens pressurized oil to flow into spool chamber (D)
for the tank circuit. through port (C).
q As a result, reversible valve spool (3) is q The pressurized oil in chamber (D) pushes
pushed to the right by reversible valve spring reversible valve spool (3) to the left overcom-
(4), motor port (MA) opens and pressurized oil ing the force of reversible valve spring (4). As a
flows in to revolve the motor in forward (clock- result, motor port (MB) opens and pressurized
wise). oil flows in to revolve the motor in reverse
(counterclockwise).
D31/37-22 10-100 9
SEN04484-00 Oil cooler bypass valve
Oil cooler bypass valve 1
a This valve consists of the oil cooler bypass valve and charge safety valve.
C1: To oil cooler inlet

C2: From oil cooler outlet
P1: From charge filter
P2: From fan motor
T: To hydraulic tank
Ts: Plug
1. Oil cooler bypass valve

2. Charge safety valve
10-100 10 D31/37-22
Oil cooler bypass valve SEN04484-00
Oil cooler bypass valve
1. Charge pump 4. Oil cooler bypass valve 4C. Plug

2. HST pump 4A. Poppet 5. Oil cooler
3. Charge safety valve 4B. Spring 6. Cooling fan motor
Function
q The oil cooler bypass valve controls the maxi-
mum pressure in the oil cooler and protects the
oil cooler.
Unit: mm
Free length x
Installed If damaged or
4B Cooler bypass valve spring diameter length deformed, replace
the spring
86.1 N 68.9 N
43.8 x 13.2 30.8 {8.78 kg} — {7.0 kg}
D31/37-22 10-100 11
SEN04484-00 Oil cooler bypass valve
Charge safety valve
1. Charge pump
2. HST pump
3. Charge safety valve
3A. Valve
3B. Spring
3C. Valve seat
3D. Poppet
3E. Spring
3F. Adjustment screw
4. Oil cooler bypass valve
5. Oil cooler
6. Cooling fan motor
10-100 12 D31/37-22
Oil cooler bypass valve SEN04484-00
Function q If the oil pressure in port (D) decreases, a

q The charge safety valve is installed to the oil pressure difference is generated between
cooler bypass valve to control the maximum ports (A) and (D) by orifice (a) of valve (3A).
pressure in the charge circuit and protect the Accordingly, valve (3A) is pushed to the right
charge circuit. by the pressure in port (A) and the oil in port
(A) is relieved. As a result, the pressure in the
Operation charge circuit does not increase any more.
q Port (A) is connected to the charge circuit and
port (B) is connected to the drain circuit. Port
(C) is connected to the tank drain circuit
through the oil cooler. Oil fills chamber (D)
through orifice (a) of valve (3A). Poppet (3D) is
in tight contact with valve seat (3C).
q When abnormal pressure is generated in the

circuit or when the shuttle valve of the HST
motor is in neutral, if the oil pressure in port (A)
and chamber (C) increases to the pressure set
by spring (3E), poppet (3D) is pushed to the
right and the oil in chamber (D) is relieved into
port (B) and the pressure in chamber (D)
decreases.
D31/37-22 10-100 13
SEN04484-00
D31/37-22 Bulldozer
©2008 KOMATSU
All Rights Reserved
10-100 14
SEN04485-00
BULLDOZER
D31EX-22
D31PX-22
D37EX-22
D37PX-22
D31EX-22 60001 and up
D31PX-22 60001 and up
D37EX-22 60001 and up
D37PX-22 60001 and up

200 Power train

Power train...................................................................................................................................................... 2
Power train system ......................................................................................................................................... 3
Damper ........................................................................................................................................................... 4
HST hydraulic equipment arrangement diagram ............................................................................................ 5
Steering and brake control .............................................................................................................................. 6
Solenoid valve................................................................................................................................................. 8
Final drive ..................................................................................................................................................... 15
HST pump..................................................................................................................................................... 18
HST motor..................................................................................................................................................... 30
Charge pump ................................................................................................................................................ 40
D31/37-22 10-200 1
200 Power train
SEN04485-00 Power train
Power train 1
Outline
q The power generated by engine (1) has its tor-
sional vibration reduced by damper (2), and is
then transmitted to the input shaft of the HST
pump.
q 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).
q HST pump (3) controls the travel direction and
turning of the machine by continuously chang-
ing the discharge direction and delivery of
each pump, or by changing the rotation direc-
tion and speed of the right and left HST motors
according to the swash plate positions of each
pump which change according to the operation
of the steering and directional and gear shift
lever.
q The hydraulic power transmitted to HST motor
(5) is output through the motor output shaft as
mechanical power and transmitted to final
drive (6).
q Final drive (6) reduces the speed with 2-stage
reduction planetary gears and rotates sprocket
(7) to drive track shoe (8).
a HST: Abbreviation for HydroStatic Transmission
10-200 2 D31/37-22
200 Power train
Power train system SEN04485-00
Power train system 1
1. Engine
2. Damper
3. HST pump
4. Work equipment and fan pump
5. High-pressure hose
6. HST motor
7. Final drive
8. Sprocket
9. Track shoe
10. Charge pump
D31/37-22 10-200 3
200 Power train
SEN04485-00 Damper
Damper 1
Unit: mm
Standard size Tolerance
Distance between HST pump
1 mounting face and boss end Adjust
62 ±0.5
Wear of internal teeth of coupling
2 (plastic) Repair limit: 1.0 Replace
3. Coupling
4. Boss
5. HST pump input shaft
6. Cover
7. Flywheel
Outline
q The damper protects the drive systems on and
after the engine from torsional vibrations by
reducing the torsional vibrations of the engine
due to the fluctuations in torque.
q The power from the engine is transmitted to
coupling (3) through flywheel (7) and torsional
vibrations are absorbed in coupling (3). Then
the power is transmitted to HST pump through
boss (4).
10-200 4 D31/37-22
200 Power train
HST hydraulic equipment arrangement diagram SEN04485-00
HST hydraulic equipment arrangement diagram 1
1. HST pump
2. Right HST motor
3. HST charge filter
4. Left HST motor
5. Solenoid valve
6. Charge pump
D31/37-22 10-200 5
200 Power train
SEN04485-00 Steering and brake control
Steering and brake control 1
a PCCS: Abbreviation for Palm Command Control System
10-200 6 D31/37-22
200 Power train
Steering and brake control SEN04485-00
1. Parking brake lever

2. Steering and directional and gear shift lever
(PCCS lever)
3. Electric lever
4. Parking brake limit switch 1
6. HST controller
7. Center brake proximity switch
8. Brake pedal potentiometer
9. Brake pedal
Outline
q Electric lever (3) sends electric signals to HST
controller (6) according to the stroke of PCCS
lever (2). Upon receiving these signals, HST
controller (6) sends signals to the EPC valve of
the HST pump to change the flow in the HST
pump and control the HST motor.
q If PCCS lever (2) is leaned to the left a little
while it is leaned to the forward position, the
machine turns to the left gradually. If it is
leaned to the left stroke end, the machine
makes a counter-rotation.
q Brake pedal potentiometer (8) sends electric
signals to HST controller (6) according to the
stroke of brake pedal (9). Upon receiving these
signals, HST controller (6) sends signals to the
EPC valve of the HST pump to decelerate the
right and left HST motors simultaneously.
q When parking brake lever (1) is in the "Free"
position, if brake pedal (9) is pressed fully, HST
controller (6) receives electric signals from
brake pedal potentiometer (8) and operates
the right and left HST hydraulic brakes simulta-
neously. If the machine stops, HST controller
(6) stops sending the signals to the parking
brake solenoid. At the same time, center brake
proximity switch (7) operates the relay to stop
sending of the signals to the slow brake sole-
noid valve. If sending of the signals to the park-
i ng br ak e so le noi d va lv e or s l ow br ak e
solenoid valve is stopped, the parking brakes
built in the right and left HST motors operate.
q If parking brake lever (1) is set in the "Lock"
position, the HST controller receives electric
signals from parking brake limit switch 1 (4)
and stops sending signals to the parking brake
solenoid valve. At the same time, parking
brake limit switch 2 (5) stops sending signals to
the slow brake solenoid valve. If sending of the
signals to the parking brake solenoid valve or
slow brake solenoid valve is stopped, the park-
ing brakes built in the right and left HST motors
are operated.
D31/37-22 10-200 7
200 Power train
SEN04485-00 Solenoid valve
Solenoid valve 1
Solenoid valve (3-spool), EPC valve (2-spool) and towing valve
10-200 8 D31/37-22
200 Power train
Solenoid valve SEN04485-00
A1: To work equipment PPC valve A6: Plug (Charge pressure pickup port)
A2: To accumulator A7: Plug (Hand pump connection port)
A3: To port (P) of right HST motor P: From charge filter outlet
A4: To port (P) of left HST motor T: To hydraulic tank
A5: To port (B) of right and left HST motors
1. Work equipment lock solenoid valve 6. Brake pressure sensor

2. Right HST motor EPC valve 7. Towing valve
3. Left HST motor EPC valve 8. Towing plate
4. Slow brake solenoid valve 9. Towing plate lock bolt
5. Parking brake solenoid valve 10. Block
Solenoid valve EPC valve

11. Nut 19. Block
12. Plunger 20. Body
13. Coil 21. Spool
14. Connector 22. Spring
15. Push pin 23. Rod
16. Spring 24. Coil
17. Spool 25. Plunger
18. Block 26. Connector
Outline
q In block (10), 3 solenoid valves, 2 EPC valves, q Work equipment lock solenoid valve (1) is
towing valve and brake pressure sensor are installed between the charge filter outlet and
installed. work equipment PPC valve. If the work equip-
q Upon receiving the signal generated by the ment lock lever is set in the "Free" position, it is
potentiometer which operates when the brake connected to the work equipment lock switch,
pedal is pressed or the signal of the limit switch and then the work equipment lock solenoid
linked with the parking brake lever from the operates to open the work equipment control
HST controller, parking brake solenoid valve circuit so that the work equipment can be oper-
(5) drains the changeover oil pressure and ated.
operates the parking brakes built in the HST
motors.
q If the machine stops and the signal of the prox-
imity switch which operates when the brake
pedal is pressed fully or the signal of the limit
switch linked with the parking brake lever is not
transmitted to slow brake solenoid valve (4)
any more, slow brake solenoid valve (4) drains
the changeover oil pressure gradually through
the orifice in it to operate the parking brakes
built in the HST motors.
q Upon receiving the PCCS lever signal from the
HST controller, right HST motor EPC valve (2)
and left HST motor EPC valve (3) output oil
pressure according to that signal to increase or q Towing valve (7) is installed between the park-
decrease the capacity of the HST motors. ing brake solenoid valve and HST motor. If the
parking brake cannot be released because of
an engine trouble, it can be released by remov-
ing towing plate (8), screwing in towing valve
(7), and applying parking brake release pres-
sure from outside.
a For the procedure for releasing the parking
brake, see Testing and Adjusting, Procedure
for releasing parking brake.
D31/37-22 10-200 9
200 Power train
Solenoid valve
a The work equipment lock solenoid valve is described below as a typical solenoid valve.
The slow brake solenoid valve and the parking brake solenoid valve operate similarly to this solenoid
valve.
C: To work equipment PPC valve P: From charge filter outlet T: To hydraulic tank
1. Nut 5. Push pin

2. Plunger 6. Spring
3. Coil 7. Spool
4. Connector 8. Block
Operation
1. When solenoid is "de-energized" 2. When solenoid is "energized"
q Since no signal current flows in the solenoid q If the signal current flows in the solenoid valve,
valve, coil (3) is de-energized. coil (3) is energized and a rightward thrust is
q Accordingly, spool (7) is pressed to the left by generated in plunger (2).
spring (6). q Accordingly, spool (7) is pushed to the right by
q Consequently, port (A) is closed and the pres- push pin (5).
surized oil from the pump does not flow to q Consequently, the pressurized oil from the
actuator (9). pump flows through ports (A) and (B) to actua-
q At the same time, the oil from actuator (9) tor (9).
flows through port (B) to port (C) and is q Since port (C) is closed at the same time, the
drained. oil is not drained.
10-200 10 D31/37-22
200 Power train
D31/37-22 10-200 11
200 Power train
EPC valve
C: To port (P) of HST motor

P: From charge filter outlet
1. Body
2. Spool
3. Rod
4. Coil
5. Plunger
6. Connector
10-200 12 D31/37-22
200 Power train
Unit: mm
Free length x If damaged or
Installed
Outside Installed load Free length Installed load deformed, replace
7 Return spring diameter
length
EPC valve
3.14 N 2.55 N assembly
9.0 8.4 —
{0.32 kg} {0.26 kg}
Function Operation
1. When signal current is 0 (coil is de-energized)
q The EPC valve consists of the proportional

solenoid and hydraulic valve. q While the signal current from the controller is
q Upon receiving signal current (i) from the con- not flowing to coil (14), coil (14) is de-ener-
troller, EPC valve generates EPC output pres- gized.
sure proportional to signal current (i), and q Spool (11) is pushed to the right by spring (12).
outputs it to the actuator. q Port (P) is closed and the pressurized oil from
the self pressure reducing valve does not flow
to the actuator.
q The pressurized oil from the actuator is
drained to the tank through port (C) and port
(T).
D31/37-22 10-200 13
200 Power train
2. When signal current is small (coil is ener- 3. When signal current is maximum (coil is
gized) energized)
q If small signal current flows to coil (5), coil (5) is q If the signal current flows to coil (5), coil (5) is
energized and plunger (6) generates the thrust energized.
toward the left. q Since the signal current is the maximum at this
q Rod (4) pushes spool (2) to the left and the time, thrust force of plunger (6) becomes the
pressurized oil from port (P) flows to port (C). maximum.
q Pressure in port (C) increases, and the com- q Spool (2) is pressed to the left by rod (4).
bined energy of the force to work on surface q The pressurized oil from port (P) flows to port
(a) of spool (2) and spring load of spring (3) (C) at the maximum flow rate, increasing the
become greater than the thrust force of circuit pressure between the EPC valve and
plunger (6). the control valve to the maximum level.
q Spool (2) is pushed to the right and port (P) is q Since port (T) is closed, the pressurized oil
disconnected from port (C). does not flow to the tank.
q Port (C) is connected to port (T).
q Spool (2) moves and balances the thrust force
of plunger (6) with the total of the pressure
force in port (C) and spring load of spring (3).
q It controls the circuit pressure between the
EPC valve and the control valve in proportion
to the magnitude of the signal current.
10-200 14 D31/37-22
200 Power train
Final drive SEN04485-00
Final drive 1
1. Oil level plug

2. Drain plug
Outline
q The final drive is a 2-stage reduction planetary
gear type, which is lubricated with oil splashed
by rotation of the gears.
q The final drive can be removed and installed
as a single unit.
q A floating seal is installed to the rotating and
sliding portion of the sprocket to prevent entry
of sand or soil from outside and to prevent
leakage of lubricating oil.
Specifications
Reduction ratio: – [(14 + 88)/14] x [(20 + 88)/20] + 1 = –38.343
D31/37-22 10-200 15
200 Power train
SEN04485-00 Final drive
3. No. 1 sun gear (Number of teeth: 14) 9. Floating seal

4. No. 2 sun gear (Number of teeth: 20) 10. HST motor
5. No. 1 planetary carrier 11. Hub
6. Cover 12. No. 2 planetary pinion (Number of teeth: 34)
7. Sprocket 13. Ring gear (Number of teeth: 88)
8. No. 2 planetary carrier 14. No. 1 planetary pinion (Number of teeth: 37)
Unit: mm
Standard clearance Clearance limit
15 Backlash between No. 1 sun gear and No. 1
planetary pinion 0.13 – 0.35 1.00
16 Backlash between No. 1 planetary pinion

and ring gear 0.17 – 0.54 1.10
Replace
17 Backlash between No. 1 planetary carrier
and No. 2 sun gear 0.27 – 0.46 1.00
18 Backlash between No. 2 sun gear and No. 2

planetary pinion 0.14 – 0.38 1.00
19 Backlash between No. 2 planetary pinion

and ring gear 0.18 – 0.54 1.10
10-200 16 D31/37-22
200 Power train
Final drive SEN04485-00
Power transmitting route
Power from HST motor

O
No. 1 sen gear (1)
O
No. 1 planetary pinion (2) o O
O O
No. 1 planetary carrier (3)
O O
No. 2 sen gear (4)
O O
No. 2 planetary pinion (5)
O O
Ring gear (6) i i
O
Hub (7)
O
Sprocket (8)
D31/37-22 10-200 17
200 Power train
SEN04485-00 HST pump
HST pump 1
Type: HPV63 + 63
Configuration
q This pump consists of a variable displacement
swash plate tandem piston pump, servo valve,
EPC valve and suction safety valve.
10-200 18 D31/37-22
200 Power train
HST pump SEN04485-00
1. EPC valve
2. Piston pump
3. Servo valve
4. Suction safety valve
D31/37-22 10-200 19
200 Power train
1. Shaft 8. Valve plate

2. Cradle bearing 9. End cap
3. Rocker cam 10. Bearing
4. Case 11. Piston
5. Servo piston 12. Spline
6. Slider 13. Shoe
7. Cylinder block 14. Bearing
Outline Structure
q This pump delivers the pressurized oil corre- q Cylinder block (7) is supported to shaft (1) by
sponding to the load by converting the rotary spline (12). Shaft (1) is supported by front and
torque transmitted to the pump shaft to hydrau- rear bearings (14) and (10).
lic energy. q The tip of piston (11) is shaped to a concave
q It is possible to change the delivery amount by ball and integrated with caulked shoe (13). Pis-
changing the swash plate angle (Forward io ton (11) and shoe (13) form a spherical bear-
0 io Reverse discharge). ing.
q Rocker cam (3) has flat surface (A), and shoe
(13) is always pressed against this surface
while sliding in a circular movement. Rocker
cam (3) can be rocked with cradle bearing (2)
which is provided between case (4) and cylin-
drical surface (B).
q Piston (11) in each cylinder chamber of cylin-
der block (7) moves relatively in the axial direc-
tion.
q Cylinder block (7) rotates relative to valve plate
(8) while sealing the pressure oil so that an
appropriate oil pressure balance is maintained
on this surface. And the oil in each cylinder
chamber of cylinder block (7) is suctioned and
discharged through valve plate (8).
10-200 20 D31/37-22
200 Power train
Operation
1. Operation of pump
q Cylinder block (9) rotates together with shaft q If centerline (X) of rocker cam (4) comes in line
(1) and shoe (7) slides on plane (A). At this with the axial direction of cylinder block (9)
time, the centerline (X) of rocker cam (4) and (s wash plate angle = 0) , the differ enc e
angle (a) of cylinder block (9) in the axial direc- between volumes (E') and (F') inside cylinder
tion are changed. Angle (a) is called the swash block (9) becomes 0, and the pump does not
plate angle. carry out any suction or discharge of oil.
q If the centerline (X) of rocker cam (4) comes to
have swash plate angle (a) in the axial direc-
tion of cylinder block (9), plane (A) works on
shoe (7) as a cam.
q Piston (8) slides in cylinder block (9), generat-
ing a difference between volumes (E) and (F)
in cylinder block (9). The pump suctions or dis-
charges the oil by this difference resulting from
(F) – (E).
q If the volume of chamber (F) is reduced by the
rotation of cylinder block (9), the oil is dis-
charged in that process. On the other hand,
volume of chamber (E) becomes larger and
the pressurized oil is suctioned in this expand-
ing process. q Piston (8) slides in cylinder block (9), generat-
ing a difference between volumes (E") and (F")
in cylinder block (9). The pump suctions or dis-
charges the oil by this difference resulting from
(E") – (F").
q In other words, when cylinder block (9) rotates
and the volume of chamber (E") becomes
smaller, the oil is discharged during that stroke.
On the other hand, the volume of chamber (F")
becomes larger, and the oil is suctioned during
that stroke. When the angle of the swash plate
is reversed, the suction and discharge of ports
(PA) and (PB) are reversed.
D31/37-22 10-200 21
200 Power train
2. Control of discharge amount

q If swash plate angle (a) is increased, the differ-
ence between volumes (E) and (F) is also
increased, thereby increasing delivery (Q).
Swash plate angle (a) is changed by servo pis-
ton (5).
q Servo spool (7) moves according to the com-
mand of the EPC valve. Servo piston (5) is
reciprocated by the commanded pressure out-
put from servo spool (7).
q This straight line movement is transmitted to
rocker cam (4) through slider (6). Rocker cam
(4), which is supported by the cylindrical sur-
face to cradle bearing (3), then rocks on the
cylindrical surface.
q For the pump, the maximum swash plate angle
(a) is ± 18.1°.
10-200 22 D31/37-22
200 Power train
D31/37-22 10-200 23
200 Power train
3. Operation of servo valve
10-200 24 D31/37-22
200 Power train
(1) When lever is operated

1) Operation of servo spool
q The command current from the pump control-
ler flows in the EPC valve solenoids (ESA and
ESB).
q This command current works on the EPC valve
to output signal pressure. This signal pressure
is supplied to chambers (sa) and (sb) through
ports (SA) and (SB). Pushing force on servo
spool (1) is changed according to this incoming
signal pressure.
q The servo spool (1) stops at a point where the
pressing force on servo spool (1) is balanced
with the force of spring (3).
q The magnitude of the command current is
decided by the software of the controller on the
basis of the stroke of the steering lever, pump
pressure, etc.
2) Operation of servo piston

q If servo spool (1) moves to the left, port (CP) is
connected to port (A) and pressure is applied
to chamber (a). At the same time, port (B) is
connected to port (T) and the oil in chamber (b)
is drained. As a result, servo piston (2) moves
to the left.
q If servo piston (2) moves to the left and port
(CP) is disconnected from port (A), servo pis-
ton (2) stops.
q In short, servo spool (1) and servo piston (2)
move by the same distance.
q Similarly, if servo spool (1) moves to the right,
port (CP) is connected to port (B) and pressure
is applied to chamber (b). At the same time,
port (A) is connected to port (T) and the oil in
chamber (a) is drained. As a result, servo pis-
ton (2) keeps on moving to the right until port
(CP) is disconnected from port (B).
(2) When lever is at neutral

q If oil does not flow from the EPC valve, servo
spool (1) does not move. Servo piston (2) is
maintained at the neutral position by the force
of spring (4) and the main pump is set to the
neutral.
D31/37-22 10-200 25
200 Power train
Suction safety valve
1. Charge pump 2A. Valve 2E. Spring

2. Charge safety valve 2B. Rod 2F. Plug
2C. Sleeve
2D. Spring
10-200 26 D31/37-22
200 Power train
1. Function as high-pressure safety 2. Function as suction valve

valve
Function Function
q This valve restricts the maximum pressure in q It secures the flow rate to the HST closed cir-
the HST circuit to protect the circuit. cuit. And it prevents inflow of charge pressure
oil to the pump high-pressure side (discharge
Operation side).
(Valve at piston pump discharge side)
q Port (A) is connected to the pump circuit and Operation
port (B) is connected to the charge circuit. The
pressure oil fills up port (C), too, through drill (1) When HST pump delivery is 0
hole (a) in valve (2A).
q The pressurized oil of high-pressure port (A) q The HST closed circuit is sealed, and the
fills up port (D), too, through passage groove charge pressure oil does not flow into the HST
(b) on the body. circuit.
q Valve (2A) is in tight contact with sleeve (2C).
q If abnormal pressure is generated in the circuit

and the oil pressure in ports (A) and (D)
reaches the pressure level set by spring (2D),
valve (2A) is pushed to the right, and the oil in
port (A) is relieved to port (B), so the oil pres-
sure in port (A) is reduced.
D31/37-22 10-200 27
200 Power train
(2) When HST pump delivery is done from 3. Suction side valve of piston pump
port (PA)
Operation
1) Piston pump discharge side valve q Meanwhile, since port (PB) turns to the suction
q When pressurized oil is discharged from port side and its pressure is set to low, sleeve (2C)
(PA) of HST pump (3), port (PA) becomes the is pushed to the right by the charge pressure
high pressure side. oil due to the difference in area (A1) < (A2). As
q This pressure oil of port (PA) flows to port (D) a result, the seat of sleeve (2C) opens.
through passage (b) on the body. q Then, the charge pressure oil in port (B) flows
q At this time, sleeve (2C) is pushed to the left to port (PB) through this clearance to charge
due to the difference in area (A1 > A2). the HST circuit.
q Therefore, the pressure oil from charge pump
(1) is prevented from flowing in.
10-200 28 D31/37-22
200 Power train
Towing valve
Function
q These valves are installed the top surface of
the pump and are provided in 2 locations; one
for the F side (for the left track) and the other
for the R side (for the right track).
q If the machine failed, it can be towed by con-
necting the valve to the HST circuit.
q Note, however, that the shaft brake of the
motor must be canceled at the same time.
Operation
q To actuate the towing valves, loosen the two
valves by 4.5 mm maximum (3 turns).
D31/37-22 10-200 29
200 Power train
SEN04485-00 HST motor
HST motor 1

Type: KMV105
1. Left HST motor

Direction of rotation (as seen facing drive shaft)
Flows in from MA: Counterclockwise rotation
Flows in from MB: Clockwise rotation
MA: (High pressure in reverse travel) Discharge port PB: Parking brake cancel signal port
MB: (High pressure in forward travel) Discharge port T: Drain
P: Capacity control signal port
1. Drive shaft 3. Speed sensor

2. Continuously variable displacement bent axis 4. Charge relief valve
piston motor (L.H.)
10-200 30 D31/37-22
200 Power train
HST motor SEN04485-00
2. Right HST motor

Direction of rotation (as seen facing drive shaft)
Flows in from MA: Counterclockwise rotation
Flows in from MB: Clockwise rotation
MA: (High pressure in forward travel) Discharge port PB: Parking brake cancel signal port
MB: (High pressure in reverse travel) Discharge port T: Drain
P: Capacity control signal port
1. Drive shaft 3. Speed sensor

piston motor (R.H.)
D31/37-22 10-200 31
200 Power train

piston motor 6. High-pressure selection check valve
2. Main piston 7. Parking brake
3. Servo valve 8. Speed sensor
4. Low-pressure shuttle valve 9. Tank
Specifications
Type: KMV105
Type: Continuously variable capacity displacement bent axis piston motor
Charge relief valve set pressure: 2.55 – 2.65 MPa {26 – 27 kg/cm2}
Parking brake release pressure: 0.98 – 1.96 MPa {10 – 20 kg/cm2}
10-200 32 D31/37-22
200 Power train
3. Operation of piston motor

Principle Pilot pressure – Displacement chart (Under no
q It is assumed that the shaft of the disc is sup- load)
ported to enable free rotation of the disc. If
force (F) is applied to this disc at an angle, this
force (F) is divided into force (F1) applied at a
right angle to the face of the disc and force
(F2) applied in the direction of the circumfer-
ence of the disc. Then force (F1) pushes the
disc in the axial direction, and force (F2)
rotates the disc in a clockwise direction.
q Similarly, if force (F') is applied to the disc
instead of (F), (F') is divided to (F'1) and (F'2),
and (F'2) rotates the disc in the counterclock-
wise direction.
Structure
q Seven pistons (2) are installed on the disc por- Operation
tion of drive shaft (1) like spherical joints. Pis- q The oil sent under pressure from the main pis-
tons (2) being installed at a certain angle to ton pump enters from the piston motor inlet
drive shaft (1) are fitted inside cylinder block port and generates oil pressure on the rear
(3). face of piston (2). And drive shaft (1) is rotated
q The inclination angle of cylinder block (3) and by angle (Q) of piston (2) and cylinder block
pistons (2) is determined by the capacity con- (3).
trol signal pressure applied to port (P). The fol-
lowing figure illustrates the relationship
between the signal pressure and volume.
D31/37-22 10-200 33
200 Power train
4. Changing capacity of continuously variable motor
1. Chamber (A) (self pressure) Function

2. Main piston q As shown in the figure above, when the main
3. Capacity control spring piston is at the lowest position, the motor
4. Servo valve capacity becomes MAX.
5. Chamber (C) (capacity control pressure) q When the main piston is at the highest posi-
6. Chamber (B) (self pressure) tion, the motor capacity becomes MIN.
7. Chamber (B) (drain) q When the main piston is situated in between
the above two positions, the motor capacity is
Pilot pressure – Displacement chart (Under no determined by the capacity control signal.
load)
Operation
q Gearshift mechanism is configured with cham-
bers (A), (B) and (C). Self pressures of cham-
ber (A) and chamber (B) work on the respective
pressure receiving areas, and the main piston
is operated according to the given balance
among the loads.
q When the EPC pressure is 0 kg/cm2, the main
piston is positioned on the MAX side.
q If EPC pressure is supplied, it is guided into
chamber (C) and pushes out the spool of the
capacity selector valve.
q The capacity selector valve spool supplies the
self pressure to chamber (B) up until the motor
capacity, which is determined by the given bal-
ance between the load generated by the pres-
sure supplied from EPC and the load applied
by the capacity control spring.
10-200 34 D31/37-22
200 Power train
5. Shuttle valve
1. Check valve Operation

2. Main piston q 2 check valves (1) guide a pressure higher
3. Low-pressure shuttle spool than (MA) and (MB) to chamber (A) of main
piston (2).
q When (MA) > (MB) in cross section (E – E),
low-pressure shuttle spool (3) moves to the
right. As a result, (MB) is selected as the low-
pressure side and it is guided to the charge
relief valve.
q When (MA) < (MB), low-pressure shuttle spool
(3) moves to the left, (MA) is selected as the
low-pressure side, and (MA) is guided to the
charge relief valve.
D31/37-22 10-200 35
200 Power train
6. Charge relief valve
1. Valve 4. Poppet
2. Spring 5. Spring
3. Valve seat 6. Adjusting screw
Function Operation
q The charge relief valve is installed inside the q Port (A) is connected to the pressure of low-
end cover. It prevents the pressure on the HST pressure side (charge circuit) on the HST
main low-pressure side (charge pressure) motor main circuit being selected by the low-
selected by the low-pressure shuttle spool pressure shuttle spool.
from going above the set pressure. At the q And ports (B) and (D) are connected to the
same time, it relieves the specified oil flow into tank drain circuit through the HST motor case.
the motor case to prevent the motor from over- q The pressurized oil also fills up chamber (C)
heating. through orifice (g) of valve (1). Poppet (4) is fit-
q In addition, it discharges the dirtiest oil inside ted tightly to valve seat (3).
the HST main circuit to the outside and acts to
keep the inside of the HST main circuit clean.
10-200 36 D31/37-22
200 Power train
q If an abnormal pressure is generated inside

the circuit, and the oil pressure in port (A) and
chamber (C) rises to the pressure level set by
spring (5), poppet (4) is pushed to the right.
And the oil in chamber (C) is relieved to port
(D), reducing the oil pressure in chamber (C).
q When the pressurized oil in chamber (C) goes

down, a differential pressure is generated
between ports (A) and (C) by orifice (g) of
valve (1).
q Valve (1) is pushed to the right by the pressur-
ized oil in port (A), and the oil in port (A) is
relieved to port (B).
q As a result, the pressure in the charge circuit is
prevented from going higher than the current
level.
D31/37-22 10-200 37
200 Power train
7. Operation of parking brake

(1) When parking brake valve is de-energized (2) When parking brake valve is energized
q If the parking brake valve is "de-energized", q If the parking brake valve is "energized", the
the pressurized oil of the control pump is shut valve is switched, allowing the pressurized oil
off and port (B) is connected to the tank. from the control pump to flow through port (B)
q As a result, brake piston (2) is pushed down by to brake chamber (A).
brake spring (1), and pushes down disc (3) and q The pressurized oil that entered chamber (A)
plate (4), enabling the brake. pushes up brake piston (2) overcoming the
force of brake spring (1). As a result, disc (3) is
detached from plate (4), and the brake is
released.
10-200 38 D31/37-22
200 Power train
8. HST motor speed sensor
1. Hall IC (with magnet) Function

2. P.C.B q The speed sensor, which is provided in the
3. Housing motor end cover, detects revolution pulses
4. Wire from the drive shaft spline in the motor and
5. O-ring transmits the electric signals to the HST con-
6. Rubber cap troller.
7. Wire protection hose q This sensor is a Hall IC type.
8. Shrinkable tube
9. Connector
D31/37-22 10-200 39
200 Power train
SEN04485-00 Charge pump
Charge pump 1
SAR(2)36
Unit: mm
No Item Criteria Remedy
Type Standard clearance Tolerance
1 Side clearance
SAR(2)36 0.100 – 0.150 0.190
Clearance between inside
2 diameter of plain bearing and SAR(2)36 0.067 – 0.125 0.200 Replace
outside diameter of gear shaft
Type Standard size Tolerance Repair limit
3 Pin driving-in depth 0
SAR(2)36 12 —
–0.5
4 Spline shaft rotating torque 2.9 – 6.9 Nm {0.3 – 0.7 kgm}
Discharge Standard Allowable
Type Speed pressure delivery delivery
Delivery —
(rpm) (l/min) (l/min)
— Oil: EO10-CD (MPa {kg/cm2})
Oil temperature: 45 – 55°C 3.2
SAR(2)36 3,000 103.9 92.0
{33}
Outline
q The HST charge pump is installed to the rear q The discharge pressure is determined by the
end of the work equipment and fan pump and charge safety valve in the oil cooler bypass
driven together with the HST pump and work valve and charge relief valve in the HST motor.
equipment and fan pump. q The charge pump draws the oil from the
q The charge pump supplies oil to the low pres- hydraulic tank.
sure side of the HST main circuit and supplies
pilot pressure to the HST pump, solenoid valve
and fan EPC.
10-200 40 D31/37-22
200 Power train
Charge pump SEN04485-00
Operation
q The charge pump is connected to the work
equipment and fan pump by the coupling and
rotates the drive gear. The drive gear rotates
the driven gear.
Specifications
Type: Gear pump
Theoretical delivery: 36.1 cc/rev
D31/37-22 10-200 41
SEN04485-00
D31/37-22 Bulldozer
©2008 KOMATSU
All Rights Reserved
10-200 42
SEN04486-00
BULLDOZER
D31EX-22
D31PX-22
D37EX-22
D37PX-22
D31EX-22 60001 and up
D31PX-22 60001 and up
D37EX-22 60001 and up
D37PX-22 60001 and up

300 Undercarriage and frame

Main frame ...................................................................................................................................................... 2
Track frame and idler cushion......................................................................................................................... 4
Idler ................................................................................................................................................................. 6
Track roller ...................................................................................................................................................... 8
Carrier roller .................................................................................................................................................. 10
Sprocket ........................................................................................................................................................ 12
Track shoe .................................................................................................................................................... 14
D31/37-22 10-300 1
SEN04486-00 Main frame
Main frame 1
1. Engine mount
2. Frame assembly
3. Middle underguard
4. Engine underguard
5. Oil drain guard
Outline
q A hull frame structure with the main frame and
underguard forming one unit is used.
10-300 2 D31/37-22
Main frame SEN04486-00
D31/37-22 10-300 3
SEN04486-00 Track frame and idler cushion
Track frame and idler cushion 1
1. Idler 9. Rod
2. Carrier roller 10. Recoil spring
3. Track frame 11. Wear ring
4. Sprocket 12. U-packing
5. Track roller end guard 13. Nut
6. Track roller center guard (if equipped) 14. Lubricator
7. Track roller 15. Cylinder
8. Seal 16. Bushing
10-300 4 D31/37-22
Track frame and idler cushion SEN04486-00
Unit: mm
Item Repair limit
17 Deformation of track frame Bend 7 (In length of 3,000) Correct
Twist 3 (In length of 300)
Opening of idler section 5
Free length Installed Installed Installed
x Outside Free length
18 Recoil spring diameter
length load load Replace
71.6 kN 63.7 kN
465 x 159 375.6 454
{7,300 kg} {6,500 kg}
Standard Tolerance Standard Clearance
size clearance limit
19 Clearance
bushing
between rod and Shaft Hole
Replace bushing
–0.030 +0.163 0.036 –
55 0.5
–0.076 +0.006 0.239
— Amount of filled grease 160 cc (Grease: G2-LI) —
Outline
q Recoil spring (10) moves rod (9) forward or
backward to adjust the track tension when
grease is added to or discharged from lubrica-
tor (14). It also dampens sudden shocks
applied to idler (1).
Track roller
Q'ty on Flange type and
each side arrangement
D31EX-22
D31PX-22 S, S, S, S, S, S
6 pieces
D37EX-22 (S, D, S, S, D, S)
D37PX-22
S: Single flange
D: Double flange
Arrangement in ( ) is for installation of double flange roller
(if equipped).
D31/37-22 10-300 5
SEN04486-00 Idler
Idler 1
10-300 6 D31/37-22
Idler SEN04486-00
Unit: mm
Outside diameter of protruding
1 portion 471 —
2 Outside diameter of tread 440 424
3 Depth of tread 15.5 23.5

Rebuild or replace
Thickness of tread
4 (center of tread)
17 9
5 Width of tread 33 37
6 Overall width 118 —

Clearance between shaft and size Shaft Hole clearance limit
7 bushing –0.250 +0.140 0.319 –
50 —
–0.300 +0.069 0.440
Clearance between shaft and –0.250 +0.062 0.250 – Replace
8 support
49.7
–0.300 0 0.362
—
Axial play of idler
9 (total axial play on both sides) 0.490 – 0.910 —
10 Clearance between guide plate

and support 1.0 — Rebuild or replace
11 Clearance between guide plate

and side plate 0.5 —
Adjust shim or
replace plate
12 Standard shim thickness at side
plate mounting area 5.0
D31/37-22 10-300 7
SEN04486-00 Track roller
Track roller 1
Single flange type
Double flange type
10-300 8 D31/37-22
Track roller SEN04486-00
Unit: mm
Outside diameter of flange
1 (outside) 198 —
Outside diameter of flange
2 (inside)
190 —
4 Thickness of tread 56.5 47.5

Rebuild or replace
5 Width of flange (outside) 14 9
6 Width of flange (inside) 12 7

Width of tread
7 (Single flange type)
34.5 —
Width of tread
8 (Double flange type)
35.5 —
9 Overall width 151 —

size clearance limit
10 Clearance
bushing
between shaft and Shaft Hole
–0.250 +0.140 0.319 –
50 –0.300 +0.069 0.440 —
Replace
11 Clearance
collar
between shaft and
49.7
–0.250
–0.300
–0.062
0
0.250 –
0.362 —
12 Axial play of roller
(total axial play on both sides) 0.29 – 0.71 —
D31/37-22 10-300 9
SEN04486-00 Carrier roller
Carrier roller 1
Unit: mm
1 Outside diameter of flange
162 —

Rebuild or replace
3 Thickness of tread 35 28
4 Width of tread 35 —
5 Width of flange 12 7

Clearance between shaft and size Shaft Hole clearance limit
6 support –0.100 +0.250 0.100 –
41 —
–0.200 0 0.450
Standard Tolerance Standard Interference
Interference between shaft and size Shaft Hole interference limit Replace
7 seal guard +0.170 +0.250 0.115 –
41.5 +0.140 0 0.170 —
8 Axial play of roller
0.14 – 0.66 —
10-300 10 D31/37-22
Carrier roller SEN04486-00
D31/37-22 10-300 11
SEN04486-00 Sprocket
Sprocket 1
Unit: mm
Standard size Tolerance Repair limit
1 Wear of tooth bottom diameter +1.0
564.9 552.9
–2.0
2 Wear of tooth tip diameter 629 ±2.0 617

Rebuild or replace
3 Wear of tooth tip width 38 — 32
4 Wear of tool bottom width 47.5 ±1.5 42
+1.5
5 Thickness of tooth bottom 54.95
–2.0
48.95
10-300 12 D31/37-22
Sprocket SEN04486-00
Full-scale dimensional drawing of sprocket tooth profile

a Make a full-scale copy on an OHP sheet.
D31/37-22 10-300 13
SEN04486-00 Track shoe
Track shoe 1
Standard bushing type
*1. Single shoe

*2. Swamp shoe
a Part P is the link on the bushing press-fitting side.
10-300 14 D31/37-22
Track shoe SEN04486-00
Unit: mm
1 Link pitch
154.3 157.3
Reverse
Standard size Reverse or
Light load Heavy load replace
2 Outside diameter of bushing
54 43.8 46.4
3 Thickness of bushing 12.7 2.5 5.1

4 Height of link Repair or replace
90 82
Thickness of link
5 (Bushing press-fitting part)
26.5 18.5 Replace
Tightening torque Retightening angle
a. (Nm {kgm}) (deg.)
Regular
Shoe bolt link 265 ± 30 {27 ± 3} —
6 (Single shoe) Retighten
(Swamp shoe) Tightening torque Retightening angle
b. (Nm {kgm}) (deg.)
Master link
150 ± 40 {15 ± 4} 180 ± 10
Tolerance Standard
Standard size
Interference between bushing and Shaft Hole interference
7 link
47 +0.234 +0.062 0.132 – 0.234
+0.194 0
Interference between regular pin –0.148 +0.15
8 and link
28
–0.2 0
0.148 – 0.350 Adjust or replace
Standard clearance
Clearance between mating faces Each side Both sides
9 of links
1.2 2.4
D31/37-22 10-300 15
SEN04486-00 Track shoe
Single shoe
Unit: mm
1 Height of grouser
47 20 Rebuild or replace
2 Overall height of shoe 55.5 28.5
Swamp shoe
Unit: mm
1 Height of grouser
74.5 62.5
Rebuild or replace
2 Thickness of grouser 17 5
10-300 16 D31/37-22
Track shoe SEN04486-00
D31/37-22 10-300 17
SEN04486-00
D31/37-22 Bulldozer
©2008 KOMATSU
All Rights Reserved
10-300 18
SEN04487-00
BULLDOZER
D31EX-22
D31PX-22
D37EX-22
D37PX-22
D31EX-22 60001 and up
D31PX-22 60001 and up
D37EX-22 60001 and up
D37PX-22 60001 and up

410 Hydraulic system, Part 1

Arrangement of hydraulic equipment for work equipment .............................................................................. 2
Work equipment control .................................................................................................................................. 4
Hydraulic tank and filter .................................................................................................................................. 6
Work equipment and fan pump ....................................................................................................................... 8
Control valve ................................................................................................................................................. 16
CLSS............................................................................................................................................................. 28
Functions and operation of each valve ......................................................................................................... 31
D31/37-22 10-410 1
SEN04487-00 Arrangement of hydraulic equipment for work equipment
Arrangement of hydraulic equipment for work equipment 1
1. Tilt cylinder 7. Hydraulic tank

2. Angle cylinder 8. Oil filter
3. Oil cooler 9. Ripper cylinder (if equipped)
4. Lift cylinder 10. Control valve
5. Blade PPC valve 11. Accumulator
6. Ripper/winch PPC valve (if equipped) 12. Main pump (Work equipment and fan pump)
10-410 2 D31/37-22
Arrangement of hydraulic equipment for work equipment SEN04487-00
D31/37-22 10-410 3
SEN04487-00 Work equipment control
Work equipment control 1
10-410 4 D31/37-22
Work equipment control SEN04487-00
1. Work equipment lock lever

2. Blade PPC valve
3. Blade control lever
4. Ripper control lever (if equipped)
5. Ripper PPC valve (if equipped)
6. PPC lock limit switch
Outline
q The work equipment control system is the PPC
type. Each spool of the control valves is moved
by operating blade PPC valve (2) with blade
control lever (3) or by operating ripper PPC
valve (5) with ripper control lever (4).
q If work equipment lock lever (1) is set in the
"Lock" position, PPC lock limit switch (6) stops
sending signals to the PPC lock solenoid
valve. The blade control lever (3) and ripper
control lever (4) can be moved but the work
equipment cannot be operated.
q If blade control lever (3) is set in the "Float"
position, the hydraulic detent of blade PPC
valve (2) works so that blade control lever (3)
will hold itself in the "Float" position.
q If work equipment lock lever (1) is set in the
"Lock" position, the hydraulic detent is reset
and blade control lever (3) returns to the "Hold"
position automatically.
q While the engine is stopped, the hydraulic
detent does not work even, if blade control
lever (3) is in the "Float" position, and blade
control lever (3) returns to the "Hold" position
automatically.
D31/37-22 10-410 5
SEN04487-00 Hydraulic tank and filter
Hydraulic tank and filter 1
1. Hydraulic tank
2. Hydraulic oil filter
3. Oil filler cap
4. Breather
5. Sight gauge
6. Strainer
7. Drain plug
8. Bypass valve
Specifications
Capacity of hydraulic tank (l) 85.2
Quantity of oil in hydraulic tank

60
(l)
Set pressure of bypass valve 0.10 ± 0.03
(MPa {kg/cm2}) {1.05 ± 0.3}
Pressure valve cracking
38 ± 15
pressure
{0.39 ± 0.15}
(kPa {kg/cm2})
Actuating pressure of vacuum
0 – 0.49
valve
{0 – 0.005}
(kPa {kg/cm2})
10-410 6 D31/37-22
Hydraulic tank and filter SEN04487-00
D31/37-22 10-410 7
SEN04487-00 Work equipment and fan pump
Work equipment and fan pump 1
Type: LPV45
P1: Pump discharge port

PS: Pump suction port
1. Pump unit
2. Servo valve
3. Air breather
10-410 8 D31/37-22
Work equipment and fan pump SEN04487-00
1. Shaft
2. Oil seal
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Spring
10. Servo piston
11. Ball
D31/37-22 10-410 9
Function q Cylinder block (7) rotates relatively to valve

q The pump converts the engine rotary torque plate (8) while sealing the pressurized oil so
transmitted to its shaft to oil pressure and that an appropriate oil pressure balance is
delivers pressurized oil corresponding to the maintained on this surface.
load. q And oil in each cylinder chamber of cylinder
q It is possible to change the delivery by chang- block (7) is available for suction or discharge
ing the swash plate angle. through valve plate (8).
q The number of holes on the cylinder block is
Structure odd, and each hole is designed to mate its cor-
q Cylinder block (7) is supported on shaft (1) responding groove on valve plate (8).
through spline (a). Shaft (1) is supported on
the front and rear bearings.
q The tip of piston (6) is shaped to a concave ball
and integrated with caulked shoe (5). Piston
(6) and shoe (5) form a spherical bearing.
q Rocker cam (4) has flat surface (A), and shoe
(5) is always pressed against this surface as it
slides in a circle. Rocker cam (4) also slides
around ball (11) using it as fulcrum.
q Piston (6) in each cylinder chamber of cylinder
block (7) moves relatively in the axial direction.
10-410 10 D31/37-22
Operation
q Cylinder block (7) rotates together with shaft q If centerline (X) of rocker cam (4) comes in line
(1) and shoe (5) slides on plane (A). At this with the axial direction of cylinder block (7)
time, rocker cam (4) slants around ball (11). As (s wash plate angle = 0) , the differ enc e
a result, angle (a) between center line (X) of between volumes (E) and (F); inside cylinder
rocker cam (4) and the axis of cylinder block block (7) becomes 0, and the pump does not
(7) changes. Angle (a) is called the swash carry out any suction or discharge of oil. (The
plate angle. swash plate angle is not set to 0 actually, how-
q If centerline (X) of rocker cam (4) comes to ever.)
have swash plate angle (a) in the axial direc- q Swash plate angle (a) is in proportion to the
tion of cylinder block (7), plane (A) works on pump delivery.
shoe (5) as a cam.
q Accordingly, piston (6) slides inside cylinder
block (7) and a difference is made between
volumes (E) and (F) in cylinder block (7). As a
result, each piston (6) suctions and discharges
oil by (F) – (E).
q In other words, when cylinder block (7) rotates
and the volume of chamber (E) becomes
smaller, the oil is discharged during that stroke.
On the other hand, the volume of chamber (F)
becomes larger, and the oil is sucked in during
that stroke. (In the figure, chamber (F) is at the
end of the suction stroke and chamber (E) is at
the end of the discharge stroke.)
D31/37-22 10-410 11
q If swash plate angle (a) is increased, the differ-

ence between volumes (E) and (F) is
increased, thereby increasing delivery (Q).
Swash plate angle (a) is changed with servo
piston (10).
q Servo piston (10) reciprocates straight accord-
ing to the signal pressure of the PC valve and
LS valve. This straight line motion is transmit-
ted to rocker cam (4). Then, rocker cam (4)
supported on ball (11) sways around ball (11).
q Output pressure (PE) from the LS valve is sup-
plied to the pressure chamber of servo piston
(10).
q If output pressure (PE) increases, rocker cam
(4) operates to reduce swash plate angle (a),
decreasing delivery (Q).
10-410 12 D31/37-22
Servo valve
PE: Control pressure output port 1. Locknut

PH: Pump pressure port 2. Plug
PLS: LS pressure input port 3. Spring
T: Drain port 4. Spool
5. Plug
6. Seat
7. Piston
8. Sleeve
9. Lever
10. Spool
11. PC valve
12. LS valve
D31/37-22 10-410 13
Function
1. LS valve 2. PC valve
q The LS valve controls the pump delivery q The stroke of the control valve may be
according to the stroke of the control lever, or increased to broaden the open area in order to
the demand flow for the actuator. increase pump delivery (Q) when pump dis-
q The LS valve controls pump delivery (Q) by charge pressure (PH) is high.
detecting the demand flow for the actuator q In other words, the PC valve decreases pump
from differential pressure (dPLS) between delivery (Q) if pump discharge pressure (PH)
pump discharge pressure (PH) and control goes higher due to the increased actuator load
valve outlet pressure (PLS). [(PH) is called the during work. And it increases delivery (Q) if
pump discharge pressure, (PLS) is called LS pump discharge pressure (PH) goes lower.
pressure, and (dPLS) is called LS differential q The following figure illustrates the relationship
pressure.] between pump discharge pressure (PH) and
q In other words, the pressure loss caused by pump delivery (Q).
flow of oil through the open area of the control
valve spool (= LS differential pressure (dPLS))
is detected, and then pump delivery (Q) is con-
trolled to keep that pressure loss constant and
supply the pump delivery according to the
demand flow for the actuator.
10-410 14 D31/37-22
D31/37-22 10-410 15
SEN04487-00 Control valve
Control valve 1
Outline
q This external view shows the control valve of machine with the ripper.
a The standard valve does not have the ripper valve.
A1: To fan pump

A2: To lift cylinder head
A3: To tilt cylinder head
A4: To angle cylinder head
A5: To ripper cylinder bottom
B1: To fan pump
B2: To lift cylinder bottom
B3: To tilt cylinder bottom
B4: To angle cylinder bottom
B5: To ripper cylinder head
LS: To hydraulic pump LS valve
P: From work equipment pump
PA2: From lift raise PPC valve
PA3: From tilt left PPC valve
PA4: From angle left PPC valve
PA5: From ripper lower PPC valve
PB1: —
PB2: From lift lower PPC valve
PB3: From tilt right PPC valve
PB4: From angle right PPC valve
PB5: From ripper raise PPC valve
PEPC: From solenoid valve
PC: Pump pressure detection port
TS: To hydraulic tank
10-410 16 D31/37-22
Control valve SEN04487-00
External view
D31/37-22 10-410 17
Sectional view
(1/5)
10-410 18 D31/37-22
1. Fan relief valve

2. Suction valve (lift bottom)
3. Suction valve (angle)
4. Suction valve (ripper bottom)
5. Safety valve
6. Suction valve (ripper head)
7. Suction valve (angle)
Unit: mm
Free length x Installed
8 Suction valve spring
diameter
length If damaged or
deformed, replace
36.3 x 4.45 33.3 —
{0.27 kg} {0.22 kg}
5.1 N 4.12 N
9 Check valve spring 39.2 x 4.45 33.5
{0.52 kg}
—
{0.42 kg}
D31/37-22 10-410 19
(2/5)
10-410 20 D31/37-22
1. Spool (fan)
2. Spool (lift)
3. Spool (tilt)
4. Spool (angle)
5. Spool (ripper)
Unit: mm
Free length x
Installed
6 Spool return spring
diameter
length
180 N 144 N
29 x 17.5 25 —
{18.4 kg} {14.7 kg}
50 N 40.0 N
7 Spool return spring 19.92 x 16.8 18.2
{5.1 kg}
—
{4.08 kg}
39.2 N 31.4 N
{4 kg}
—
{3.2 kg} If damaged or
deformed, replace
{5.7 kg}
—
{4.56 kg}
77.5 N 62.0 N
10 Spool return spring 33.34 x 17.2 26.8 {7.9 kg} — {6.32 kg}
75.4 N 60.0 N
49.9 N 39.9 N
189 N 151 N
D31/37-22 10-410 21
(3/5)
10-410 22 D31/37-22
1. Unload valve
2. Pressure compensation valve F (fan)
3. Pressure compensation valve F (lift)
4. Pressure compensation valve F (tilt)
5. Pressure compensation valve F (angle)
6. Pressure compensation valve F (ripper)
7. Pressure compensation valve R (ripper)
8. Pressure compensation valve R (angle)
9. Pressure compensation valve R (tilt)
10. Pressure compensation valve R (lift)
11. Pressure compensation valve R (fan)
F: Flow control valve

R: Pressure reducing valve
Unit: mm
Free length x
Installed If damaged or
12 Unload valve spring diameter length deformed, replace
the spring
28.64 x 18.6 18 91.2 N — 73.0 N
{9.3 kg} {7.44 kg}
D31/37-22 10-410 23
(4/5)
10-410 24 D31/37-22
1. Unload valve
2. Main relief valve
3. Fan relief valve
4. Spool (fan)
5. Pressure compensation valve R (fan)
6. Pressure compensation valve F (fan)
7. Suction valve (lift)
8. Spool (lift)
9. Pressure compensation valve R (lift)
10. Pressure compensation valve F (lift)
11. Spool (tilt)
12. Pressure compensation valve R (tilt)
13. Pressure compensation valve F (tilt)

D31/37-22 10-410 25
(5/5)
10-410 26 D31/37-22
1. Suction valve
2. Suction valve
3. Spool (angle)
4. Pressure compensation valve R (angle)
5. Pressure compensation valve F (angle)
6. Suction valve
7. Suction valve
8. Spool (ripper)
9. Pressure compensation valve R (ripper)
10. Pressure compensation valve F (ripper)
11. Safety valve
12. Pressure bleed plug

Unit: mm
Free length x Installed If damaged or
13 Check valve spring diameter length deformed, replace
the spring
21.9 x 5 15.8 1.96 N — 1.57 N
{0.2 kg} {0.16 kg}
D31/37-22 10-410 27
SEN04487-00 CLSS
CLSS 1
Outline of CLSS
Features Configuration
CLSS stands for Closed center Load Sensing Sys- q CLSS consists of a variable capacity piston
tem, and has the following features. pump, control valves, and respective actua-
tors.
q Fine control not influenced by load q The pump unit consists of the main pump, PC
q Controllability enabling digging even under the valve, and LS valve.
fine control
q Ease of compound operation ensured by flow
divider function using the open area of spool
during compound operations
q Energy saving using variable pump control
10-410 28 D31/37-22
CLSS SEN04487-00
Basic principle
Pump swash plate angle control
q The pump swash plate angle (pump delivery) q If the LS differential pressure (dPLS) goes
is controlled so that the LS differential pressure lower than the set pressure of the LS valve
(dPLS), which is the differential pressure (the actuator load pressure is high), the pump
between pump discharge pressure (PP) and swash plate angle is adjusted toward the maxi-
control valve outlet port LS pressure (PLS) mum. If the LS differential pressure goes
(actuator load pressure), is maintained at a above the set pressure (the actuator load pres-
constant level. sure is low), the pump swash plate angle is
[LS differential pressure (dPLS) = Pump dis- adjusted toward the minimum.
charge pressure (PP) – LS pressure (PLS)]
a For details of the operation, see "HST pump".
D31/37-22 10-410 29
SEN04487-00 CLSS
Pressure compensation control

q The valves (pressure compensation valves) to
balance the load are installed to the outlet side
of the control valve. In the compound operation
of the actuators, this valve maintains the pres-
sure differenc e (dP) between the spool
upstream (inlet port) and downstream (outlet
port) of each valve at a constant level indepen-
dent of the magnitude of the load (pressure). In
this way, the oil flow from the pump is divided
(compensated) in proportion to the open areas
(S1) and (S2) of each valve being operated.
10-410 30 D31/37-22
Functions and operation of each valve SEN04487-00
Functions and operation of each valve 1
Names of hydraulic circuits and valves
1. Unload valve 8. Fan spool

2. Safety valve 9. Lift spool
Set pressure: 30.4 MPa {310 kg/cm2} 10. Tilt spool
3. Pressure compensation valve 11. Angle spool
4. Suction valve 12. Ripper spool
5. Main relief valve
Set pressure: 27.5 MPa {280 kg/cm2}
6. Fan relief valve
Set pressure: 19.6 MPa {200 kg/cm2}
7. Check valve
D31/37-22 10-410 31
SEN04487-00 Functions and operation of each valve
Unload valve 1
1. When control valve is at HOLD
PP: Pump circuit

PLS: LS circuit
T: Tank circuit
1. Spool
2. Spring
Function Operation
q When the control valve is at HOLD, delivery q Pump pressure (PP) is applied to the left end
(Q) at the minimum pump swash plate angle is face of spool (1) and LS pressure (PLS) is
released to the tank circuit. At this time, the applied to its right end face.
pump (discharge) pressure (PP) is set to 2.16 q Since LS pressure (PLS) is set to 0 when the
MPa {22 kg/cm2} with spring (2) in the valve. control valve is at HOLD, only pump pressure
(LS pressure (PLS) is 0 MPa {0 kg/cm2}). (PP) is applied, and (PP) is set only with the
spring load of spring (2).
q If pump pressure (PP) rises to the spring load
of spring (2) (2.16 MPa {22 kg/cm2}), spool (1)
moves to the right and pump circuit (PP) is
connected to tank circuit (T) through hole (a) of
spool (1).
q As a result, pump pressure (PP) is set to 2.16
MPa {22 kg/cm2}.
10-410 32 D31/37-22
2. When control valve is controlled in fine control
PP: Pump circuit

PLS: LS circuit
T: Tank circuit
1. Spool
2. Spring
Function Operation
q If the flow rate demanded for the actuator is q If the control valve is controlled in fine control,
within the delivery available with the minimum LS pressure (PLS) is generated and applied to
pump swash plate angle when the control the right end face of spool (1). Since the open
valve is controlled in fine control, pump pres- area of the control valve spool is narrow, the
sure (PP) is set to the sum of LS pressure difference between LS pressure (PLS) and
(PLS) + 2.16 MPa {22 kg/cm2}. When the differ- pump discharge pressure (PP) is large.
ential pressure between pump pressure (PP) q When the differential pressure between pump
and LS pressure (PLS) reaches the spring load pressure (PP) and LS pressure (PLS) reaches
of spring (2) (2.16 MPa {22 kg/cm 2 }), the the spring load of spring (2) (2.16 MPa {22 kg/
unload valve opens. Thus, LS differential pres- cm2}), spool (1) moves to the right and pump
sure (dPLS) is set to 2.16 MPa {22 kg/cm2}. circuit (PP) is connected to tank circuit (T).
q In short, pump pressure (PP) is set to the sum
of the spring force (3.43 MPa {35 kg/cm2}) + LS
pressure (PLS), and LS differential pressure
(dPLS) is set to 2.16 MPa {22 kg/cm2}.
D31/37-22 10-410 33
3. When control valve is operated (Work equipment)
PP: Pump circuit

PLS: LS circuit
T: Tank circuit
1. Spool
2. Spring
3. Actuator circuit
Function Operation
q When the control valve is operated, if the q If the control valve is operated with large
demand flow for the actuator exceeds the stroke, LS pressure (PLS) is generated and
delivery available at the minimum pump swash applied to the right end face of spool (1). Since
plate angle, the oil flow to tank circuit (T) is the open area of the control valve is wide at
stopped and all of pump delivery (Q) is sup- this time, the difference between LS pressure
plied to the actuator circuit. (PLS) and pump pressure (PP) is small.
q Since the differential pressure between pump
pressure (PP) and LS pressure (PLS) does not
reach the spring load of spring (2) (2.16 MPa
{22 kg/cm2}), spool (1) is pushed to the left by
spring (2).
q Pump circuit (PP) is disconnected from tank
circuit (T) and all of pump delivery (Q) is sup-
plied to actuator circuit (3).
10-410 34 D31/37-22
Operation of work equipment 1
1. When blade lift is operated to "LOWER"
q When the blade lift is operated to "LOWER",

spool (1) moves to the right from the HOLD
position, and the oil from the pump enters
bridge circuit (C), passes through cylinder port
(B), and enters the cylinder bottom.
q Then the oil in the cylinder head is drained
through cylinder port (A).
D31/37-22 10-410 35
2. When blade lift is operated to "FLOAT"
q When the blade lift is operated to "FLOAT",

spool (1) moves further to the right. The oil
from the pump does not flow into bridge circuit
(C).
q And the oil in cylinder port (B) is connected to
the drain circuit through bridge circuit (C),
opening (a), and cylinder port (A).
10-410 36 D31/37-22
Introduction of LS pressure
For lift, tilt, angle, and ripper valve
Function q At this time, LS circuit (PLS) is connected to

q LS pressure means the actuator load pressure tank circuit (TS) through LS bypass valve (4).
on the outlet side of the control valve. (See the section on the LS bypass valve.)
q Practically, pump pressure (PP) is reduced by q Actuator circuit pressure (PA) = (A) is applied
pressure reducing valve (3) of the pressure to the left end face of the pressure reducing
compensation valve to the same pressure as valve (3), and reduced pump discharge pres-
actuator circuit pressure (A), and is sent to LS sure (PP) is applied to the opposite side.
circuit (PLS). q As a result, pressure reducing valve (3) is bal-
anced at a position where actuator circuit pres-
Operation sure (PA) and the pressure in spring chamber
q When spool (1) is operated, pump discharge (PLS1) become the same. Pump discharge
pressure (PP) flows to actuator circuit (A) pressure (PP) being decreased on notch (C) is
through flow control valve (2), notch (a) of the supplied to LS circuit (PLS) as actuator circuit
spool (1), and bridge passage (b). pressure (A).
q Since pressure reducing valve (3) also moves
to the right at the same time, pump discharge
pressure (PP) is reduced by the pressure loss
on notch (C) and supplied to LS circuit (PLS),
and then further led to spring chamber (PLS1).
D31/37-22 10-410 37
Pressure compensation valve
Function q Flow control valve (2) reduces the open area

q In the compound operation, if the load pres- between pump circuit (PP) and spool upstream
sure of the left side becomes lower than that (PPA) to generate a pressure loss between
for the actuator of the other side and an (PP) and (PPA).
increased flow rate is potentially needed, the q Flow control valve (2) and pressure reducing
pressure compensation valve compensates valve (1) are stopped at a position where the
the pressure. (At this point of the compound pressure difference between (PA) and (PLS)
operation, the load pressure to the actuator on applied to the both end of pressure reducing
the other side (right side) is higher than the valve (1) becomes the same as the pressure
load pressure to the actuator on this side (left loss between (PP) and (PPA) on both sides of
side).) flow control valve (2).
q As a result, pressure difference between
Operation upstream pressure (PPA) and downstream
q In the compound operation, if the load pres- pressure (PA) of the both spools engaged in
sure for the actuator on the other side (right the compound operation becomes even. Then,
side) goes higher, the flow rate in actuator cir- the pump flow is distributed in proportion to the
cuit (A) of the actuator on this side (left side) open area of notch (a) of each spool.
starts increasing.
q In this case, LS pressure (PLS) for the actua-
tors of the other side is applied to spring cham-
ber (PLS1) to push pressure reducing valve (1)
and flow control valve (2) to the left.
10-410 38 D31/37-22
LS bypass valve
PLS: LS circuit
T: Tank circuit
1. LS bypass valve
2. Valve cover
Function Operation
q The LS bypass valve releases residual LS q The pressurized oil in LS circuit (PLS) flows to
pressure (PLS). tank circuit (T) through filter (a) of LS bypass
q While moderating increasing rate of LS pres- valve (1) and orifice (b).
sure (PLS), this valve generates pressure loss
in the throttle function with this discarded throt-
tle flow, decreasing the effective LS differential
pressure and enhancing stability.
D31/37-22 10-410 39
SEN04487-00
D31/37-22 Bulldozer
©2008 KOMATSU
All Rights Reserved
10-410 40
SEN04488-00
BULLDOZER
D31EX-22
D31PX-22
D37EX-22
D37PX-22
D31EX-22 60001 and up
D31PX-22 60001 and up
D37EX-22 60001 and up
D37PX-22 60001 and up


Blade PPC valve ............................................................................................................................................. 2
Accumulator ...................................................................................................................................................11
D31/37-22 10-420 1
SEN04488-00 Blade PPC valve
Blade PPC valve 1
a PPC: Abbreviation for Proportional Pressure Control
1. For blade lift, tilt and angle
10-420 2 D31/37-22
Blade PPC valve SEN04488-00
P: From control pump P1: To blade lift valve (raise)

T: To hydraulic tank P4: To blade lift valve (lower)
P1: To blade tilt valve (left tilt) P5: To blade angle valve (right angle)
P2: To blade tilt valve (right tilt) P6: To blade angle valve (left angle)
1. Spool 6. Cap (For connecting the lever)

2. Metering spring 7. Joint
3. Centering spring 8. Plate
4. Piston 9. Retainer
5. Disc 10. Body
D31/37-22 10-420 3
Operation
1. When in neutral
1) For blade lift 2) For blade tilt
q Ports (PA) and (PB) of the blade lift control q Ports (PA) and (PB) of the blade tilt control
valve and ports (P3) and (P4) of the PPC valve valve and ports (P1) and (P2) of the PPC valve
are connected to drain chamber (D) through are connected to drain chamber (D) through
fine control hole (f) of spool (1). fine control hole (f) of spool (1).
10-420 4 D31/37-22
3) For blade angle (10) (where fine control hole (f) is between
q Ports (PA) and (PB) of the blade angle control drain chamber (D) and pump pressure cham-
valve and ports (P5) and (P6) of the PPC valve ber (PP)) does not change until retainer (9)
are connected to drain chamber (D) through comes in contact with spool (1).
fine control hole (f) of spool (1). q Therefore, metering spring (2) is compressed
an amount proportional to the movement of the
control lever, so the pressure at port (P4) also
rises in proportion to the movement of the con-
trol lever.
q The control valve spool moves to a position
where the pressure in chamber (PB) (same as
pressure at port (P4)) is balanced with the
force of the return spring.
2. When in fine control mode

(Neutral o Fine control)
q When piston (4) is pushed by disc (5), retainer
(9) is pushed, and spool (1) is also pushed
through metering spring (2), and moves down-
ward.
q As a result, if fine control hole (f) is shut off
from drain chamber (D), at almost the same
time, it is connected with pump pressure
chamber (PP), and the pilot pressure oil from
the control pump flows from port (P4) to port
(PB) through fine control hole (f).
q When the pressure at port (P4) becomes high,
if spool (1) is pushed back and fine control hole
(f) is shut off from pump pressure chamber
(PP), at almost the same time, it is connected
with drain chamber (D) and releases the pres-
sure at port (P4).
q As a result, spool (1) moves up and down so
that the force of metering spring (2) is bal-
anced with the pressure at port (P4). The posi-
tional relationship between spool (1) and body
D31/37-22 10-420 5
3. When in fine control mode 4. At full stroke

(When control lever is returned) q When disc (5) pushes down piston (4) and
q When disc (5) starts to be returned, spool (1) is retainer (9) pushes down spool (1), fine control
pushed up by the pressure at port (P4) and the hole (f) is shut off from drain chamber (D) and
force of centering spring (3). is connected to pump pressure chamber (PP).
q As a result, fine control hole (f) is connected to q Therefore, the pilot pressure oil from the con-
drain chamber (D), and the pressure oil at port trol pump is taken from port (P4) to chamber
(P4) is released. (PB) through fine control hole (f), and pushes
q If the pressure at port (P4) goes down too far, the control valve spool.
spool (1) is pushed down by metering spring q The return oil from chamber (PA) passes from
(2). Fine control hole (f) is shut off from drain port (P3) and flows to drain chamber (D)
chamber (D), and at almost the same time, it is through fine control hole (f').
connected to pump pressure chamber (PP).
Pump pressure is supplied until the pressure at
port (P4) recovers to a pressure equivalent to
the position of the lever.
q When the control valve spool returns, the oil in
drain chamber (D) flows in through fine control
hole (f') of the valve which is not in operation
and then flows into chamber (PA) through port
(P3).
10-420 6 D31/37-22
5. When blade is operated to "FLOAT" 6. When blade is released from "FLOAT"

q When piston (4) at port (P4) "LOWER" side is q When disc (5) is returned from the "FLOAT"
pushed by disc (5) and moves downward, ball position, it is pushed down by a force greater
(11) contacts protrusion (a) of the piston during than the hydraulic force in chamber (E).
the stroke. (Detent starts to act.) q As a result, chamber (E) is shut off from pas-
q When piston (4) is pushed in further, ball (11) sage (d) and is connected to the drain cham-
pushes up collar (12), which is being held by ber. Therefore, the oil pressure inside chamber
detent spring (13). While pushing up collar (E) is lost, and the "FLOAT" position is can-
(12), it escapes to the outside and passes over celed.
protrusion (a) of the piston.
q When this happens, piston (4') on the opposite
side is pushed up by spring (14).
q As a result, the oil inside chamber (F) flows to
chamber (E) through (b) and (c), and piston
(4') follows disc (5). Passage (d) is connected
to port (P4), so more or less the same pres-
sure is applied as is applied to port (P4).
q Chamber (E) is normally connected to drain
chamber (D), but if ball (11) passes over pro-
trusion (a) of the piston, passage (d) and
chamber (E), which were shut off, are con-
nected and the pressure oil flows.
q At the same time, the control valve also moves
to the "FLOAT" position and the circuit is set to
the "FLOAT" condition.
q Piston (4') is being pushed up by the oil pres-
sure inside chamber (E), so even if the lever is
released, blade is held at the "FLOAT" posi-
tion.
D31/37-22 10-420 7
2. Solenoid valve
C: To control valve 1. Body

P: From self pressure reducing valve 2. Plug
T: To hydraulic tank 3. Connector
10-420 8 D31/37-22
Function Operation
q EPC valve consists of the proportional sole-
noid and hydraulic valve. 1) When the signal current is 0
q Upon receiving signal current (i) from the pump (coil is de-energized)
controller, EPC valve generates EPC output q While the signal current from the controller is
pressure proportional to the intensity of the not flowing to coil (14), coil (14) is de-ener-
current, and outputs it to the control valve. gized.
q Spool (11) is pushed to the right by spring (12).
q Port (P) is closed, and the pressurized oil from
the front pump does not flow to the control
valve.
q The pressurized oil from the actuator is
drained to the tank through port (C) and port
(T).
D31/37-22 10-420 9
2) When the signal current is small 3) When the signal current is maximum
(coil is energized) (coil is energized)
q If small signal current flows to coil (5), coil (5) is q If the signal current flows to coil (5), coil (5) is
energized and plunger (6) generates the thrust energized.
toward the left. q Since the signal current is the maximum at this
q Push pin (4) pushes spool (2) to the left and time, thrust force of plunger (6) becomes the
the pressurized oil from port (P) flows to port maximum.
(C). q Spool (2) is pushed to the left by push pin (4).
q Pressure in port (C) increases, and the com- q The pressurized oil from port (P) flows to port
bined energy of the force to work on surface (C) at the maximum flow rate, increasing the
(a) of spool (2) and spring load of spring (3) circuit pressure between the EPC valve and
become greater than the thrust force of the control valve to the maximum level.
plunger (6). q Port (T) is closed and the pressurized oil does
q Spool (2) is pushed to the right, port (P) is dis- not flow to the hydraulic tank.
connected from port (C), and port (C) is con-
nected to port (T).
q Spool (2) moves to strike a balance between
the plunger (6) thrust force and the combined
energy of port (C) pressure and spring load of
spring (3).
q It controls the circuit pressure between the
EPC valve and the control valve in proportion
to the magnitude of the signal current.
10-420 10 D31/37-22
Accumulator SEN04488-00
Accumulator 1
(For PPC circuit)
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications
Gas used Nitrogen gas
Amount of gas (cc) 300
Charged pressure 1.18 {12}

(MPa {kg/cm2}) (at 80 ± 5°C)
Max. pressure used
6.86 {70}
(MPa {kg/cm2})
Outline
q The accumulator is installed between the
charge pump and work equipment PPC valve.
If the work equipment is raised and the engine
stops, the pressure of the compressed nitro-
gen gas of the accumulator applies the pilot oil
pressure to the work equipment control valve
so that the work equipment will lower by its
weight.
D31/37-22 10-420 11
SEN04488-00
D31/37-22 Bulldozer
©2008 KOMATSU
All Rights Reserved
10-420 12
SEN04489-00
BULLDOZER
D31EX-22
D31PX-22
D37EX-22
D37PX-22
D31EX-22 60001 and up
D31PX-22 60001 and up
D37EX-22 60001 and up
D37PX-22 60001 and up

500 Work equipment

Work equipment .............................................................................................................................................. 2
Cutting edge and end bit................................................................................................................................. 6
Ripper ............................................................................................................................................................. 7
Work equipment cylinder ................................................................................................................................ 8
Piston valve....................................................................................................................................................11
D31/37-22 10-500 1
500 Work equipment
SEN04489-00 Work equipment
Work equipment 1
1. Tilt cylinder 5. Pitching rod

2. Cutting edge 6. Angle cylinder
3. End bit 7. U-frame
4. Blade 8. Lift cylinder
10-500 2 D31/37-22
500 Work equipment
Work equipment SEN04489-00
D31/37-22 10-500 3
500 Work equipment
SEN04489-00 Work equipment
10-500 4 D31/37-22
500 Work equipment
Work equipment SEN04489-00
Unit: mm
Clearance between frame size Shaft Hole clearance limit
1 connecting pin and bushing –0.030 +0.174
60 0.13 – 0.25 0.5
–0.076 +0.100
Clearance between frame –0.030 +0.3 0.13 –
2 connecting pin and U-frame bracket
60
–0.076 +0.1 0.376
1.0
3 Clearance between lift cylinder

bottom pin and frame bracket
45
–0.025
–0.087
+0.039
0
0.025 –
0.126
1.0
4 Clearance between lift cylinder

head pin and U-frame bracket
45
–0.025
–0.064
+0.3
+0.1
0.125 –
0.364
1.0
Replace
5 Clearance between angle cylinder
bottom pin and U-frame bracket
45
–0.025
–0.064
+0.3
+0.1
0.125 –
0.364
1.0
6 Clearance between angle cylinder

head pin and blade bracket
45
–0.025
–0.064
+0.3
+0.1
0.125 –
0.364
1.0
7 Clearance between tilt cylinder

bottom pin and blade bracket
45
–0.025
–0.064
+0.3
+0.1
0.125 –
0.364
1.0
8 Clearance between tilt cylinder

head pin and U-frame bracket
45
–0.025
–0.064
+0.15
+0.05
0.075 –
0.214
1.0
9 Clearance
and bushing
between pitching rod
45
–0.025
–0.064
+0.003
–0.015
0.01 –
0.067
0.5
10 Clearance between blade center

ball and U-frame cap
148 –0.25
–0.75
+0.5
0
0.25 – 1.25 5.0
Adjust with
shims
11 Standard shim thickness between
main blade ball and U-frame cap
8.0
D31/37-22 10-500 5
500 Work equipment
SEN04489-00 Cutting edge and end bit
Cutting edge and end bit 1
Unit: mm
1 Cutting edge height
160 110
2 End bit height 160 110
D31EX-22 360 — Replace
D31PX-22 405 (370) —

3 End bit width
D37EX-22 370 —
D37PX-22 405 (370) —
10-500 6 D31/37-22
500 Work equipment
Ripper SEN04489-00
Ripper 1
(If equipped)
Unit: mm
size Shaft Hole clearance limit
1
Clearance between pin and –0.030 +0.074
bushing 55 0.03 – 0.15
–0.076 0
1.0
–0.025 +0.062 0.025 – Replace
2 50
–0.064 0 0.126
3 Wear of point
160 85
4. Support
5. Ripper cylinder
6. Shank
7. Point
8. Beam
9. Link
D31/37-22 10-500 7
500 Work equipment
SEN04489-00 Work equipment cylinder
Work equipment cylinder 1
Lift cylinder
Tilt cylinder
10-500 8 D31/37-22
500 Work equipment
Work equipment cylinder SEN04489-00
Angle cylinder
Ripper cylinder
(If equipped)
D31/37-22 10-500 9
500 Work equipment
SEN04489-00 Work equipment cylinder
Unit: mm
Cylinder Standard Tolerance Standard Clearance
name size Shaft Hole clearance limit
–0.025 +0.121 0.030 –
Lift 40 0.485
–0.064 +0.005 0.185
Clearance between –0.025 +0.141 0.021 –
1 piston rod and bushing Tilt 45 0.505
–0.064 –0.004 0.205
–0.025 +0.121 0.030 –
Angle 40 0.485
–0.064 +0.005 0.185
–0.030 +0.151 0.024 –
Ripper 55 0.527
–0.076 –0.006 0.227
–0.025 +0.142 0.105 –
Lift 45 1.0
–0.064 +0.080 0.206
–0.025 +0.003 0.010 – Replace
Clearance between Tilt 45 0.5 bushing
–0.064 –0.015 0.0067
2 piston rod supporting
shaft and bushing –0.025 +0.003 0.010 –
Angle 45 0.5
–0.064 –0.015 0.067
–0.030 +0.174 0.130 –
Ripper 55 1.0
–0.076 +0.100 0.250
–0.025 +0.142 0.105 –
Lift 45 1.0
–0.087 +0.080 0.229
Clearance between Tilt 45 –0.025 +0.003 0.010 – 0.5
cylinder bottom –0.064 –0.015 0.067
3 supporting shaft and
Angle 45 –0.025 +0.003 0.010 – 0.5
bushing –0.064 –0.015 0.067
Ripper 55 –0.030 +0.174 0.130 – 1.0
–0.076 +0.100 0.250
Lift 569 ± 57.0 Nm {58 ± 5.8 kgm}
Tilt 677 ± 67.5 Nm {69 ± 6.9 kgm}

— Tightening torque of
cylinder head
Angle 588 ± 59.0 Nm {60 ± 6.0 kgm}
Ripper 863 ± 86.5 Nm {88 ± 8.8 kgm}

Retighten
Lift 784 ± 78.4 Nm {80 ± 8.0 kgm} (Width across flats: 46 mm)
Tilt 1,250 ± 125 Nm {127 ± 12.2 kgm} (Width across flats: 50 mm)
— Tightening torque of
cylinder piston locknut
Angle 912 ± 91.0 Nm {93 ± 9.3 kgm} (Width across flats: 46 mm)
Ripper 2,160 ± 210 Nm {220 ± 22.0 kgm} (Width across flats: 60 mm)
10-500 10 D31/37-22
500 Work equipment
Piston valve SEN04489-00
Piston valve 1
(Angle cylinder)
Outline
q The piston valve is installed to the piston sec-
tion of the angle cylinder.
q When the piston rod is at the stroke end, the
pressurized oil from the pump is released into
the port on the opposite side to lower the pres-
sure applied to the piston.
Operation
When piston valve is "closed" When piston valve is "opened"
q The pressurized oil from the pump pushes pis- q Before piston rod (1) reaches the stroke end,
ton (2) open against the force of spring (4) and slider (6) meets cylinder bottom (b) and stops.
flows in chamber (A). q Slider (6) meets the end of piston valve (5) and
q The pressurized oil fills up chamber (A) and only piston (3) keeps moving.
presses piston valve (5) to the right to seal the q The pressurized oil in chamber (A) sealed by
tapered part of piston valve seat (a). piston valve (5) is released through piston
q Accordingly, the pressure in the cylinder valve seat (a) to the bottom side, thus the pres-
increases and piston (3) moves to the right. sure in the cylinder decreases.
D31/37-22 10-500 11
SEN04489-00
D31/37-22 Bulldozer
©2008 KOMATSU
All Rights Reserved
10-500 12
SEN04490-00
BULLDOZER
D31EX-22
D31PX-22
D37EX-22
D37PX-22
D31EX-22 60001 and up
D31PX-22 60001 and up
D37EX-22 60001 and up
D37PX-22 60001 and up

600 Cab and its attachments

ROPS cab ....................................................................................................................................................... 2
Cab mount ...................................................................................................................................................... 3
Canopy mount................................................................................................................................................. 4
Air conditioner ................................................................................................................................................. 5
D31/37-22 10-600 1
SEN04490-00 ROPS cab
ROPS cab 1
1. ROPS cab
2. Door
3. Front wiper
4. Rear wiper
5. Door wiper
10-600 2 D31/37-22
Cab mount SEN04490-00
Cab mount 1
1. Damper mount (Front)

2. Damper mount (Rear)
3. ROPS stopper (Front)
4. ROPS stopper (Rear)
Outline
q The mounts are installed at 2 places each on
the front and rear sides to fix the cab on the
floor frame.
q Oil-filled damper mounts (1) and (2) are
employed to absorb vibrations.
q ROPS stoppers (3) and (4) are installed at 2
places each on the front and rear sides to
secure the cab containing the ROPS when the
machine rolls over.
D31/37-22 10-600 3
SEN04490-00 Canopy mount
Canopy mount 1
1. Rubber mount (Front)

2. Rubber mount (Rear)
Outline
q The mounts are installed at 2 places each on
the front and rear sides to fix the canopy on the
floor frame.
q Large-sized rubber mounts (1) and (2) are
employed to absorb vibrations.
10-600 4 D31/37-22
Air conditioner SEN04490-00
Air conditioner 1
Air conditioner and floor heater
1. Air conditioner unit

2. Heater unit (Floor)
3. Condenser
4. Receiver tank
5. Water valve
6. Refrigerant piping
7. Front window defroster
8. Side window defroster
9. Rear window defroster
10. Air outlet (Face side)
11. Air outlet (Foot side)
A: Fresh air inlet (Unit bottom)

B: Recirculated air circulation port
D31/37-22 10-600 5
SEN04490-00 Air conditioner
Air conditioner piping diagram
1. Compressor
2. Refrigerant discharge piping
3. Refrigerant suction piping
4. Hot water outlet
5. Hot water return piping
10-600 6 D31/37-22
Air conditioner SEN04490-00
Circuit diagram related to air conditioner
Refrigerant circuit diagram Hot water circuit diagram
1. Compressor 1. Valve
2. Air conditioner unit 2. Bracket
3. Access valve 3. Heater assembly (Foot)
4. Indicator 4. Bracket
5. Receiver tank 5. Air conditioner unit
6. Condenser
D31/37-22 10-600 7
SEN04490-00
D31/37-22 Bulldozer
©2008 KOMATSU
All Rights Reserved
10-600 8
SEN04491-01
BULLDOZER
D31EX-22
D31PX-22
D37EX-22
D37PX-22
D31EX-22 60001 and up
D31PX-22 60001 and up
D37EX-22 60001 and up
D37PX-22 60001 and up

700 Electrical system

Monitor system................................................................................................................................................ 2
Engine control ................................................................................................................................................. 4
Engine control system..................................................................................................................................... 5
Cooling control system.................................................................................................................................... 6
HST control system......................................................................................................................................... 8
Parking brake control system........................................................................................................................ 14
KOMTRAX system........................................................................................................................................ 16
Component equipment of system ................................................................................................................. 18
PCCS lever (for steering).............................................................................................................................. 27
Sensor........................................................................................................................................................... 30
D31/37-22 10-700 1
SEN04491-01 Monitor system
Monitor system 1
1. Sensors 5. Battery a. Sensor signal

2. HST controller 6. Alarm buzzer b. CAN signal
3. Engine controller 7. Display panel A c. Power supply
4. KOMTRAX terminal 8. Display panel B d. Alarm buzzer signal
The content of panel display can be mainly

classified into the following:
1. Travel direction, gear speed, shift mode
(Display panel A)
2. Coolant temperature, hydraulic oil tempera-
ture, and fuel level (Gauge section)
3. Machine trouble alarm (Monitor section)
4. Current and voltage of each sensor and
solenoid, action code and failure code (Dis-
play panel B)
q The monitor system consists of the monitor
panel, controllers, sensors, alarm buzzer, and
power supply.
q The component parts are connected by wiring
q The monitor system notifies the operator of the harnesses and the monitor panel is powered
machine condition. It monitors the machine by the battery.
condition with the sensors installed to the q If the machine has any trouble (and a sensor
machine and processes and displays the detects it), the monitor and alarm lamp flash
obtained information on the monitor panel and the alarm buzzer sounds to protect the
immediately. machine. The alarm buzzer can be turned OFF
temporarily with the buzzer cancel switch.
10-700 2 D31/37-22
Monitor system SEN04491-01
Processing in monitor panel (Common to all specifications)

Display of monitor panel
Contents and conditions of processing Method Flow of signals
1. Display of travel direction and gear speed
• Signals (F1, R3, etc.) are displayed on the monitor panel according CAN signal
to the information of the HST controller.
2. Display of coolant temperature, hydraulic oil temperature and fuel level
by gauge
• Sensor signals are processed by the controller and the results are CAN signal
sent to the monitor panel.
3. Display of trouble Sensors/solenoids
• If there is any trouble, its failure code signal is sent to the monitor O
panel. Controller
• Information for sounding the buzzer or flashing the caution lamp is O
sent according to the contents of the trouble. Monitor panel
1) In normal state,
Action and failure codes are displayed. CAN signal
2) In failure history display mode,
Failure code (6 digits)
• Elapsed time after first occurrence (case of an electrical failure)
• Elapsed time after latest occurrence (case of an electrical failure)
• Number of occurrence,
etc.
Display of monitoring
1. Display of sensors and solenoids information and communicating state
of CAN signals, etc. CAN signal Sensors/solenoids
• Signals on the condition of each device are sent to the monitor panel. O
Controller
2. Item to be monitored are selected by using the buzzer cancel switch O
CAN signal Monitor panel
(U, t) and the information switch (>, <)
a For details of the operating method, see Testing and adjusting, Special functions of monitor panel
(EMMS).
Others
1. Operator mode
1) Operating mode
2) Action code display mode
3) Failure code display mode
4) Oil and filter maintenance mode
5) Brightness adjustment mode
2. Service mode
Sensors/solenoids
6) Electrical system failure history display mode
O
7) Mechanical system failure history display mode
CAN signal Controller
8) Real-time monitoring mode
O
9) Cylinder cut-out mode
Monitor panel
10) No injection cranking mode
11) Tuning mode
12) Maintenance interval setting mode
13) Telephone number setup mode
14) Model selection mode
15) Optional function selection mode
16) Initialize mode (Factory mode)
a For details of the operating method, see Testing and adjusting, Special functions of monitor panel
(EMMS).
D31/37-22 10-700 3
SEN04491-01 Engine control
Engine control 1
1. Battery
2. Starting switch
3. Engine
4. Starting motor
5. Monitor panel
6. HST controller
7. Neutral safety relay
8. Safety relay
9. Limit switch
11. Electric lever
12. Steering and directional and gear shift lever (PCCS lever)
Input and output signals

a. Battery power supply
b. Engine start signal
c. Starting switch "ACC" signal
d. Parking brake signal
e. Neutral signal
Function
q A limit switch is installed to the parking brake
and the HST controller controls the engine with
it so that the engine can start only when the
parking brake lever is in the LOCK position and
the PCCS lever is in the N (Neutral) position.
10-700 4 D31/37-22
Engine control system SEN04491-01
Engine control system 1
1. Battery Engine speed control system

2. Starting switch q When the engine controller receives throttle
3. Engine controller No. 1 signal (fuel dial signal) and throttle No. 2
4. HST controller signal (decelerator signal), it selects either one
5. Monitor panel of the two whichever shows lower engine
6. Fuel control dial speed as the command signal to control the
7. Decelerator pedal fuel supply pump and the injectors.
8. Engine q The engine controller information is shared by
9. Engine speed sensor and sent to other controllers on network to opti-
10. Coolant temperature sensor mi ze re lati ons b etween the en gin e an d
11. Engine oil pressure switch machine body.
12. Injector
13. Fuel supply pump valve Engine stop system
q Setting the starting switch to "OFF" cuts off
Input and output signals ACC signal from the starting switch to the
a. Throttle No. 1 signal (fuel dial signal) engine controller.
b. Throttle No. 2 signal (decelerator pedal signal) q The engine controller stops fuel supply to the
c. Throttle No. 3 signal (controller control signal) engine, and lowers the engine speed until it
d. Starting switch ACC signal stops.
e. Controller power supply
f. Engine speed signal
g. Coolant temperature signal
h. Engine oil pressure signal
j. Sensor signal
k. Monitor display signal
D31/37-22 10-700 5
SEN04491-01 Cooling control system
Cooling control system 1
1. Battery Input and output signals

2. Battery relay a. Controller power supply
3. HST controller b. Fan rotation selector signal
4. Engine controller c. Fan speed signal
5. Monitor panel d. Hydraulic oil temperature signal
6. Cooling fan motor e. Engine speed signal
7. Work equipment and fan pump f. Coolant temperature signal
8. Fan rotation selector switch g. Aftercooler temperature signal
9. Control valve h. CAN signal
10. Fan EPC valve j. Fan speed control signal
11. Fan speed sensor k. Fan reverse signal
12. Hydraulic oil temperature sensor
13. Engine
14. Engine speed sensor
15. Coolant temperature sensor
16. Aftercooler temperature sensor
10-700 6 D31/37-22
Cooling control system SEN04491-01
Outline
q Based on the monitoring results of the coolant, Fan rotation mode selection
hydraulic oil and aftercooler temperatures, the q When the starting switch is set to "ON" position
HST controller controls the fan to optimal and the engine is not running, fan rotation
speed for the temperatures monitored. mode can be selected by operating the fan
rotation selector switch.
Function Fan rotation mode consists of:
Fan speed control 1) Normal rotation mode
q Based on the monitoring results of the temper- 2) Cleaning mode
ature from the coolant, hydraulic oil and after- The HST controller selects the direction of fan
cooler temperature sensors, the HST controller by operating the cooling fan motor reverse
controls the flow rate to the cooling fan motor solenoid valve according to the mode selected.
to obtain appropriate fan speed.
q A maximum number of target fan speeds 1) Normal rotation mode
obtained from respective temperatures of the The reverse solenoid valve does not oper-
coolant, hydraulic oil and aftercooler is output ate. The fan makes normal rotation. Fan
from the HST controller to the fan EPC valve speed changes according to the signal
as the fan speed control signal. received from the temperature sensor.
q The fan EPC valve controls the flow rate of oil This mode is normally in use.
to the cooling fan motor by changing the open- 2) Cleaning mode
ing area of the fan spool in the control valve. Irrespective of the temperature sensor sig-
q Monitoring the actual fan speed with the fan nal, the fan rotates in reverse at high
speed sensor, the HST controller controls it to speed to blow away dirt deposited on the
the target fan speed. radiator fins. Extended cleaning intervals
of radiator may be expected by periodi-
cally using this mode.
In addition, to protect the radiator during
"cleaning mode", the machine would not
operate if the PCCS lever is turned to
"FORWARD" or "REVERSE" position. To
operate again, set the starting switch from
"OFF" to "ON" and select "normal rotation
mode".
Interlocking at mode selection

q Changing the direction of fan rotation while the
fan is rotating causes the fan drive circuit to be
damaged. To prevent this, operation of the fan
rotation selector switch will be ignored while
the engine is running, and the fan operation
monitor lamp on the monitor panel flashes for 3
seconds.
D31/37-22 10-700 7
SEN04491-01 HST control system
HST control system 1
1. Battery Input and output signals

2. Battery relay a. Controller power supply
3. Engine controller b. CAN signal
4. Fuse box c. Reverse travel speed setting signal
5. HST controller d. Shift mode signal
6. Decelerator pedal potentiometer e. Decelerator pedal stroke signal
7. Brake pedal potentiometer f. Brake pedal stroke signal
8. PCCS lever (for steering) g. Steering and directional and gear shift signal
9. Fuel dial potentiometer h. Fuel control dial stroke signal
10. Monitor panel j. Engine speed signal
11. Reverse travel speed setting switch k. HST circuit oil pressure signal
12. Shift mode switch m. HST motor speed signal
13. Engine speed sensor n. HST pump EPC valve drive signal
14. L.H. HST pump forward EPC valve p. HST motor EPC drive signal
15. R.H. HST pump forward EPC valve
16. L.H. HST pump reverse EPC valve
17. R.H. HST pump reverse EPC valve
18. L.H. HST circuit oil pressure sensor
19. R.H. HST circuit oil pressure sensor
20. L.H. HST motor speed sensor
21. R.H. HST motor speed sensor
22. L.H. HST motor EPC valve
23. R.H. HST motor EPC valve
a PCCS: Abbreviation for Palm Command Con-
trol System
10-700 8 D31/37-22
HST control system SEN04491-01
D31/37-22 10-700 9
Gear shift control system

Gear shifting by operator
Function
q Upon receiving the gear shift signal from the a The figure below shows the setting of 1st
shift-up or shift-down switch of the steering and (default) reverse speed (C).
directional and gear shift lever, the HST con-
troller decides the capacity of the HST pump
and HST motor and shifts the gear.
q The operator can select the quick shift mode or
the variable shift mode with the shift mode
switch.
q If the steering and directional and gear shift
lever is leaned forward (for forward travel), a
set travel speed is decided according to the
gear speed of broken line (B) in the above
graph.
q If the steering and directional and gear shift
lever is leaned backward (for reverse travel), a
set travel speed is decided according to the
gear speed of set (A) to (E) of the reverse
travel speed switch in the above graph.
q When the steering and directional and gear
shift lever is in the neutral position, the set
travel speed is 0 km/h.
10-700 10 D31/37-22
Set travel speeds corresponding to gear speeds

Number of lighting segments in gear speed gauge Set travel speed (km/h)
Gear
F-shift R-shift gauge Reverse
speed Forward
gauge A B C D E A B C D E
2 2 2 2 2 2 0.8 0.8 0.8 0.8 0.8 0.8
4 3 4 4 5 5 1.0 0.9 1.0 1.1 1.2 1.3
6 5 6 7 8 9 1.5 1.2 1.5 1.7 1.9 2.2
8 7 8 9 11 12 2.0 1.6 2.0 2.3 2.7 3.0
10 8 10 12 14 16 2.4 2.0 2.4 2.9 3.4 3.8
12 10 12 14 17 19 2.9 2.3 2.9 3.5 4.1 4.7
1 14 11 14 17 20 23 3.4 2.7 3.4 4.1 4.8 5.5
16 13 16 19 22 25 3.8 3.0 3.8 4.5 5.2 6.0
18 15 18 21 25 28 4.1 3.4 4.1 4.9 5.7 6.4
20 16 20 24 27 31 4.5 3.7 4.5 5.3 6.1 6.9
22 18 22 26 30 33 4.9 4.0 4.9 5.7 6.5 7.4
24 20 24 28 32 36 5.2 4.4 5.2 6.1 7.0 7.8
2 26 22 26 30 34 38 5.6 4.7 5.6 6.5 7.4 8.3
28 24 28 32 36 40 6.0 5.1 6.0 6.9 7.8 8.5
30 26 30 34 38 40 6.4 5.5 6.4 7.3 8.2 8.5
32 28 32 36 40 40 6.8 5.9 6.8 7.7 8.5 8.5
34 30 34 38 40 40 7.3 6.4 7.3 8.2 8.5 8.5
36 32 36 40 40 40 7.7 6.8 7.7 8.5 8.5 8.5
38 34 38 40 40 40 8.1 7.2 8.1 8.5 8.5 8.5
3 40 36 40 40 40 40 8.5 7.6 8.5 8.5 8.5 8.5
a The values of bold-face type are for the quick shift mode.
D31/37-22 10-700 11
Deceleration command map Brake command map
q If the fuel control dial or decelerator pedal is q If the brake pedal is operated, a brake com-
operated, a deceleration command is issued mand is issued according to the brake com-
according to the deceleration command map. mand map.
q The deceleration command of fuel control dial a The brake command means the ratio to the set
is higher than that of the decelerator pedal. travel speed.
Accordingly, even if the fuel control dial is
returned from the "Full" speed position, higher Example)
output is secured. q When the brake pedal is pressed halfway:
a The deceleration command means the ratio to The travel speed is limited according to the for-
the set travel speed. mula of Command travel speed = Brake com-
mand x Set travel speed/100.
Example)
q When the fuel control dial is at the "Full" speed
position and the decelerator pedal is not
pressed:
The deceleration command is 100%, and the
command travel speed is equal to the set
travel speed.
q When the fuel control dial or the decelerator

pedal is set in the Medium speed position:
The travel speed is limited according to the for-
mula of Command travel speed = Deceleration
command x Set travel speed/100.
10-700 12 D31/37-22
Changing travel speed according to

change of engine speed
When external load increases and engine speed HST motor capacity command map
lowers
q The HST controller reduces the command
travel speed according to command travel
speed map (A).
In addition, the HST controller decides the
EPC valve control signal of HST pump and
HST motor to lower the travel speed according
to the HST pump capacity command map and
the HST motor capacity command map.
When external load decreases and engine

speed rises
q The HST controller raises the command travel
speed according to the command travel speed
map (A). 2. HST motor capacity
In addition, the HST controller decides the
EPC valve control signal of HST pump and
HST motor to increase the travel speed
Straight-travel correction control system
according to the HST pump capacity command
Function
map and the HST motor capacity command
q The HST controller monitors the operating con-
map.
ditions of each lever and each pedal and con-
stantly controls the swash plate angle of the
Command travel speed map
HST pump, or the delivery of the HST pump,
so that the output speed of the right and left
HST motors will be the same.
q While the machine is traveling straight forward,
if the right HST motor speed is higher than the
left HST motor speed, the HST controller low-
ers the control signal of the right forward HST
pump EPC valve so that the machine will
always travel straight.
q Conditions for resetting straight travel correc-
tion control system
1. When the steering and directional and
gear shift lever is set to the Right or Left
turn position.
HST pump capacity command map 2. When the steering and directional and
gear shift lever is set to the Neutral posi-
tion.
3. When a pedal or the fuel control dial is
operated and the travel speed sensed by
the HST motor speed sensor is 0.15 km/h
or lower.
4. When the HST motor speed sensor is
judged faulty because of disconnection,
etc.
Straight travel is secured when none of the
above condition applies.
1. HST pump capacity
D31/37-22 10-700 13
SEN04491-01 Parking brake control system
Parking brake control system 1
1. Battery
2. Battery relay
3. Fuse box
4. HST controller
5. Engine
6. HST pump
7. Charge pump
8. Brake pedal
9. Brake pedal potentiometer
10. Center brake proximity switch
14. Center brake relay
15. Slow brake solenoid valve
16. Parking brake solenoid valve
17. Towing valve
18. Brake oil pressure sensor
19. HST motor
19a. Parking brake

a. Controller power supply
b. Parking brake lever LOCK signal
c. Brake pedal stroke signal
d. Solenoid valve drive signal
e. Brake oil pressure signal
10-700 14 D31/37-22
Parking brake control system SEN04491-01
Function
q Parking brake limit switches 1 (12) and 2 (13)
are installed interlocked with parking brake
lever (11) so that parking brake (19a) will be
released only when parking brake lever (11) is
in the FREE position.
q Center brake proximity switch (10) is installed,
which is interlocked with brake pedal (8) so
that when brake pedal (8) is pressed fully, cen-
ter brake relay (14) will be turned OFF and
slow brake solenoid valve (15) will be de-ener-
gized and parking brake (19a) will be applied.
Conditions (controlled by the controller) for the parking brake solenoid valve to be turned "OFF".
Operating state Operation
1. When either condition (a) or (b) shown below is satisfied and travel
speed is 0.6 km/h or lower.
2. When either condition (a) or (b) shown below is satisfied continuously
for one (1) second or longer.
o Parking brake operates.
(a) Parking brake lever is set to "Lock" position.
(Parking brake limit switch 1 is turned "ON".)
(b) Brake pedal is fully depressed.
(Pedal stroke is 90% or higher)
Condition for the slow brake solenoid valve to be turned "OFF" (without the controller)
Operating state Operation
1. When either condition (a) or (b) shown below is satisfied
(a) Parking brake lever is set to "Lock" position. Parking brake operates
o
(Parking brake limit switch 2 is turned "ON") approximately 1 second later.
(b) Brake pedal is fully depressed.
(Center brake proximity switch is turned "ON")
D31/37-22 10-700 15
SEN04491-01 KOMTRAX system
KOMTRAX system 1
KOMTRAX terminal system
q KOMTRAX terminal transmits various machine

information by use of the radio communication.
The KOMTRAX operator is allowed to refer-
ence these information in the office and offer
them to the customer through various services.
a When offering the information to the cus-

tomer, it is required to separately imple-
ment the KO MT RA X s ys tem s ta ti on
opening procedure.
The information transmitted from the

KOMTRAX terminal includes the following.
1. Traveling map
2. Service meter
3. Position information
4. Error history
10-700 16 D31/37-22
KOMTRAX system SEN04491-01
D31/37-22 10-700 17
SEN04491-01 Component equipment of system
Component equipment of system 1
Monitor panel
Outline Caution items

q The monitor panel consists of the monitor sec- q The caution items are checked constantly
tion which outputs an alarm when the machine while the engine is running.
has any trouble and the gauge section and dis- If any item is abnormal, it and alarm lamp flash
play panel which display the machine condition synchronously. The alarm buzzer may sound
constantly. simultaneously depending on the state of
The monitor panel has a microcomputer, which abnormality.
processes and displays the signals from the
sensors, solenoids, and controllers. Buzzer cancel switch
The items displayed on the monitor section q If this switch is operated while the alarm
and gauge section are shown in "Monitor panel buzzer is sounding, the buzzer is turned OFF
display". temporarily.
While the buzzer is turned OFF, if a new trou-
Operation ble which turns on the buzzer is detected, the
When power is turned ON (When starting switch buzzer sounds again.
is turned to ON position) q The lamp lights up and goes off at the intervals
q All the LCD segments and lamps of the moni- of about 0.8 seconds.
tor panel light up for 2 seconds and the alarm q The flashing intervals of the lamp may change
buzzer sounds for 2 seconds. a little when the temperature is low (below
about –10°C). This does not indicate a trouble.
Check before starting
q After the operation performed when the power
is turned ON, if there is any abnormal one in
the check-before-starting items, the lamp of
that item flashes or the contents of the abnor-
mality are displayed on display panel B.
10-700 18 D31/37-22
Component equipment of system SEN04491-01

AMP070-20P [CN-1] AMP070-12P [CN-2]
Pin Input/output Pin Input/output
Signal name Signal name
No. signal No. signal
1 Starting switch (ACC) Input 1 CAN(0)H Input/Output
2 Starting switch (ACC) Input 2 NC (*) —
3 GND Input 3 CAN(0)L Input/Output
4 GND Input 4 NC (*) —
5 Constant power supply (24 V) Input 5 NC (*) —
6 Constant power supply (24 V) Input 6 CAN (0) (with the terminal resistor) Input
7 Starting switch (C) Input 7 NC (*) —
8 Lighting signal Input 8 NC (*) —
9 Preheating signal Input 9 Alternator (R) Input
10 NC (*) — 10 Fuel level Input
11 NC (*) — 11 NC (*) —
12 NC (*) — 12 NC (*) —
13 Air cleaner clogging sensor Input *: Positively do not connect to NC to prevent malfunction and
14 Information switch (<) Input failure.
15 Information switch (>) Input
16 Buzzer cancel switch (U) Input
17 Buzzer cancel switch (t) Input
18 Alarm buzzer Output
19 NC (*) —
20 WAKE UP signal Input/Output
*: Positively do not connect to NC to prevent malfunction and
failure.
D31/37-22 10-700 19
Monitor panel display

a The figure below shows an example of display in the quick shift mode.
a The figure below shows an example of display A in the variable shift mode.
10-700 20 D31/37-22
Display Alarm Alarm Display

No. Display items Display range Display method lamp buzzer Remarks
category color
output output
Corresponding segment and
1a Gauge See figure at left — — Black LCD
segments below it light up
Coolant temperature Max. 102°C OFF OFF OFF
1b Caution 102°C – 105°C Flashing Flashing OFF Red LED
Min. 105°C Flashing Flashing ON
2a Gauge See figures at left — — Black LCD
Hydraulic oil Max. 100°C OFF OFF OFF
temperature
2b Caution 100°C – 110°C Flashing Flashing OFF Red LED
Min. 110°C Flashing Flashing ON
3 Gauge Fuel level See figures at left — —
P: Parking lever "Lock"
Travel direction N: PCCS lever "Neutral"
4a (P, N, F and R) F: PCCS lever "Forward"
R: PCCS lever "Reverse"
Indicator 1: PCCS lever OFF OFF
Shift switch "1st"
[*3] 2: PCCS lever
4b
Gear speed (1, 2, and 3) Shift switch "2nd"
Display panel A 3: PCCS lever
(Travel direction, Shift switch "3rd"
gear speed, shift Black LCD
mode) [*1]
4c Forward gear shift
(See figures at left) Corresponding segment and
Gauge segments below it light up — —
[*1]
4d Reverse gear shift
(See figures at left)
4e Variable shift mode ON — —
Pilot
4f Quick shift mode ON — —
Character [*2] Display panel B 0 – 99999.9 h/ Time is counted while engine is

5 (Service meter/ — —
display engine speed) 0 – 9999 rpm running (alternator is generating)
When charge is faulty OFF (While engine is stopped) OFF OFF

6 Charge level
(Max. 12 V) Flashing (While engine is running) Flashing OFF
Below set pressure OFF (While engine is stopped) OFF OFF
7 Engine oil pressure
(49 kPa {0.5 kg/cm2}) Flashing (While engine is running) Flashing ON
Caution Red
OFF (While engine is stopped) OFF OFF
8 Charge filter clogging Above set value
(200 kPa {2.0 kg/cm2}) Flashing (While engine is running) Flashing ON
HST charge oil Below set pressure OFF (While engine is stopped) OFF OFF
9
pressure (785 kPa {8.0 kg/cm2}) Flashing (While engine is running) Flashing ON
When preheater is
10 Pilot Preheater turned ON ON OFF OFF Green
Before 30 h or more OFF

Before 30 h – Flashes for 30 seconds after
11 Maintenance Replacement time starting switch is turned "ON" OFF OFF Red
LED
Lights for 30 seconds after
After replacement time
starting switch is turned "ON"
12 Warning lamp See the "Aram lamp output" column of this table — — Red
Clogging of air Below specified value

13 Flashing OFF OFF Red
cleaner (–7.47 kPa)
Caution
• Operate fan selector
switch while the Flashing (several times)
engine is running.
14 Check fan operation • Fan in cleaning mode ON OFF OFF Orange
(reverse)
• Fan in normal rotation OFF
mode
Water separator • When water level
15 (Not used) rising Flashing OFF OFF Red
*1: For details, see HST control system.

*2: For details on the service mode, see Testing and adjusting, Special functions of monitor panel (EMMS).
*3: Displays only in the quick shift mode.
D31/37-22 10-700 21
Engine controller

q The following is the list of the symbols used for signal classification in the input/output signal chart.
A: Power supply
B: Input
C: Ground/shield/return
D: Output
E: Communication
DTP-4P [CN-CE03]
Signal
Pin No. Signal name
classification
1 GND C
2 NC —
3 Constant power supply (24 V) A
4 NC —
10-700 22 D31/37-22
DRC-60P(1) [CN-CE01]
Pin Signal name Signal Pin Signal name Signal
No. classification No. classification
1 NC (*) — 31 NC (*) —
2 NC (*) — 32 Engine oil pressure switch B
3 NC (*) — 33 NC (*) —
4 NC (*) — 34 NC (*) —
5 NC (*) — 35 NC (*) —
6 NC (*) — 36 Sensor power supply (5 V) A
7 NC (*) — 37 Camshaft speed sensor B
8 NC (*) — 38 NC (*) —
9 NC (*) — 39 NC (*) —
10 Fuel supply pump regulator (+) B 40 NC (*) —
11 Boost temperature sensor B 41 NC (*) —
12 NC (*) — 42 Crankshaft speed sensor B
13 NC (*) — 43 NC (*) —
14 Fuel supply pump regulator (–) C 44 Crankshaft speed sensor GND C
15 NC (*) — 45 Injector #2 (+) D
16 NC (*) — 46 NC (*) —
17 NC (*) — 47 Coolant temperature sensor GND C
18 NC (*) — 48 Sensor GND C
19 Boost pressure sensor B 49 Coolant temperature sensor D
20 Ambient pressure sensor B 50 NC (*) —
21 NC (*) — 51 Injector #4 (–) C
22 NC (*) — 52 NC (*) —
23 NC (*) — 53 Injector #1 (–) C
24 NC (*) — 54 NC (*) —
25 NC (*) — 55 Injector #3 (+) D
26 Crankshaft speed sensor (5 V) A 56 Injector #4 (+) D
27 NC (*) — 57 Injector #1 (+) D
28 NC (*) — 58 Injector #2 (–) C
29 Common rail pressure sensor B 59 Injector #3 (–) C
30 NC (*) — 60 NC (*) —
*: Positively do not connect to NC to prevent malfunction and *: Positively do not connect to NC to prevent malfunction and
failure. failure.
DRC-60P(2) [CN-CE02]
Pin Signal name Signal Pin Signal name Signal
No. classification No. classification
1 CAN (+) E 31 NC (*) —
2 NC (*) — 32 Engine controller power cut-off relay GND C
3 NC (*) — 33 NC (*) —
4 NC (*) — 34 NC (*) —
5 NC (*) — 35 Fuel control dial (+) B
6 NC (*) — 36 NC (*) —
7 NC (*) — 37 NC (*) —
8 NC (*) — 38 NC (*) —
9 NC (*) — 39 NC (*) —
10 NC (*) — 40 NC (*) —
11 NC (*) — 41 NC (*) —
12 NC (*) — 42 NC (*) —
13 NC (*) — 43 NC (*) —
14 NC (*) — 44 Electrical intake air heater relay (return) C
15 NC (*) — 45 Starting switch ACC signal B
16 NC (*) — 46 NC (*) —
17 NC (*) — 47 NC (*) —
18 NC (*) — 48 NC (*) —
19 NC (*) — 49 NC (*) —
20 NC (*) — 50 NC (*) —
21 CAN (–) E 51 NC (*) —
22 NC (*) — 52 NC (*) —
23 NC (*) — 53 NC (*) —
24 NC (*) — 54 Electrical intake air heater relay (output) D
25 NC (*) — 55 Engine controller power cut-off relay D
26 NC (*) — 56 NC (*) —
27 Fuel control dial (5 V) A 57 NC (*) —
28 Fuel control dial (–) C 58 NC (*) —
29 NC (*) — 59 NC (*) —
30 NC (*) — 60 NC (*) —
failure. failure.
D31/37-22 10-700 23
HST controller
10-700 24 D31/37-22

DEUTSCH-24P [CN-ST1] DEUTSCH-40P (1) [CN-ST2] DEUTSCH-40P (2) [CN-ST3]
Input/ Input/ Input/
Pin Pin Pin
Signal name output Signal name output Signal name output
No. No. No.
signal signal signal
1 PCCS lever position FR4 Input 1 NC (*) — 1 Power supply (Controller) Input
Fuel control dial 2 NC (*) — 2 Power supply (Solenoid) Input
2 Input
potentiometer 3 NC (*) — 3 Ground (Solenoid) —
3 Brake pedal potentiometer Input 4 NC (*) — 4 Battery relay drive Output
4 GND (Signal) — Parking brake limit switch 1 Left forward HST pump EPC
5 Input 5 Output
5 Charge filter clogging sensor Input (NC) valve
6 NC (*) — 6 NC (*) — Left reverse HST pump EPC
6 Output
7 PCCS lever position ST2 Input Fan rotation selector switch valve
7 Input
8 Brake oil pressure sensor Input (Forward) 7 Fan reverse solenoid Output
Hydraulic oil temperature 8 NC (*) —
9 Input 8 Neutral safety relay Output
sensor Parking brake limit switch 2
9 Input
10 GND (Signal) — 9 NC (*) — (NO)
11 NC (*) — 10 Fan speed sensor Input 10 Starting switch (C) Input
12 Shift-up switch (NC) Input 11 NC (*) — 11 Power supply (Controller) Input
13 PCCS lever position FR3 Input 12 NC (*) — 12 Power supply (Solenoid) Input
L.H. HST circuit oil pressure 13 Immobilize signal Input 13 Ground (Solenoid) —
14 Input
sensor 14 NC (*) — 14 Starting switch (ACC) Input
15 Alternator (R) Input Parking brake limit switch 1 Right forward HST motor
15 Input 15 Output
16 NC (*) — (NO) EPC valve
17 NC (*) — 16 NC (*) — Right reverse HST motor
16 Output
18 Shift-down switch (NO) Input Fan rotation selector switch EPC valve
17 Input
19 PCCS lever position ST1 Input (Reverse) 17 NC (*) —
R.H. HST circuit oil pressure 18 NC (*) — 18 Back-up alarm Output
20 Input
sensor 19 NC (*) — 19 NC (*) —
21 GND (Analog) — L.H. HST motor speed 20 NC (*) —
20 Input
22 Sensor power supply (+5 V) Output sensor 21 GND (Power supply) —
23 Shift-up switch (NO) Input 21 NC (*) — 22 Power supply (Solenoid) Input
24 Shift-down switch (NC) Input Input/ 23 Ground (Solenoid) —
22 CAN0 (L)
*: Positively do not connect to NC to prevent Output 24 Starting switch (ACC) Input
malfunction and failure. 23 NC (*) — 25 Fan control EPC Output
Flash ROM write enable 26 L.H. HST motor EPC valve Output
24 Input
signal 27 Parking brake solenoid valve Output
Reverse travel speed setting 28 NC (*) —
25 Input
switch (Up) 29 NC (*) —
26 NC (*) — 30 NC (*) —
27 Shift mode switch (Variable) Input 31 GND (Power supply) —
28 NC (*) — 32 GND (Power supply) —
29 GND (Pulse) — 33 GND (Power supply) —
R.H. HST motor speed 34 Sensor power supply (+5 V) Output
30 Input
sensor 35 NC (*) —
31 GND (Communication) — 36 R.H. HST motor EPC valve Output
Input/ 37 Slow brake solenoid valve Output
32 CAN0 (H)
Output 38 NC (*) —
33 NC (*) — 39 NC (*) —
34 GND (Communication) — 40 NC (*) —
Reverse travel speed setting *: Positively do not connect to NC to prevent
35 Input
switch (Down) malfunction and failure.
36 NC (*) —
37 Shift mode switch (Quick) Input
38 NC (*) —
39 GND (Pulse) —
40 NC (*) —
*: Positively do not connect to NC to prevent
malfunction and failure.
D31/37-22 10-700 25
KOMTRAX terminal
Type: TC301
• The KOMTRAX system uses satellite waves.
1. Communication antenna connector

2. GPS antenna connector
3. Machine harness connector (DEUTSCH-40P)

DEUTSCH-40P [CN-G01]
Pin Signal name Input/output Pin Signal name Input/output
No. signal No. signal
1 NC (*) — 21 Operation mode selection 1 Input
2 NC (*) — 22 Operation mode selection 2 Input
3 NC (*) — 23 NC (*) —
4 NC (*) — 24 NC (*) —
5 NC (*) — 25 NC (*) —
6 NC (*) — 26 Power-saving mode input Input
7 CAN signal (L) Input/Output 27 Starting switch (C) Input
8 CAN signal (H) Input/Output 28 Alternator (R) Input
9 NC (*) — 29 NC (*) —
10 NC (*) — 30 NC (*) —
11 NC (*) — 31 NC (*) —
12 NC (*) — 32 NC (*) —
13 NC (*) — 33 NC (*) —
14 NC (*) — 34 NC (*) —
15 NC (*) — 35 NC (*) —
16 NC (*) — 36 Starting switch (ACC) Input
19 NC (*) — 39 Constant power supply (24 V) Input
20 Immobilize signal Output 40 Constant power supply (24 V) Input
failure. failure.
Outline
q The KOMTRAX controller can send informa- q Use of KOMTRAX terminal must be limited for
tion via wireless communication antenna, the countries in which such communication is
acquiring various information of the machine allowed.
from the network signal in the machine and the q There are the LED lamp and the 7-segment
input signal. Also, the controller incorporates indicator lamp in the display area, and these
CPU (Central Processing Unit) and provides lamps are used for the testing and the trouble-
the wireless communication function and the shooting.
GPS (Global Positioning System) function. q Information of, the LED lamp and the 7-seg-
ment indicator lamp can be displayed for
checking on the monitor panel by EMMS.
10-700 26 D31/37-22
PCCS lever (for steering) SEN04491-01
PCCS lever (for steering) 1

a Do not disassemble the electric lever.
If it is disassembled, the output voltage characteristics and operating effort characteristics will need to
be adjusted.
1. Boot 4. Bolt
2. Bracket 5. Lever
3. Plate 6. Connector
D31/37-22 10-700 27
SEN04491-01 PCCS lever (for steering)
Function
1. Operating effort characteristics

(1) Operation for forward and reverse travel (2) Operation for steering
q The lever is held at the 3 positions of "For- q Free return
ward", "Neutral", and "Reverse". q The operating effort rises and falls when enter-
ing and returning from the counter-rotation
range respectively.
10-700 28 D31/37-22
PCCS lever (for steering) SEN04491-01
2. Output voltage characteristics

q The control unit is installed to the left control
stand and the control lever is installed directly
onto it.
q The operating angle (stroke) of the control
lever is detected with potentiometers and sig-
nal voltages are output to the HST controller.
q A potentiometer is installed for both the for-
ward-reverse direction and the left-right direc-
tion. Each potentiometer outputs 2 opposing
signal voltages as shown in the figure to the
right.
D31/37-22 10-700 29
SEN04491-01 Sensor
Sensor 1
q Signal from sensors is input to the monitor panel via controller.

Display category Sensor system When normal When abnormal
Caution Brake oil pressure sensor Semiconductor — —
Gauge Hydraulic oil temperature sensor Resistance — —
— HST circuit oil pressure sensor Semiconductor — —
Caution Air cleaner clogging sensor Contact (N.C.) Closed Open
— Decelerator and brake pedal potentiometer Resistance — —
— Fuel control dial Resistance — —
Gauge Fuel level sensor Resistance — —
Caution Charge filter clogging sensor Contact (N.O.) Open Closed
Gauge Coolant temperature sensor Resistance — —
Caution Engine oil pressure switch Contact (N.C.) Open Closed
Electromagnetic
— Engine speed sensor — —
type
— Intake air pressure and temperature sensors Resistance — —
— HST motor speed sensor Hall IC — —
10-700 30 D31/37-22
Sensor SEN04491-01
Brake oil pressure sensor

(HST charge oil pressure sensor)
1. Sensor
2. Connector
Function
q Installed to the parking brake solenoid valve
piping, this sensor detects the brake circuit
pressure with a built-in semiconductor as volt-
age variation. A signal is generated according
to the measured pressure.
Operation
q Oil pressure from the hydraulic oil intake port is
applied to the diaphragm of oil pressure sensor
to deform it.
q Deformed diaphragm causes the gauge resis-
tance to change. Output voltage changes
accordingly and the voltage is transmitted to
the amplifier (of the voltage).
q Relation between pressure (P) applied to the
sensor and output voltage (E) is shown to the
right.
D31/37-22 10-700 31
SEN04491-01 Sensor
Hydraulic oil temperature sensor
1. Thermistor
2. Plug
3. Connector
Function
q Installed to the suction piping of the pump, this
sensor detects the change in the temperature
as a resistance change of the built-in ther-
mistor, and sends signal according to the mea-
sured temperature.
10-700 32 D31/37-22
Sensor SEN04491-01
HST circuit oil pressure sensor
1. Sensor
2. Connector
Function
q Installed to the HST pump, this sensor detects
the R.H. and L.H. HST circuit pressure with a
built-in semiconductor as voltage variation. A
signal is generated according to the measured
pressure.
Operation
q Relation between pressure (P) applied to the
sensor and output voltage (E) is shown to the
right.
D31/37-22 10-700 33
SEN04491-01 Sensor
Air cleaner clogging sensor
1. Boss
2. Switch
3. Conduit
4. Wire
5. Connector
10-700 34 D31/37-22
Sensor SEN04491-01
Decelerator pedal potentiometer

Brake pedal potentiometer
1. Potentiometer
2. Connector
Function
q The potentiometer is connected to the deceler-
ator pedal and brake pedal. Its shaft rotates
according to the working angle of the pedals.
q Shaft movements cause the internal variable
resistor to function, which changes the 5 V
supply voltage according to the working angle
to generate the signal voltage.
D31/37-22 10-700 35
SEN04491-01 Sensor
Fuel control dial
1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector
Function
q Fuel control dial is installed to the left side of
operator seat.
q Turning knob (1) rotates the shat of potentiom-
eter (5). This changes resistance of the vari-
able resistor, and the throttle signal is sent
accordingly to the engine controller via HST
controller.
q The shaded portions in the graph below indi-
cate the abnormality detection range. Within
these ranges, the engine speed drops to one-
half.
10-700 36 D31/37-22
Sensor SEN04491-01
Fuel level sensor
1. Connector
2. Float
3. Arm
4. Body
5. Spring
6. Contact
7. Spacer
Function
q The fuel level sensor is installed to the side of
the fuel tank. The float moves up and down
according to the fuel level. The float movement
actuates the variable resistor through the arm.
As the result, a signal is generated by the
resistor as the change in resistance.
D31/37-22 10-700 37
SEN04491-01 Sensor
Charge filter clogging sensor
Function
q Installed to the charge filter, the contact of
charge filter clogging sensor detects the pres-
sure before and after the filter. When the differ-
ence in the pressure before and after the filter
exceeds the set level, the switch is turned ON.
Coolant temperature sensor
1. Sensor
2. O-ring
3. Connector
10-700 38 D31/37-22
Sensor SEN04491-01
Engine oil pressure switch
1. Connector
2. Sensor
3. O-ring
Engine speed sensor
1. Connector
2. Sensor
3. O-ring
D31/37-22 10-700 39
SEN04491-01 Sensor
Boost pressure and temperature sensor
1. Connector
2. Sensor
3. O-ring
Water-in-fuel sensor (machine with the large capacity fuel prefilter)
1. Connector
2. Tube
3. Sensor
4. O-ring
10-700 40 D31/37-22
Sensor SEN04491-01
HST motor speed sensor
a See Power train, "HST motor".
D31/37-22 10-700 41
SEN04491-01
D31/37-22 Bulldozer
©2014 KOMATSU
All Rights Reserved
10-700 42
SEN04501-02
BULLDOZER
D31EX-22
D31PX-22
D37EX-22
D37PX-22
D31EX-22 60001 and up
D31PX-22 60001 and up
D37EX-22 60001 and up
D37PX-22 60001 and up
20 Standard value table 20
100 Standard service value table

Standard service value table for engine .......................................................................................................... 2
Standard service value table for chassis......................................................................................................... 4
D31/37-22 20-100 1
SEN04501-02 Standard service value table for engine
Standard service value table for engine 1
D31EX-22, D31PX-22
Machine model D31EX-22, D31PX-22

Serial No. 60001 and up
Engine SAA4D95LE-5
Cate- Standard value for
Item Measurement conditions Unit Service limit value
gory new machine
• Engine coolant tempera- High idle 2400 ± 50 2400 ± 50

ture: Within operating
range
Engine speed • HST oil temperature Low idle rpm 975 ± 25 975 ± 25
(hydraulic oil tempera-
ture): Within operating
range (40 – 60°C) Rated speed 2200 2200
• Engine coolant temperature: Within operating

range
Intake air pressure kPa Min. 107
• HST oil temperature (hydraulic oil temperature): —
(Boost pressure) Within operating range (40 – 60°C)
{mmHg} {Min. 800}
• High idle + HST stall (*1)
range
Exhaust temperature • HST oil temperature (hydraulic oil temperature): °C Max. 500 Max. 700
Within operating range (40 – 60°C)
• Engine coolant tempera- At sharp acceleration Max. 30 Max. 30
Exhaust gas color ture: Within operating %
range At high idle Max. 10 Max. 20
Intake valve 0.35 —
Valve clearance • Normal temperature mm
Exhaust valve 0.50 —
Engine
• SAE30 or SAE15W-40 Compression MPa Min. 2.9 Min. 2.0

oil pressure {kg/cm2} {Min. 30} {Min. 20}
Compression pressure
• Engine oil temperature:
40 – 60°C Engine speed rpm 320 – 360 —
range
• HST oil temperature (hydraulic oil temperature): MPa Max. 0.98 1.47
Blow-by pressure
Within operating range (40 – 60°C) {mmH2O} {Max. 100} {150}
• Stall pressure test mode + Work equipment
relief
0.34 – 0.59 Min. 0.25
SAE30 oil
{3.5 – 6.0} {Min. 2.5}
• At rated speed
0.29 – 0.49 Min. 0.21
SAE10W oil
Engine oil pressure MPa {3.0 – 5.0} {Min. 2.1}
(Oil temperature:
Min. 80°C) {kg/cm2} Min. 0.18 Min. 0.15
SAE30 oil
{Min. 1.8} {Min. 1.5}
• At low idle
Min. 0.15 Min. 0.13
SAE10W oil
{Min. 1.5} {Min. 1.3}
Oil temperature • All speed range (In oil pan) °C 80 – 115 Max. 120
• Between fan pulley – alternator pulley
Fan belt tension mm 6 – 10 6 – 10
• Pressing force: Approx. 58.8 N {6 kg}
*1: Aim of engine speed: 2,130 rpm
20-100 2 D31/37-22
Standard service value table for engine SEN04501-02
D37EX-22, D37PX-22

Engine SAA4D95LE-5
Cate- Standard value for
Item Measurement conditions Unit Service limit value
gory new machine
• Engine coolant tempera- High idle 2400 ± 50 2400 ± 50

ture: Within operating
range
Engine speed • HST oil temperature Low idle rpm 975 ± 25 975 ± 25
range (40 – 60°C) Rated speed 2200 2200

range
Intake air pressure kPa Min. 120
• HST oil temperature (hydraulic oil temperature): —
(Boost pressure) Within operating range (40 – 60°C) {mmHg} {Min. 900}
range
Exhaust temperature • HST oil temperature (hydraulic oil temperature): °C Max. 550 Max. 700
• Engine coolant tempera- At sharp acceleration Max. 30 Max. 30
Exhaust gas color ture: Within operating %
range At high idle Max. 10 Max. 20
Intake valve 0.35 —
Valve clearance • Normal temperature mm
Exhaust valve 0.50 —
Engine
• SAE30 or SAE15W-40 Compression MPa Min. 2.9 Min. 2.0

oil pressure {kg/cm2} {Min. 30} {Min. 20}
Compression pressure
• Engine oil temperature:
40 – 60°C Engine speed rpm 320 – 360 —
range
• HST oil temperature (hydraulic oil temperature): MPa Max. 0.98 1.47
Blow-by pressure
Within operating range (40 – 60°C) {mmH2O} {Max. 100} {150}
• Stall pressure test mode + Work equipment
relief
0.34 – 0.59 Min. 0.25
SAE30 oil
{3.5 – 6.0} {Min. 2.5}
• At rated speed
0.29 – 0.49 Min. 0.21
SAE10W oil
Engine oil pressure {3.0 – 5.0} {Min. 2.1}
MPa
(Oil temperature:
{kg/cm2} Min. 0.18 Min. 0.15
Min. 80°C) SAE30 oil
{Min. 1.8} {Min. 1.5}
• At low idle
Min. 0.15 Min. 0.13
SAE10W oil
{Min. 1.5} {Min. 1.3}
Oil temperature • All speed range (In oil pan) °C 80 – 115 Max. 120
• Between fan pulley – alternator pulley
Fan belt tension mm 6 – 10 6 – 10
• Pressing force: Approx. 58.8 N {6 kg}
D31/37-22 20-100 3
SEN04501-02 Standard service value table for chassis
Standard service value table for chassis 1
D31EX-22, D31PX-22

Category
Standard value Service limit

Item Measurement conditions Unit
for new machine value
Forward and • Engine: Stopped N – Forward /

29 ± 6 29 ± 6
reverse • Center of lever grip Reverse
PCCS lever
• Engine: Stopped N – Sharp turn to
Steering 50 ± 10 50 ± 10
• Center of lever knob right/left
• Engine: Stopped 1st stage 52 ± 10 52 ± 10

Brake pedal
• Center of pedal 2nd stage 75 ± 10 75 ± 10
• Engine: Stopped mm
Stroke
Decelerator pedal 50 ± 10 50 ± 10
• Center of pedal
Neutral – Raise 47 ± 10 47 ± 20
Neutral – Lower 46 ± 10 46 ± 20
• Engine: Stopped
Neutral – Float 71 ± 10 71 ± 20
• Center of lever knob
Blade control lever
• Angle: Twisting angle of Neutral – Left/Right
lever 52 ± 10 52 ± 20
tilt
Neutral – Left/Right °
15 ± 3 15 ± 6
angle (Degree)
Forward and N – Forward / 37.3 – 65.7 35.3 – 67.7
reverse Reverse {3.8 – 6.7} {3.6 – 6.9}
N – Sharp turn to 44.1 ± 7.8 44.1 ± 9.8
Steering • Engine: Stopped right/left {4.5 ± 0.8} {4.5 ± 1.0}
PCCS lever • Center of lever knob
• Button switch 6.9 – 12.7 Max. 14.8
Shift-up
Shift-up/down {0.7 – 1.3} {Max. 1.5}
switch 6.9 – 12.7 Max. 14.8
Shift-down
{0.7 – 1.3} {Max. 1.5}
142 ± 28 Max. 199
1st stage
• Engine: Stopped {14.5 ± 2.9} {Max. 20}
Operating effort
Brake pedal
• Center of pedal N 230 ± 46 Max. 322
2nd stage
{kg} {23.5 ± 4.7} {Max. 33}
• Engine: Stopped 70 ± 14.0 Max. 98
Decelerator pedal
• Center of pedal {7.1 ± 1.4} {Max. 10}
22.5 ± 10 Max. 39.2
Neutral – Raise
{2.3 ± 1.0} {Max. 4.0}
25.5 ± 10 Max. 39.2
Neutral – Lower
{2.6 ± 1.0} {Max. 4.0}
• Engine: Low idle 70 ± 22 Max. 118
Blade control lever Neutral – Float
• Center of lever knob {7.1 ± 2.2} {Max. 12.0}
Neutral – Left/Right 22.5 ± 10 Max. 39.2
tilt {2.6 ± 1.0} {Max. 4.0}
Neutral – Left/Right Nm 2.9 – 5.4 Max. 8.3
angle {kgm} {0.3 – 0.55} {Max. 0.9}
20-100 4 D31/37-22
Standard service value table for chassis SEN04501-02

Category

40.2 – 44.1 39.2 – 45.1

Left
{410 – 450} {400 – 460}
• Engine: High idle Forward
• HST oil temperature 40.2 – 44.1 39.2 – 45.1
Right
(hydraulic oil tempera- {410 – 450} {400 – 460}
HST oil pressure
Main circuit pressure

ture): Within operating 40.2 – 44.1 39.2 – 45.1
range (40 – 60°C) Left
{410 – 450} {400 – 460}
• Stall pressure test mode Reverse MPa
{kg/cm2} 40.2 – 44.1 39.2 – 45.1
Right
{410 – 450} {400 – 460}
• Engine: High idle PCCS lever: 3.23 ± 0.29 3.23 ± 0.29
• HST oil temperature Neutral {33 ± 3.0} {33 ± 3.0}
Charge circuit pressure (hydraulic oil tempera-
ture): Within operating PCCS lever: 3.04 ± 0.29 3.04 ± 0.49
range (40 – 60°C) Forward or reverse {31 ± 3.0} {31 ± 5.0}
1st 3.4 ± 0.2 3.4 ± 0.4
• Engine: High idle Forward 2nd 5.6 ± 0.3 5.6 ± 0.6

• Quick shift mode
• Reverse travel speed: Set
to default 3rd 8.5 ± 0.5 8.5 ± 0.8
• HST oil temperature
(hydraulic oil tempera- 1st 4.1 ± 0.2 4.1 ± 0.4
range (40 – 60°C)
• Measure on flat place. Reverse 2nd 6.5 ± 0.3 6.5 ± 0.6
Travel speed km/h
3rd 8.5 ± 0.5 8.5 ± 0.8
HST
• Engine: High idle MIN 0.8 ± 0.2 0.8 ± 0.3

• Variable shift mode Forward
to default MAX 8.5 ± 0.5 8.5± 0.8
(hydraulic oil tempera- MIN 0.8 ± 0.2 0.8 ± 0.3
range (40 – 60°C) Reverse
• Measure on flat place. MAX 8.5 ± 0.5 8.5 ± 0.8
• Engine: High idle

• HST oil temperature (hydraulic oil tempera-
ture): Within operating range (40 – 60°C)
• Flat place (Hard and level place such as con-
Travel deviation crete floor) mm Max. 120 Max. 150
• After approach run of at least 10 m, measure
deviation in travel of 20 m.
• Measure deviation (x).
• For measuring posture, see “Travel 1”.
• Travel lever: N (Neutral)
• Travel lock lever: Free
Hydraulic drift of travel • Stop machine on slope of 20°. m Max. 3.6 Max. 4.0
• Posture of machine: With front side up and
down
• Hydraulic drift (Hydraulic travel distance) in 1
minute
D31/37-22 20-100 5

Category


Work equipment relief pres- 27.44 ± 0.98 Min. 24.5
sure {280 ± 10} {Min. 250}
Min. 1.65 Min. 1.65
Neutral – Raise
{Min. 16.8} {Min. 16.8}
Min. 1.37 Min. 1.37
Neutral – Lower MPa
• Engine: High idle {Min. 14.0} {Min. 14.0}
• HST oil temperature {kg/cm2}
Work equipment PPC valve Min. 2.01 Min. 2.01
(hydraulic oil tempera- Neutral – Float
output pressure {Min. 21.0} {Min. 21.0}
range (40 – 60°C) Neutral – Left/Right Min. 1.72 Min. 1.72
tilt {Min. 17.5} {Min. 17.5}
Neutral – Left/Right Min. 1.96 Min. 1.96
angle {Min. 20.0} {Min. 20.0}

Raise 1.9 ± 0.2 Max. 2.5
Blade lifting speed range (40 – 60°C)
• Between max. lifting
height and ground
Work equipment
Lower 1.5 ± 0.2 Max. 2.2

• For measuring posture,
see “Work equipment 1”.
Work equipment speed

Left tilt 1.4 ± 0.2 Max. 1.8
Blade tilting speed range (40 – 60°C)
• Between max. left and
right tilting positions
Right tilt 1.4 ± 0.2 Max. 1.8
• For measuring posture, sec.

Left angle 3.1 ± 0.3 Max. 3.8
Blade angling speed range (40 – 60°C)
right angling positions
Right angle 3.1 ± 0.3 Max. 3.8

Time lag

Blade lifting time lag Max. 1.0 Max. 1.5
• Lower blade from max. lifting height and mea-
sure time after blade comes in contact with
ground until starts rising.
20-100 6 D31/37-22

Category

• Measure on level and flat place.

• Engine: Stopped
• Lever: Neutral
Hydraulic drift of work equipment
Hydraulic drift of lifted ture): Within operating range (40 – 60°C)

Max. 50 Max. 50
blade • Start measurement just after setting.
• Measure lowering distance (H) after 15 min-
utes.
• For measuring posture, see “Work equipment
4”. mm/15
• Measure on level and flat place. min.
Work equipment
• Engine: Stopped
• Lever: Neutral
Hydraulic drift of tilted ture): Within operating range (40 – 60°C)
Max. 100 Max. 100
utes.
5”.
Leaking from cylinder

Blade lift cylinder • HST oil temperature (hydraulic oil tempera- Max. 1.6 Max. 6.5
• Fully extend piston rod of cylinder to be mea- cc/min.
sured and disconnect hose on head side.
Blade tilt cylinder • Relieve circuit and measure leakage for 1 min- Max. 1.6 Max. 6.5
ute. (Lift and tilt only)
Cooling fan
Fan speed • Fan 100% mode rpm 1,800 ± 15 1,800 ± 50

Work equipment pump • HST oil temperature (Hydraulic oil tempera- MPa 13.7 ± 1.0 13.7 ± 2.0
pressure ture): 50 – 60°C {kg/cm2} {140 ± 10} {140 ± 20}
D31/37-22 20-100 7
D37EX-22, D37PX-22

Category

Forward and • Engine: Stopped N – Forward /

29 ± 6 29 ± 6
reverse • Center of lever grip Reverse
PCCS lever
• Engine: Stopped N – Sharp turn to
Steering 50 ± 10 50 ± 10
• Center of lever knob right/left
• Engine: Stopped 1st stage 52 ± 10 52 ± 10

Brake pedal
• Center of pedal 2nd stage 75 ± 10 75 ± 10
• Engine: Stopped mm
Stroke
Decelerator pedal 50 ± 10 50 ± 10
• Center of pedal
Neutral – Raise 47 ± 10 47 ± 20
Neutral – Lower 46 ± 10 46 ± 20
• Engine: Stopped
Neutral – Float 71 ± 10 71 ± 20
• Center of lever knob
Blade control lever
• Angle: Twisting angle of Neutral – Left/Right
lever 52 ± 10 52 ± 20
tilt
Neutral – Left/Right °
15 ± 3 15 ± 6
angle (Degree)
Forward and N – Forward / 37.3 – 65.7 35.3 – 67.7
reverse Reverse {3.8 – 6.7} {3.6 – 6.9}
N – Sharp turn to 44.1 ± 7.8 44.1 ± 9.8
Steering • Engine: Stopped right/left {4.5 ± 0.8} {4.5 ± 1.0}
PCCS lever • Center of lever knob
• Button switch 6.9 – 12.7 Max. 14.8
Shift-up
Shift-up/down {0.7 – 1.3} {Max. 1.5}
switch 6.9 – 12.7 Max. 14.8
Shift-down
{0.7 – 1.3} {Max. 1.5}
142 ± 28 Max. 199
1st stage
• Engine: Stopped {14.5 ± 2.9} {Max. 20}
Operating effort
Brake pedal
• Center of pedal N 230 ± 46 Max. 322
2nd stage
{kg} {23.5 ± 4.7} {Max. 33}
• Engine: Stopped 70 ± 14.0 Max. 98
Decelerator pedal
• Center of pedal {7.1 ± 1.4} {Max. 10}
22.5 ± 10 Max. 39.2
Neutral – Raise
{2.3 ± 1.0} {Max. 4.0}
25.5 ± 10 Max. 39.2
Neutral – Lower
{2.6 ± 1.0} {Max. 4.0}
• Engine: Low idle 70 ± 22 Max. 118
Blade control lever Neutral – Float
• Center of lever knob {7.1 ± 2.2} {Max. 12.0}
Neutral – Left/Right 22.5 ± 10 Max. 39.2
tilt {2.6 ± 1.0} {Max. 4.0}
Neutral – Left/Right Nm 2.9 – 5.4 Max. 8.3
angle {kgm} {0.3 – 0.55} {Max. 0.9}
20-100 8 D31/37-22

Category

40.2 – 44.1 39.2 – 45.1

Left
{410 – 450} {400 – 460}
• Engine: High idle Forward
• HST oil temperature 40.2 – 44.1 39.2 – 45.1
Right
(hydraulic oil tempera- {410 – 450} {400 – 460}
HST oil pressure
Main circuit pressure

ture): Within operating 40.2 – 44.1 39.2 – 45.1
range (40 – 60°C) Left
{410 – 450} {400 – 460}
• Stall pressure test mode Reverse MPa
{kg/cm2} 40.2 – 44.1 39.2 – 45.1
Right
{410 – 450} {400 – 460}
• Engine: High idle PCCS lever: 3.23 ± 0.29 3.23 ± 0.29
• HST oil temperature Neutral {33 ± 3.0} {33 ± 3.0}
Charge circuit pressure (hydraulic oil tempera-
ture): Within operating PCCS lever: 3.04 ± 0.29 3.04 ± 0.49
range (40 – 60°C) Forward or reverse {31 ± 3.0} {31 ± 5.0}
1st 3.4 ± 0.2 3.4 ± 0.4
• Engine: High idle Forward 2nd 5.6 ± 0.3 5.6 ± 0.6

• Quick shift mode
to default 3rd 8.5 ± 0.5 8.5 ± 0.8
(hydraulic oil tempera- 1st 4.1 ± 0.2 4.1 ± 0.4
range (40 – 60°C)
• Measure on flat place. Reverse 2nd 6.5 ± 0.3 6.5 ± 0.6
Travel speed km/h
3rd 8.5 ± 0.5 8.5 ± 0.8
HST
• Engine: High idle MIN 0.8 ± 0.2 0.8 ± 0.3

• Variable shift mode Forward
to default MAX 8.5 ± 0.5 8.5± 0.8
(hydraulic oil tempera- MIN 0.8 ± 0.2 0.8 ± 0.3
range (40 – 60°C) Reverse
• Measure on flat place. MAX 8.5 ± 0.5 8.5 ± 0.8

• Flat place (Hard and level place such as con-
Travel deviation crete floor) mm Max. 120 Max. 150
• After approach run of at least 10 m, measure
deviation in travel of 20 m.
• Measure deviation (x).
• Travel lever: N (Neutral)
• Travel lock lever: Free
Hydraulic drift of travel • Stop machine on slope of 20°. m Max. 3.6 Max. 4.0
• Posture of machine: With front side up and
down
• Hydraulic drift (Hydraulic travel distance) in 1
minute
D31/37-22 20-100 9

Category


Work equipment relief pres- 27.44 ± 0.98 Min. 24.5
sure {280 ± 10} {Min. 250}
Min. 1.65 Min. 1.65
Neutral – Raise
{Min. 16.8} {Min. 16.8}
Min. 1.37 Min. 1.37
Neutral – Lower MPa
• Engine: High idle {Min. 14.0} {Min. 14.0}
• HST oil temperature {kg/cm2}
Work equipment PPC valve Min. 2.01 Min. 2.01
(hydraulic oil tempera- Neutral – Float
output pressure {Min. 21.0} {Min. 21.0}
range (40 – 60°C) Neutral – Left/Right Min. 1.72 Min. 1.72
tilt {Min. 17.5} {Min. 17.5}
Neutral – Left/Right Min. 1.96 Min. 1.96
angle {Min. 20.0} {Min. 20.0}

Raise 1.9 ± 0.2 Max. 2.5
Blade lifting speed range (40 – 60°C)
• Between max. lifting
height and ground
Work equipment
Lower 1.5 ± 0.2 Max. 2.2

Work equipment speed

Left tilt 1.4 ± 0.2 Max. 1.8
Blade tilting speed range (40 – 60°C)
right tilting positions
Right tilt 1.4 ± 0.2 Max. 1.8
• For measuring posture, sec.

Left angle 3.1 ± 0.3 Max. 3.8
Blade angling speed range (40 – 60°C)
right angling positions
Right angle 3.1 ± 0.3 Max. 3.8

Time lag

Blade lifting time lag Max. 1.0 Max. 1.5
• Lower blade from max. lifting height and mea-
sure time after blade comes in contact with
ground until starts rising.
20-100 10 D31/37-22

Category

• Measure on level and flat place.

• Engine: Stopped
• Lever: Neutral
Hydraulic drift of work equipment
Hydraulic drift of lifted ture): Within operating range (40 – 60°C)

Max. 50 Max. 50
utes.
4”. mm/15
• Measure on level and flat place. min.
Work equipment
• Engine: Stopped
• Lever: Neutral
Hydraulic drift of tilted ture): Within operating range (40 – 60°C)
Max. 100 Max. 100
utes.
5”.
Leaking from cylinder

Blade lift cylinder • HST oil temperature (hydraulic oil tempera- Max. 1.6 Max. 6.5
• Fully extend piston rod of cylinder to be mea- cc/min.
sured and disconnect hose on head side.
Blade tilt cylinder • Relieve circuit and measure leakage for 1 min- Max. 1.6 Max. 6.5
ute. (Lift and tilt only)
Cooling fan
Fan speed • Fan 100% mode rpm 1,800 ± 15 1,800 ± 50

Work equipment pump • HST oil temperature (Hydraulic oil tempera- MPa 16.2 ± 1.0 16.2 ± 2.0
pressure ture): 50 – 60°C {kg/cm2} {16.5 ± 10} {16.5 ± 20}
D31/37-22 20-100 11
Performance measurement posture and method
Travel 1: Travel deviation Work equipment 2: Blade tilting speed
Travel 2: Hydraulic drift travel Work equipment 3: Blade angling speed
Work equipment 1: Blade lifting speed Work equipment 4: Hydraulic drift of lifted blade
Work equipment 5: Hydraulic drift of tilted blade
20-100 12 D31/37-22
D31/37-22 20-100 13
SEN04501-02
D31/37-22 Bulldozer
©2010 KOMATSU
All Rights Reserved
20-100 14
SEN04502-02
BULLDOZER
D31EX-22
D31PX-22
D37EX-22
D37PX-22
D31EX-22 60001 and up
D31PX-22 60001 and up
D37EX-22 60001 and up
D37PX-22 60001 and up
30 Testing and adjusting 30
110 Testing and adjusting, Part 1

Tools for testing, adjusting, and troubleshooting............................................................................................. 3
Measuring engine speed................................................................................................................................. 7
Measuring intake air pressure (boost pressure) ............................................................................................. 8
Testing exhaust temperature......................................................................................................................... 10
Measuring exhaust gas color (boost pressure)..............................................................................................11
Adjusting valve clearance ............................................................................................................................. 12
Testing compression pressure ...................................................................................................................... 14
Measuring blow-by pressure......................................................................................................................... 16
Testing oil pressure ....................................................................................................................................... 18
Handling fuel system equipment................................................................................................................... 19
Releasing residual pressure in fuel system .................................................................................................. 19
Bleeding air from fuel circuit.......................................................................................................................... 20
Testing fuel pressure..................................................................................................................................... 23
Testing leakage from pressure limiter and return rate from injector.............................................................. 24
Testing leakage in fuel system ...................................................................................................................... 27
Measuring fan circuit pressure and fan speed .............................................................................................. 28
Adjustment of fan speed sensor ................................................................................................................... 29
Handling reduced cylinder mode operation .................................................................................................. 30
Handling no-injection cranking operation...................................................................................................... 30
Check of muffler and muffler stack for looseness and damage .................................................................... 31
Check of muffler function .............................................................................................................................. 31
Check of installed condition of cylinder head and manifolds ........................................................................ 32
Check of engine piping for damage and looseness ...................................................................................... 32
D31/37-22 30-110 1
SEN04502-02
Testing and adjusting alternator belt tension................................................................................................. 33

Testing and adjusting air conditioner compressor belt tension...................................................................... 34
30-110 2 D31/37-22
Tools for testing, adjusting, and troubleshooting SEN04502-02
Tools for testing, adjusting, and troubleshooting 1
Testing and Sym-

Part No. Part Name Q'ty Remarks
adjusting item bol
Measuring intake air
–101 – 200 kPa
pressure (boost A 799-201-2202 Boost gauge kit 1
pressure) {–760 – 1,500 mmHg}
Testing exhaust
B 799-101-1502 Digital thermometer 1 –99.9 – 1,299°C
temperature
1 799-201-9001 Handy smoke checker 1
Measuring exhaust gas
C Commercially Bosch index: 0 – 9
color 2 Smoke meter 1
available
Adjusting valve Commercially Intake: 0.35 mm
D Clearance gauge 1
clearance available Exhaust: 0.50 mm
795-502-1370 Adapter 1
Testing compression 1 For 95E-5
E 6271-11-3880 Gasket 1
pressure
2 795-502-1590 Compression gauge 1 0 – 7 MPa {0 – 70 kg/cm2}
Testing blow-by
F 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH2O}
pressure
6732-81-3170 Adapter 1
1
07002-11023 O-ring 1
Pressure gauge: 2.5, 6, 40, 60 MPa
Testing oil pressure G 799-101-5002 Hydraulic tester 1
2 {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
3 799-401-2320 Hydraulic tester 1 Pressure gauge: 1 MPa {10 kg/cm2}
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
Testing fuel pressure H
2 799-201-2202 Boost gauge kit 1 Pressure gauge: 1 MPa {10 kg/cm2}
795-471-1450 Adapter 1 8 × 1.25 mm o R1/8
3
07005-00812 Seal washer 1
1 6151-51-8490 Spacer 1 Inside diameter: 14 mm
2 6206-71-1770 Joint 1 Inside diameter of joint: 10 mm
3 07042-20108 Plug 1 PT1/8
Commercially
4 Hose 1 φ 15 mm x 2 – 3 m
Testing leakage from available
pressure limiter and J Commercially
return rate from injector 5 Hose 1 φ 5 mm x 2 – 3 m
available
Commercially
6 Measuring cylinder 1
available
Commercially
7 Stopwatch 1
available
799-101-5002 Hydraulic tester 1 * Same as G2
1
Testing and adjusting 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
K
HST oil pressure 799-101-5220 Nipple 4 Size: 10 × 1.25 mm
2
07002-11023 O-ring 4
D31/37-22 30-110 3
SEN04502-02 Tools for testing, adjusting, and troubleshooting
Testing and Sym- Q'ty

Part No. Part Name Remarks
adjusting item bol
1 * Same as G2
790-261-1204 Digital hydraulic tester 1
Measuring solenoid 799-401-3100 Adapter 1 Size 02
L 2
valve pressure for HST 799-401-3200 Adapter 1 Size 03
799-101-5230 Nipple 1
3 Size: 14 × 1.5 mm
07002-11423 O-ring 1
Method of releasing 1 790-190-1500 Pump assembly 1
parking brake 799-101-5220 Nipple 4
M
(Procedure for 2 Size: 10 × 1.25 mm
emergency escape) 07002-11023 O-ring 4
Testing and adjusting 1
790-261-1204 Digital hydraulic tester 1
work equipment oil N * Same as G2
pressure 799-101-5200 Nipple 1
2
07002-11023 O-ring 1
Measuring work 799-101-5002 Hydraulic tester 1

1 * Same as G2
equipment PPC valve P 790-261-1204 Digital hydraulic tester 1
output pressure 2 790-401-3100 Adapter 1 Size 02
Testing leakage in work Commercially
Q Measuring cylinder 1
equipment cylinder available
Measuring water
temperature and oil — 799-101-1502 Digital thermometer 1 * Same as B
temperature
Adjusting decelerator
— 79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
pedal & brake pedal
Measuring stroke and Commercially
— Scale 1
hydraulic drift available
Measuring work Commercially
— Stopwatch 1
equipment speed available
Measuring voltage and Commercially
— Multimeter 1
resistance available
For Ne sensor, Bkup sensor
799-601-4130 T-adapter —
(Cam sensor)
799-601-4190 Socket — For common rail pressure sensor
799-601-4240 Socket — For atmospheric pressure sensor
For boost pressure and temperature
799-601-4310 Socket —
sensor
799-601-4160 T-adapter — For lubricating oil pressure switch
Diagnosis for engine Deep socket (21mm)
controllers, sensors, — (MITOLOY 4ML-21 or
and actuators Commercially equivalent)
1
available Applicable engine serial
No.:
500001-502653 For coolant temperature sensor
Deep socket (19mm)
(MITOLOY 4ML-19 or
795T-981-1010 equivalent) 1
Applicable engine serial
No.: 502654 and up
30-110 4 D31/37-22
Tools for testing, adjusting, and troubleshooting SEN04502-02
Testing and Sym-

Part No. Part Name Q'ty Remarks
adjusting item bol
799-601-9000
or
799-601-9200
— or T-adapter assembly 1
799-601-4101
or
799-601-4202
— 799-601-9020 Adapter for DT 1 For DT
For DT (Excl. 799-601-4101 and
— 799-601-9030 Adapter for DT 1
799-601-4201)
— 799-601-9040 Adapter for DT 1 For DT
— 799-601-9050 Adapter for DT 1
799-601-4201)
Diagnosis for chassis — 799-601-9060 Adapter for DT (Gray) 1
799-601-4201)
related controller,
sensor actuator and For DT (Excl. 799-601-4101 and
— 799-601-9070 Adapter for DT (Black) 1
harness 799-601-4201)
799-601-7000
or
799-601-7100
— or T-adapter assembly 1
799-601-7400
or
799-601-8000
— 799-601-7050 Adapter for SWP 1 For SWP (Excl. 799-601-8000)
— 799-601-7060 Adapter for SWP 1 For SWP (Excl. 799-601-8000)
— 799-601-7090 Adapter for M 1 For M
— 799-601-7500 T-adapter assembly 1
— 799-601-7550 Adapter for 070 1 For 070
— 799-601-7520 Adapter for 070 1 For 070
D31/37-22 30-110 5
SEN04502-02 Tools for testing, adjusting, and troubleshooting
Socket
30-110 6 D31/37-22
Measuring engine speed SEN04502-02
Measuring engine speed 1
a Measure the engine speed under the following

condition.
q Engine coolant temperature: Within oper-
ating range
q HST oil (Hydraulic oil) temperature: Within
operating range (40 – 60°C)
1. Preparation work
Turn the starting switch ON and set the monitor
panel in the “Real-time monitoring mode” to
prepare for measurement of the engine speed.
a For the operating method, see “Special
functions of monitor panel (EMMS)”.
q Controller: ENGINE
q Monitoring code: 01002-ENG SPEED
q The engine speed is displayed in rpm.
2. Measuring low idle speed

1) Start the engine and set the fuel control
dial in the low idle position.
2) Set the PCCS lever and blade control
lever in neutral and measure the engine
speed.
3. Measuring high idle speed

dial in the high idle position.
2) Set the PCCS lever and blade control
lever in neutral and measure the engine
speed.
4. Measuring decelerator pedal speed

dial in the high idle position.
2) Set the PCCS lever and work equipment
control lever in neutral and press the
decelerator pedal and measure the engine
speed.
a The engine speed when the decelerator
pedal is pressed to the stroke end is the
same as the low idle speed.
D31/37-22 30-110 7
SEN04502-02 Measuring intake air pressure (boost pressure)
Measuring intake air pressure 3. Close the side cover on the left side of the
(boost pressure) 1
engine and, if necessary, fix it with gummed
tapes etc. so that the hose connected for
Necessary tool inspection will not be flattened and will not
Symbol Part No. Part Name interfere with the lift cylinder when the blade is
raised.
A 799-201-2202 Boost gauge kit
q In addition, check that the front cover is
k
not open. If it is open, close it.
Stop the machine on a flat place and lower
a Perform the above work securely so that
the work equipment to the ground.
k
the side cover and front cover will not
Take care not to touch a hot part when install-
break by interfering with the blade or cylin-
ing or removing a testing tool.
k
ders when the blade is raised in the follow-
Before raising the blade, check that the side
ing work.
cover on the left side of the engine and front
cover are closed.
4. Turn the starting switch ON, set the monitor
a Measure the intake air pressure under the fol-
lowing condition. panel in the “Adjustment mode”, and prepare
for stalling the HST.
q Engine coolant temperature: Within oper-
a When performing this operation, set the
ating range
parking brake lever in the LOCK position
and the PCCS lever in the neutral posi-
operating range
tion.
1. Open the side cover of engine left side and a For the operating method, see “Special
remove intake air pressure pickup plug (1) functions of monitor panel (EMMS)”.
q Adjustment code: 3016-STALL CHECK
(Rc1/8) from the intake air connector.
5. Run the engine at middle or higher speed and

2. Install nipple [2] of boost gauge kit A and con-
bleed oil from the hose.
nect it to gauge [1].
a Insert the connecting parts of the gauge
and hose about a half and open the self-
seal on the hose side repeatedly, and the
oil will be drained.
a If Pm kit (A) is available, you use the air
bleeding coupling (790-261-1130) in that
kit.
a If oil is left in the hose, the gauge does not
work. Accordingly, be sure to drain the oil.
6. Keep the parking brake lever in the LOCK

position.
a Stall the HST with the parking brake lever
in the LOCK position.
30-110 8 D31/37-22
Measuring intake air pressure (boost pressure) SEN04502-02
7. While running the engine at high idle, operate

PCCS lever in the forward or reverse position
to stall the HST, then measure the intake air
pressure (boost pressure).
a If the PCCS lever is set in the forward or
reverse position, the HST stalls. If the
PCCS lever is returned, stalling of the
HST stops.
k While the HST is stalled, the oil temper-
ature rises sharply and locally. Accord-
ingly, do not stall the HST continuously
for more than 30 seconds.
Because it is the measurement of 30
seconds, the measurements are not
stable, and there is a case to appear
lower than a standard value.
8. After finishing measurement, remove the mea-

suring tools and return the removed parts.
D31/37-22 30-110 9
SEN04502-02 Testing exhaust temperature
Testing exhaust temperature 1 4. Keep the parking brake lever in the LOCK
position.
a Testing tools a Stall the HST with the parking brake lever
Symbol Part No. Part name
B 799-101-1502 Digital thermometer 5. While running the engine at high idle, operate
k Remove and install the testing tools after to stall the HST, then measure the intake air
the exhaust manifold temperature has low- pressure (boost pressure).
ered. a If the PCCS lever is set in the forward or
1. Remove the side cover of the engine right side. PCCS lever is returned, stalling of the
HST stops.
2. Remove exhaust temperature pickup plug (1) k While the HST is stalled, the oil temper-
from the side face of the center of the exhaust ature rises sharply and locally. Accord-
manifold. ingly, do not stall the HST continuously
Because it is the measurement of 30
seconds, the measurements are not
stable, and there is a case to appear
lower than a standard value.
3. Install sensor [1] of digital thermometer B and

connect it to thermometer [2].
6. After finishing testing, remove the testing tools

and return the removed parts.
30-110 10 D31/37-22
Measuring exhaust gas color (boost pressure) SEN04502-02
Measuring exhaust gas color

(boost pressure) 1
Necessary tools
Symbol Part No. Name

1 799-201-9001 Handy smoke checker
C Commercially
2 Smoke meter
available
k Stop the machine on a flat place and lower

k Take care not to touch a hot part when
installing or removing a testing tool. 2) Connect the probe hose, receptacle of the
a If an air source and an electric power source accelerator switch, and air hose to smoke
are not available in the field, use handy smoke meter C2.
checker C1. When recording official data, use a Limit the supplied air pressure to 1.5
smoke meter C2. MPa {15 kg/cm2}.
a Measure the exhaust gas color under the fol- 3) Connect the power cable to a receptacle
lowing condition. of AC socket.
• Engine coolant temperature: Within operat- a Before connecting the cable, check
ing range that the power switch of the smoke
meter is turned OFF.
1. Measuring with handy smoke checker C1 4) Loosen the cap nut of the suction pump
1) Stick a sheet of filter paper to smoke and fit the filter paper.
checker C1. a Fit the filter paper securely so that the
2) Insert the exhaust gas intake pipe in exhaust gas will not leak.
exhaust pipe (1). 5) Turn on the power switch of smoke meter C2.
3) Run the engine.
4) Accelerate the engine suddenly or run it at
high idle and operate the handle of smoke
checker C1 so that the filter paper will
absorb the exhaust gas.
6) Start the engine.

7) Accelerate the engine suddenly or run it at
high idle and press the pedal of smoke
meter C2 and collect the exhaust gas into
the filter paper.
5) Remove the filter paper and compare it
8) Place the contaminated filter paper on the
with the attached scale.
clean filter paper (at least 10 sheets) in the
6) After finishing measurement, remove the
filter paper holder and read the indicated
measuring instrument and return the
value.
removed parts.
measuring instrument and return the
2. Measuring with smoke meter C2
removed parts.
1) Insert probe [1] of smoke meter C2 in the
outlet of exhaust pipe (1) and fix it to the
exhaust pipe with a clip.
D31/37-22 30-110 11
SEN04502-02 Adjusting valve clearance
Adjusting valve clearance 1 4. Rotate the crankshaft forward (clockwise seen

from the front) and set wide notch (a) (Width:
Necessary tools 25 mm) of signal plate (3) at the rear of the
Symbol Part No. Part Name crankshaft pulley to embossed letters
Commercially "1.4TOP" (b) of front cover (4).
D Clearance gauge Reference: All of the other notches of the sig-
available
nal plate are 5 mm in width.
k Stop the machine on a level ground and a Rotate the crankshaft with the crankshaft
lower the work equipment to the ground. pulley bolt (5) (Width across flats: 27 mm).
a Measure the valve clearance under the follow- a Always rotate the crankshaft pulley bolt
ing condition. forward to prevent it from being loosened.
q Engine coolant temperature: Normal tem-
perature
1. Remove the engine hood.
2. Remove the cover (1) of the engine front side.
3. Remove cylinder head cover (2).
5. Ensure that the No. 1 cylinder is at the com-

pression top dead center.
a When the No. 1 cylinder is at the compres-
sion top dead center, the rocker arm of the
No. 1 cylinder can be moved by the valve
clearance with the hand. If the rocker arm
cannot be moved, rotate the crankshaft
one more turn.
30-110 12 D31/37-22
Adjusting valve clearance SEN04502-02
6. Adjust the clearances of the valves marked

with q in the valve arrangement drawing
according to the following procedure.
7. Rotate the crankshaft forward by one turn to

set the No. 4 cylinder to the compression top
dead center and adjust the valve clearances
1) While fixing adjustment screw (6), loosen
marked with Q, similarly to the valves marked
locknut (7).
with q.
2) Insert clearance gauge D in the clearance
Reference: You may rotate the crankshaft pul-
between rocker arm (8) and valve stem
ley by 180° and adjust the valve
upper end (9) and adjust the valve clear-
clearance of the cylinder which is
ance with adjustment screw (6).
set to the compression top dead
a With the clearance gauge inserted,
center at this time (Firing order: 1 –
turn the adjustment screw to a degree
2 – 4 – 3).
that you can move the clearance
gauge lightly.
8. After finishing adjustment, return the removed
a Valve clearance
parts.
3 Cylinder head cover mounting bolt:
Intake valve: 0.35 ± 0.02 mm
Exhaust valve: 0.50 ± 0.02 mm
7.84 – 9.8 Nm {0.8 – 1.0 kgm}
3) While fixing adjustment screw (6), tighten
locknut (7).
3 Locknut:
39.2 – 49 Nm {4 – 5 kgm}
a After tightening the locknut, check the
valve clearance again.
D31/37-22 30-110 13
SEN04502-02 Testing compression pressure
Testing compression pressure 1
a Testing tools

795-502-1370 Adapter
1
E 6271-11-3880 Gasket
2 795-502-1590 Compression gauge
k When measuring the compression pres-

sure, take care not to burn yourself on the
exhaust manifold, muffler, etc. or get
caught in a rotating part.
a Measure the compression pressure after the
engine is warmed up 4. Insert adapter E1 in the injector mounting hole
(Engine oil temperature: 40 – 60°C). and fix it with holder (7).
a Fit the gasket to the adapter end.
3 Holder mounting bolt:
1. Remove the engine hood.
27 – 30 Nm {2.8 – 3.1 kgm}
2. Install the engine controller and air cleaner a Seat the fulcrum of the holder perfectly
again. before tightening the mounting bolts.
3. Remove the injector of the cylinder to be mea-

sured.
a Measuring procedure for No. 1 cylinder is
described below as an example.
1) Remove wiring harness connector (2)
from injector (1).
2) Remove fuel scatter prevention cover (3)
from the joint.
3) Remove clamp (4) and high-pressure pipe
(5).
4) Pull out spill hose connector (6) from
injector (1).
5. Connect compression gauge E2 to adapter E1.
5) Remove holder (7) and injector (1).

a If injector is stuck and cannot be
removed easily, pass a wire under the
fuel inlet and pull it up to remove the
injector.
a Do not apply an external force to any
part other than the injector top termi-
nal.
30-110 14 D31/37-22
Testing compression pressure SEN04502-02
6. Set it in the no-injection cranking mode. 3) Connect spill hose connector (6) to injec-
a For operating method, see “Special func- tor (1).
tion of monitor panel (EMMS)”. 4) Install high-pressure pipe (5).
k Since starting of engine is dangerous, 3 High-pressure pipe flare nut (Both
be sure to set the injectors so that they ends):
will not inject fuel before starting the 25.5 – 29.4 Nm {2.6 – 3.0 kgm}
check. 5) Install fuel scatter prevention cover (3) to
the joint of high-pressure pipe (5).
7. Crank the engine with the starting motor and a Install fuel scatter prevention cover
measure the compression pressure. (3) with the slit down (on both injector
a Read the pressure when the gauge side and common rail side).
pointer is stabilized. 6) Install clamp (4) to high-pressure pipe (5).
a Install the clamp to the position from
8. After finishing measurement, remove the mea- which it was removed. (The mounting
suring instruments and return the removed bolt goes through the clamp and
parts according to the following procedure. enters the bolt hole of the air intake
1) Install O-ring (8) and gasket (9) to injector manifold. Accordingly, if the mounting
(1). bolt is installed normally, the clamp is
a Do not install O-ring (8) to groove "a". installed to its original position.)
7) Connect wiring harness connector (2) to
injector (1).
2) Insert injector (1) in the cylinder head and

fix it with holder (7).
3 Holder mounting bolt:
27 – 30 Nm {2.8 – 3.1 kgm}
a Seat the fulcrum of the holder per-
fectly before tightening the mounting
bolts.
D31/37-22 30-110 15
SEN04502-02 Measuring blow-by pressure
Measuring blow-by pressure 1 4. Check that the side cover on the left side of the
engine and front cover are not open. If they are
Necessary tools open, close them.
Symbol Part No. Part Name a Perform the above work securely so that
F 799-201-1504 Blow-by checker the side cover and front cover will not
break by interfering with the blade or cylin-
k Stop the machine on a flat place and lower ders when the blade is raised in the follow-
the work equipment to the ground. ing work.
k Take care not to touch a hot part when install-
ing or removing a testing tool. 5. Turn the starting switch ON, set the monitor
k Before raising the blade, check that the side panel in the “Adjustment mode”, and prepare
cover on the left side of the engine and front for stalling the HST.
cover are closed. a When performing this operation, set the
a Measure the blow-by pressure under the fol- parking brake lever in the LOCK position
lowing condition. and the PCCS lever in the neutral posi-
q Engine coolant temperature: tion.
Within operating range a For the operating method, see “Special
q HST oil (Hydraulic oil) temperature: functions of monitor panel (EMMS)”.
a Adjustment code: 3016-STALL CHECK
Within operating range (40 – 60?)
1. Remove the cover (1) under the engine left

side cover.
6. While keeping the parking brake lever in the

LOCK position, set the work equipment lock
lever in the FREE position and raise the blade
2. Pull out blow-by hose (2). to the stroke end.
a Stall the HST with the parking brake lever
3. Install nozzle [1] to blow-by hose (2) and con- in the LOCK position.
nect it to gauge [2] of blow-by checker F.
a Ensure that the blow-by hose drawn out is
not bent.
30-110 16 D31/37-22
Measuring blow-by pressure SEN04502-02
7. While running the engine at high idle, operate

to stall the HST and relieve the blade circuit by
raising the blade, and then measure the blow-
by pressure.
a If the PCCS lever is set in the forward or
PCCS lever is returned, stalling of the
HST stops.
k While the HST is stalled, the oil temper-
ature rises sharply and locally. Accord-
ingly, do not stall the HST continuously

suring instruments and return the removed
parts.
a Pass the blow-by hose end through the
positioning ring.
D31/37-22 30-110 17
SEN04502-02 Testing oil pressure
Testing oil pressure 1 4. Run the engine at the rated output and low idle
and test the oil pressure.
a Testing tools

6732-81-3170 Adapter
1
07002-11023 O-ring
G 799-101-5002 Hydraulic tester
2
790-261-1204 Digital hydraulic tester
3 799-401-2320 Hydraulic tester

installing or removing a testing tool.
1. Remove the side cover of the engine right side. and return the removed parts.
3 Plug (1): 20 – 22 Nm{2.0 – 2.2 kgm}
2. Remove 1 oil pressure pickup plug (1) from the

left side of the cylinder block.
a Remove any one of the 3 oil pressure
pickup plugs.
3. Install adapter G1 and connect it to hydraulic

tester G3 by using hose [1] of hydraulic tester
G2.
30-110 18 D31/37-22
Handling fuel system equipment SEN04502-02
Handling fuel system equipment 1 Releasing residual pressure in

a Precautions for testing and maintaining fuel fuel system 1
system a Pressure is generated in the low-pressure cir-

The common rail fuel injection system (CRI) cuit and high-pressure circuit of the fuel sys-
consists of more precise parts than the con- tem while the engine is running.
ventional fuel injection pump and nozzle. If for- Low-pressure circuit:
eign matter enters this system, it can cause a Fuel pre-filter – Fuel main filter – Supply pump
trouble. High-pressure circuit:
When testing and maintaining the fuel system, Supply pump – Common rail – Injector
take care more than the past. If dust, etc. sticks a The pressure in both low-pressure circuit and
to any part, wash that part thoroughly with high-pressure circuit lowers to a safety level
clean fuel. automatically 30 seconds after the engine is
a Precautions for replacement of fuel filter car- stopped.
tridge a Before the fuel circuit is tested and its parts are
The fuel filter cartridge used must be a genuine removed, the residual pressure in the fuel cir-
Komatsu part. cuit must be released completely. Accordingly,
The fuel injection pump and nozzle of the com- observe the following.
mon rail type fuel injection system (CRI) con- k Before testing the fuel system or removing
sist of more precision parts than those used for its parts, wait at least 30 seconds after stop-
the current pumps and nozzles. This system, ping the engine until the residual pressure
therefore, employs a special filter with highly in the fuel circuit is released. (Do not start
efficient filtering performance to prevent mixing the work just after stopping the engine
of foreign substances. Thus, substituting it with since there is residual pressure.)
a non-genuine filter could cause troubles in the
fuel system. It is strictly prohibited to use such
part.
D31/37-22 30-110 19
SEN04502-02 Bleeding air from fuel circuit
Bleeding air from fuel circuit 1 a Do not add fuel to fuel main filter (3) exter-
nally.
a If fuel is used up or if a fuel circuit part is
removed and installed, bleed air from the fuel
circuit according to the following procedure.
k Stop the machine on a level ground and
lower the work equipment to the ground.
1. Fill the fuel tank with fuel.
2. Open the front side cover of the engine hood.
3. Remove fuel pre-fuel filter (1) and fill it with

fuel.
4. Install pre-fuel filter (1) to the filter head.

a Apply engine oil thinly over the packing on
the pre-fuel filter side.
a After the packing of the pre-fuel filter
touches the sealing face of the filter head,
tighten the fuel filter 3/4 turns.
a Fill the fuel filter with clean fuel and take

care that dirt will not enter it.
a Check that the cap is fitted to part (a)
(central hole) of the pre-fuel filter, and then
add fuel through part (b) (holes around the
central hole).
a After filling the pre-fuel filter with fuel,

remove the cap from part (a).
a If clean fuel is not available, do not
remove the pre-fuel filter but fill it with the
fuel by operating priming pump (2).
30-110 20 D31/37-22
Bleeding air from fuel circuit SEN04502-02
5. Loosen air bleeding plug (4) of the fuel prefilter

bracket and operate priming pump (2).
a Operate the priming pump until fuel flows

out of the plug hole. After checking that
fuel flows out, tighten the plug.
a Confirm that air does not coexist in fuel.
6. Loosen air bleeding plug (5) of the fuel main fil-

ter bracket and operate priming pump (2).
a Operate the priming pump until fuel flows

out of the plug hole. After checking that
fuel flows out, tighten the plug (5).
a Confirm that air does not coexist in fuel.
3 Air bleeding plug (5):
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
7. Push the knob of the priming pump, and fix it.
8. Start the engine with the starting motor.

a The air in the high-pressure circuit is bled
automatically if the engine is cranked.
a If the engine does not start, there may be
still air in the low-pressure circuit. In this
case, repeat the above procedure from
step 5.
D31/37-22 30-110 21
SEN04502-02 Bleeding air from fuel circuit
a Air bleeding route of fuel circuit

Fuel tank o Pre-filter o Main filter o Feed pump o Metering unit o Fuel tank
1. Fuel tank
2. Pre-filter with water separator
3. Priming pump
4. Main filter
5. Feed pump
6. IMV (Inlet Metering Valve)
7. Overflow valve
8. Rail
9. Injector
10. Safety valve
11. High pressure pump
30-110 22 D31/37-22
Testing fuel pressure SEN04502-02
Testing fuel pressure 1 3. Install adapter H3 and nipple [1] of hydraulic

tester H1 and connect it to hydraulic tester H2.
3 Adapter H3:
a Testing tools
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
799-101-5002 Hydraulic tester
1
H 2 799-201-2202 Boost gauge kit
795-471-1450 Adapter
3
07005-00812 Seal washer

a Test only the fuel pressure in the low-pressure
circuit from the feed pump through the fuel fil-
ter to the supply pump.
k Since the pressure in the high-pressure cir- 4. Run the engine at high idle and measure the
cuit from the supply pump through the fuel pressure.
common rail to the injector is very high, it a If the fuel pressure is in the following
cannot be measured. range, it is normal.
Reference: A value is negative pressure.
1. Open the side cover of engine left side. Engine speed Fuel pressure
–49 – 0 kPa
2. Remove plug (1) from the fuel filter head. High idle
{–0.5 – 0 kg/cm2}

3 Plug: 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
D31/37-22 30-110 23
SEN04502-02 Testing leakage from pressure limiter and return rate from injector
Testing leakage from pressure

limiter and return rate from
injector 1

1 6151-51-8490 Spacer
2 6206-71-1770 Joint
3 07042-20108 Plug
J 4 Commercially available Hose
5 Commercially available Hose
6 Commercially available Measuring cylinder
7 Commercially available Stopwatch
5) Insert spacer J1 on return block (4) side
a Prepare an oil pan of about 20 l to receive the and tighten the removed joint bolt again.
fuel flowing out during the test. a Be sure to fit the gaskets to both ends
k Stop the machine on a flat place and lower of the spacer.
k Before raising the blade, check that the
side cover on the left side of the engine and
front cover are closed.
1. Preparation work
1) Remove cover (1) under the side cover on
the left side of the engine.
6) Insert joint J2 on common rail (2) side and

tighten the removed joint bolt again.
a Be sure to fit the gaskets to both ends
of the joint.
7) Remove spill hose connector joint (6) and
install plug J3.
3 Plug J3:
3.9 – 6.9 Nm {0.4 – 0.7 kgm}
2) To make a working space, raise the

machine with the blade and support the
tracks with blocks etc. (Lower the lift cylin-
der to the stroke end.)
3) Remove spill hose (3) between common
rail (2) and injector.
4) Remove tube (5) between common rail (2)
and return block (4).
30-110 24 D31/37-22
Testing leakage from pressure limiter and return rate from injector SEN04502-02
2. Testing leakage from pressure limiter

1) Lay test hose J4 so that it will not slacken
and put its end in the oil pan.
2) Set the machine so that the engine speed
can be checked. For details, see “Testing
engine speed”.
3) Run the engine at the rated output.
4) After the engine speed is stabilized, test
the leakage in 1 minute with measuring
cylinder J6.
a You may test for 20 seconds and
judge by multiplying the result by 3.
a If the leakage from the pressure lim-
iter is in the following range, it is nor-
mal.
8) Connect test hose J4 to the end of joint
Engine speed Leakage
J2.
(rpm) (cc/min)
a Bind the connecting part of the test
hose with a wire, etc. to prevent it At rated output Max. 20
from coming off.
9) Connect test hose J5 to connector (7) side Reference:
of spill hose (3). A limit value is the value mentioned
a Bind the connecting part of the test above, but a standard value in normalcy is
hose with a wire, etc. to prevent it “0 cc/min. (no leak)”.
from coming off.
5) After finishing testing, stop the engine.
10) The above is the preparation work for test-

ing.
D31/37-22 30-110 25
SEN04502-02 Testing leakage from pressure limiter and return rate from injector
3. Testing return rate from injector

1) Lay test hose J5 so that it will not slacken
and put its end in the oil pan.
2) Set the machine so that the engine speed
can be checked. For details, see “Testing
engine speed”.
3) Run the engine at the rated output.
4) After the engine speed is stabilized, test
the return rate in 1 minute with measuring
cylinder J6.
a You may test for 20 seconds and
judge by multiplying the result by 3.
a If the supply pump is not supplying
fuel, the engine speed may not rise.
In this case, record the engine speed,
too, during the test.
a If the return rate (spill) from the injec-
tor is in the following range, it is nor-
mal.
Rated output speed Return (Spill) rate
(rpm) limit (cc/min)
1,600 190
1,700 200
1,800 210
1,900 220
2,000 230
5) After finishing testing, stop the engine.
4. Work after finishing testing

After finishing all testing, remove the testing
tools and return the removed parts.
3 Joint (6): 3.9 – 6.9 Nm {0.4 – 0.7 kgm}
30-110 26 D31/37-22
Testing leakage in fuel system SEN04502-02
Testing leakage in fuel system 1 8. Check that the side cover on the left side of the
k
engine and front cover are not open. If they are
Very high pressure is generated in the high- open, close them.
pressure circuit of the fuel system. If fuel a Perform the above work securely so that
leaks while the engine is running, it is dan- the side cover and front cover will not
gerous since it can catch fire. break by interfering with the blade or cylin-
After testing the fuel system or removing ders when the blade is raised in the follow-
its parts, test it for fuel leakage according ing work.
to the following procedure.
k Stop the machine on a flat place and lower 9. Start the engine and stall the HST or relieve
k
the hydraulic pump to apply some load on the
Before raising the blade, check that the engine.
front cover are closed. 10. Inspect the fuel piping and devices for fuel
a Clean and degrease the engine and the parts leakage.
around it in advance so that you can test it eas- a Check mainly around the high-pressure
ily for fuel leakage. circuit parts coated with the color checker
for fuel leakage.
1. Spray color checker (developer) over the fuel a If fuel leakage is recognized, repeat the
supply pump, common rail, fuel injector, and procedure from step 1 after repairing the
joints of the high-pressure piping. leakage.
a If no fuel leakage is detected, check is
2. Run the engine at speed below 1,000 rpm and completed.
stop it after its speed is stabilized.
3. Inspect the fuel piping and devices for fuel

leakage.
a Check mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If fuel leakage is recognized, repeat the
procedure from step 1 after repairing the
leakage.
4. Run the engine at low idle.

leakage.
for fuel leakage.
leakage.
6. Run the engine at high idle.

leakage.
for fuel leakage.
leakage.
D31/37-22 30-110 27
SEN04502-02 Measuring fan circuit pressure and fan speed
Measuring fan circuit pressure 2. Measurement of fan circuit pressure and

and fan speed 1
fan speed
a Measure the fan circuit pressure and fan dial to the high idle position.
speed under the following condition. 2) Set the PCCS lever and blade control
q HST oil temperature (Hydraulic oil tempera- lever in neutral.
ture): 50 – 60°C 3) Wait for about 1 minute until the fan speed
q Fan 100% mode is stabilized and then measure the fan cir-
cuit pressure and fan speed.
1. Preparation for work a Since this machine has the fan speed
1) Install the oil pressure gauge to the place feedback function for correcting the
for measuring both fan circuit pressure fan speed constantly, measure the
and work equipment oil pressure, referring fan speed after it is stabilized.
to Testing and adjusting, “Testing and a If the hydraulic oil temperature is
adjusting work equipment oil pressure”. below 45°C or the coolant tempera-
2) Turn the starting switch ON, set the moni- ture is below 60°C, the fan EPC
tor panel in the “Adjustment mode”, and command current is set to 1,000 mA
select the “Fan 100% mode”. and the fan speed is decreased to
a For the operating method, see “Spe- below 200 rpm even in the fan 100%
cial functions of monitor panel mode.
(EMMS)”. In this case, increase the hydraulic oil
q Adjustment code: 3032 FAN MODE temperature above 55°C and the
3) Change the monitor panel to the “Real coolant temperature above 65°C
time monitoring mode” and prepare for and then measure.
measurement of the fan speed.
a For the operating method, see “Spe-
cial functions of monitor panel
(EMMS)”.
q Controller: HST
q Monitoring code: 10007 FANSPEED
q The fan speed is indicated in units of
rpm.
30-110 28 D31/37-22
Adjustment of fan speed sensor SEN04502-02
Adjustment of fan speed sensor 1 4. After finishing adjustment, check that the moni-
k
tor panel displays the fan speed normally in the
“Real-time monitoring mode”.
the work equipment to the ground. a For the operating method, see “Special
a If the fan speed sensor was removed and
installed or a signal error was made, adjust the q Controller: HST
fan speed sensor according to the following q Monitoring code: 10007 FANSPEED
procedure.
a Before adjusting fan speed sensor (1), remove
it and check that its tips is free of iron dust and
flaw (It is installed to the left bottom of the fan
motor).
a The figure shows state where the fan motor
cover and travel alarm • bracket assembly are
removed from the rear mask.
1. Screw in sensor (1) until its tip touches fan

speed sensor gear (2).
a Finger tighten the sensor lightly so that its
tip will not be damaged.
2. Return sensor (1) by the specified angle and

direct the wiring harness as shown in the figure
(45° left up).
a Returning angle of screw: 2 ± 1/2 turn
a After this adjustment, clearance (a)
between the sensor tip and fan speed
sensor gear (2) is 3 ± 0.75 mm.
3. While fixing sensor (1), tighten nut (3).

2 Nut: 49.0 – 68.6 Nm {5 – 7 kgm}
D31/37-22 30-110 29
SEN04502-02 Handling reduced cylinder mode operation
Handling reduced cylinder mode Handling no-injection cranking

operation 1 operation 1
a Reduced cylinder mode operation means to a No-injection cranking means to crank the
run the engine with the fuel injectors of 1 or engine with the starting motor while all the
more cylinders disabled electrically to reduce injections are stopped electrically. The purpose
the number of effective cylinders. The pur- and effect of this operation are as follows.
poses and effects of this operation are as fol- q When a machine or engine has been stored for
lows. a long time, implementing the no-injection
cranking before starting the engine lubricates
1. This operation is used to find out a cylinder the engine parts and thus prevents its seizure.
which does not output power normally (or, a The no-injection cranking operation is set from
combustion in it is abnormal). the service mode of the monitor panel. For
details, see “Special functions of monitor panel
2. When a cylinder is selected for the reduced (EMMS)”, “No-injection cranking mode”.
cylinder mode operation, if the engine speed
and output do not change from the normal
operation (all-cylinder operation), that cylinder
has 1 or more defects. The possible defects
are as follows.
q Compression leakage through cylinder
head gasket
q Defective injection
q Defective piston or piston ring.
q Defective valve mechanism (Moving valve
system)
q Defect in electrical system
3. Since the common rail fuel injection system

controls the injector of each cylinder electroni-
cally, the operator can perform the cylinder cut
out mode operation easily with switches to find
out a defective cylinder.
a The cylinder cut out mode operation is set
from the service mode of the monitor
panel.
For details, see “Special functions of mon-
itor panel (EMMS)”, “5. Cylinder cut out
mode operation function”.
30-110 30 D31/37-22
Check of muffler and muffler stack for looseness and damage SEN04502-02
Check of muffler and muffler Check of muffler function 1
stack for looseness and damage 1

q Check the muffler for abnormal sound and dif-
1. Check the muffler and muffler stack visually for ference in sound from a new machine. If it
a crack and damage. If any part is damaged, makes abnormal sound, repair it, referring to
replace it. the Troubleshooting Volume.
2. Check the mounting bolts and nuts of the muf-

fler and muffler stack for looseness. If they are
loosened, retighten them.
D31/37-22 30-110 31
SEN04502-02 Check of installed condition of cylinder head and manifolds
Check of installed condition of Check of engine piping for

cylinder head and manifolds 1 damage and looseness 1
Check the installed condition of the cylinder head Air intake and exhaust systems:
and air intake manifold and exhaust manifold. If Check the piping for damage, looseness of the
they are loosened, retighten them. mounting bolts and nuts, and suction of air and
a For the tightening torque, see the “Disassem- leakage of exhaust gas through the joints. If it
bly and assembly” volume. is loosened or damaged, retighten or repair.
Cooling system:
Check the piping for damage, looseness of the
mounting bolts and nuts, and leakage of water
through the joints. If it is loosened or dam-
aged, retighten or repair.
Fuel system:
Check the piping for damage, looseness of the
mounting bolts and nuts, and leakage of fuel
through the joints. If it is loosened or dam-
aged, retighten or repair.
30-110 32 D31/37-22
Testing and adjusting alternator belt tension SEN04502-02
Testing and adjusting alternator Adjusting

belt tension 1 a If the deflection is out of the standard range,
k
adjust it according to the following procedure.
the work equipment to the ground. 1. Remove the side cover of engine right side.
Testing 2. Loosen alternator fixing bolt (1) and mounting

1. Open the front cover of engine hood. nut (2).
2. Remove the cover (1) of engine front side.
3. Remove the engine controller (2) and the

cover (3).
3. Using a hammer shaft etc., move the alternator

to adjust the alternator belt tension.
4. After adjusting the belt tension, tighten alterna-

4. Press the intermediate point of the belt tor fixing bolt (1) and mounting nut (2).
between alternator pulley (4) and water pump
pulley (5) with a finger and measure deflection 5. Check again that the tension of alternator belt
(a) of the belt. is in the standard range.
a Pressing force: Approx. 58.8 N {Approx. 6 kg}
a Deflection (a): 6 – 7 mm 6. After finishing adjustment, return the removed
parts.
D31/37-22 30-110 33
SEN04502-02 Testing and adjusting air conditioner compressor belt tension
Testing and adjusting air Adjusting

conditioner compressor belt a If the belt deflection is abnormal, adjust it
tension 1
k Stop the machine on a flat ground and 1. Loosen mounting bolts (4) and (5).
lower the work equipment to the ground. Reference: Bolt (4) is a through bolt. When
loosening it, hold set nut (4a) on the back side
Testing (adjustment side).
1. Open the front cover of the engine hood.
2. Remove cover (1) on the front side of the

engine.
2. Loosen set nut (4a). (It was loosened in step

1.)
3. Loosen locknut (6) and adjust the belt tension

3. Press the middle point between water pump with adjustment bolt (7).
pulley (2) and compressor pulley (3) with a fin-
ger and measure deflection (a) of the belt.
q Belt pressing force: 98 N{10 kg}
q Deflection (a): 13 – 15.5 mm
4. After adjusting the belt tension, tighten locknut

(6), set nut (5) and mounting bolt (4).
a Check each pulley for breakage, wear of 5. Check the air conditioner compressor belt ten-
the V-groove and contact of the V-belt and sion again and ensure that it is in the standard
V-groove. range.
a If the V-belt has been elongated and the
adjustment allowance is lost or it is cut or
cracked, replace it with new one.
a If the V-belt is replaced, test and adjust its
tension again after operating for 1 hour.
30-110 34 D31/37-22
Testing and adjusting air conditioner compressor belt tension SEN04502-02
D31/37-22 30-110 35
SEN04502-02
D31/37-22 Bulldozer
©2009 KOMATSU
All Rights Reserved
30-110 36
SEN04503-01
BULLDOZER
D31EX-22
D31PX-22
D37EX-22
D37PX-22
D31EX-22 60001 and up
D31PX-22 60001 and up
D37EX-22 60001 and up
D37PX-22 60001 and up

Adjusting decelerator pedal ............................................................................................................................ 2
Testing and adjusting HST oil pressure .......................................................................................................... 4
Measuring solenoid valve output oil pressure................................................................................................. 9
Testing travel deviation ................................................................................................................................. 12
Adjusting parking brake lever........................................................................................................................ 13
Simple brake performance test procedure.................................................................................................... 15
Adjusting brake pedal ................................................................................................................................... 16
Method of releasing parking brake (Procedure for emergency escape) ....................................................... 18
Testing and adjusting idler clearance............................................................................................................ 20
Testing and adjusting track shoe tension ...................................................................................................... 21
Testing work equipment oil pressure............................................................................................................. 22
Testing work equipment PPC valve output oil pressure................................................................................ 24
Adjusting play of work equipment PPC valve ............................................................................................... 26
Adjusting work equipment lock lever............................................................................................................. 27
Testing internal leakage of work equipment cylinder .................................................................................... 28
Releasing residual pressure in hydraulic circuit............................................................................................ 30
Bleeding air from hydraulic circuit ................................................................................................................. 31
Adjusting play of blade center ball ................................................................................................................ 32
Procedure for testing diodes ......................................................................................................................... 33
Preparation work for troubleshooting for electrical system ........................................................................... 34
How to start operation of KOMTRAX terminal .............................................................................................. 38
Lamp display of KOMTRAX terminal ............................................................................................................ 41
D31/37-22 30-120 1
SEN04503-01 Adjusting decelerator pedal
Adjusting decelerator pedal 1
k Stop the machine on the flat ground and 3) Adjust (Rotate) the installed position of the
lower the work equipment to the ground. potentiometer so that the decelerator
a When adjusting the decelerator pedal, remove pedal potentiometer voltage will be the
the dashboard cover, dashboard undercover specified voltage when decelerator pedal
and pedal assembly. (1) is in neutral.
Place the removed pedal assembly on the floor q DECEL PEDAL VOLTAGE:
and connect the wiring harness connector 1.23 ± 0.10 V
between floor and pedal. 4) Adjust stopper (3) temporarily so that
pedal height (c) will be 159 mm when
1. Adjusting decelerator pedal potentiometer decelerator pedal (1) is pressed to the
1) Turn the starting switch ON and change stroke end.
the monitor for display of the decelerator 5) Adjust installed dimension (d) of stopper
pedal potentiometer voltage in the “real- (3) so that decelerator pedal potentiome-
time monitoring mode”. ter voltage will be the specified voltage
q Controller: ENGINE when decelerator pedal (1) is pressed to
q Monitoring code: the stroke end.
31702-DECEL PEDAL q DECEL PEDAL VOLTAGE:
a For the operating method, see “Spe- 2.59 ± 0.10 V
cial functions of monitor panel q Dimension (d) = 22.3 mm (Reference
(EMMS)”. value)
2) Adjust installed dimension (b) of stopper
(2) so that pedal height (a) will be 209 mm
when decelerator pedal (1) is in neutral.
q Dimension (b) = 33.1 mm (Reference
value)
30-120 2 D31/37-22
Adjusting decelerator pedal SEN04503-01
2. Measuring decelerator pedal pressing

effort
1) Press the decelerator pedal with the foot
to check that it operates smoothly.
2) If the decelerator pedal does not operate
smoothly, supply grease through grease
fitting (4) and apply grease to spring (5).
2 Grease fitting (4): Grease (G2-LI)
2 Spring (5): Grease (G2-LI)
3) Using push-pull scale A, measure the full-
stroke pressing effort of the decelerator
pedal.
q Full-stroke pressing effort:
71 N {7.3 kg}
3. Work after finishing measurement

After finishing all adjustment, return the
removed parts.
4. Testing decelerator pedal potentiometer

1) Turn the starting switch ON and change
the monitor for display of the decelerator
pedal operating degree in the “real-time
monitoring mode”.
q Controller: ENGINE
q Monitoring code:
31701-DECEL PEDAL
(EMMS)”.
2) The relationship between the position and
operating degree of the decelerator pedal
is shown in Table 1.
Table 1
Decelerator pedal
Decelerator pedal
operating degree
Released 100%
Pressed (Fully) 0%
D31/37-22 30-120 3
SEN04503-01 Testing and adjusting HST oil pressure
Testing and adjusting HST oil

pressure 1
Necessary tools

1
K
799-101-5220 Nipple
2
07002-11023 O-ring

installing or removing a testing tool. 2) Start the engine and keep the parking
k Before raising the blade, check that the brake lever in the LOCK position.
side cover on the left side of the engine and a Stall the HST with the parking brake
front cover are closed. lever in the LOCK position.
3) While running the engine at high idle,
Measuring operate PCCS lever in the forward or
reverse position to stall the HST and mea-
a Measure the HST oil pressure under the fol-
sure the HST main circuit pressure.
lowing condition.
a If the PCCS lever is set in the forward
or reverse position, the HST stalls. If
the PCCS lever is returned, stalling of
the HST stops.
k While the HST is stalled, the oil
1. Measuring HST main circuit pressure
a Measure the HST main circuit pressure in
temperature rises sharply and
the “Tuning mode” of the monitor panel.
k If the HST is stalled while the bypass
locally. Accordingly, do not stall
the HST continuously for more
valve (tow valve) of the parking brake
than 30 seconds.
circuit is closed, the HST equipment
may be damaged or it may move
2. Measuring HST charge circuit pressure
beyond your expectations. Accord-
2-1. Measuring method with real-time moni-
ingly, do not stall the HST out of the
tor
“Tuning mode”. 1) Measure the HST charge circuit pressure
1) Turn the starting switch ON, set the moni-
with the “Real-time monitoring mode” of
tor panel in the “Tuning mode”, and pre-
the monitor panel.
pare for stalling the HST.
a If the parking brake is released (the
a When performing this operation, set
parking brake lever is in the FREE
the parking brake lever in the LOCK
position and the brake pedal is
position and the PCCS lever in the
released), the HST charge circuit
neutral position.
pressure and the brake pressure are
the same. Measure the brake pres-
sure in this case.
k The HST charge circuit pressure needs
(EMMS)”.
q Tuning code:
to be measured while the machine is
3016-STALL CHECK
stopped and while the machine is trav-
q If the HST main circuit pressure is
eling actually. Accordingly, measure it
selected in the tuning mode, it is dis-
on a level ground where there are not
played in 0.1 MPa.
obstacles.
(The figure shows the item displayed
first (Right side HST main oil pres-
sure) when the mode is selected.)
30-120 4 D31/37-22
Testing and adjusting HST oil pressure SEN04503-01
1] Turn the starting switch ON and dis- k Turn the starting switch ON, set the
play the “Real-time monitoring mode” work equipment lock lever in the FREE
on the monitor panel to prepare for position, and lower the blade to the
measuring the brake pressure. ground. Move the blade control lever
a For the operating method, see until it is not held in the FLOAT posi-
“Special functions of monitor tion to release the residual pressure in
panel (EMMS)”. the accumulator. After the residual
q Controller: HST pressure is released, set the work
q Monitoring code: equipment lock lever in the LOCK posi-
91902-BRAKE PRESS tion and turn starting switch OFF.
q The brake pressure is displayed k Loosen the oil filler cap of the hydrau-
in 0.01 MPa. lic tank slowly to release the internal
pressure of the tank.
1] Remove the inspection cover of the
floor and remove HST charge circuit
pressure pickup plug (1) on the 5-
spool solenoid valve.
2] Start the engine and set the parking

brake lever in the FREE position.
3] Measure the brake pressure with the
PCCS lever in the neutral position
while running the engine at high idle
and with the PCCS lever in the for- 2] Install nipple [1] of hydraulic tester K1
ward or reverse position while travel- and connect it to oil pressure gauge
ing the machine. [2].
a While the machine is stopped, a Use the oil pressure gauge of 6
only the charge safety valve on MPa {60 kg/cm2}.
the oil cooler bypass valve side
operates. While the machine is
traveling, the charge relief valve
on the HST motor side operates,
too.
2-2. Measuring method with oil pressure
gauge
When measuring the HST charge circuit
pressure directly for troubleshooting of the
brake pressure sensor, parking brake
solenoid or slow brake solenoid, apply the
following method.
k The HST charge circuit pressure needs
to be measured while the machine is
stopped and while the machine is trav-
eling actually. Accordingly, measure it
on a level ground where there are not
obstacles.
D31/37-22 30-120 5
3] Start the engine and set the parking 2) Install nipple K2 and connect it to oil pres-
brake lever in the FREE position. sure gauge [2].
4] Measure the brake pressure with the a Use the oil pressure gauge of 6 MPa {60
PCCS lever in the neutral position kg/cm2}.
while running the engine at high idle
and with the PCCS lever in the for-
ward or reverse position while travel-
ing the machine.
3) Start the engine and set the parking brake

lever in the FREE position.
4) Select the quick shift mode and set the
gear speed to the 1st.
5] After finishing measurement, remove 5) While the engine is running at high idle,
the measuring instruments and return set the PCCS lever in the neutral position
the removed parts. and forward or reverse position and mea-
sure the EPC valve output pressure.
3. Measuring HST pump EPC valve output a If the EPC valve output pressure is as
pressure follows, it is normal.
k Since the machine will be stopped and
driven actually to measure the EPC EPC valve output
During travel
valve output pressure, work on a flat pressure
place where there is not an obstacle. Neutral 0 MPa {0 kg/cm2}
k Loosen the oil filler cap of the hydrau- Travel in F1 Min. 1.0 MPa
lic tank slowly to release the residual Travel in R1 {Min. 10 kg/cm2}
pressure in the hydraulic tank.
1) Remove the cover at the floor, and then
remove EPC valve output pressure pickup
plugs (2) – (5) at the top of the HST pump.
Plug (2): For left forward EPC valve
Plug (3): For left reverse EPC valve
Plug (4): For right forward EPC valve
Plug (5): For right reverse EPC valve

measuring instruments and return the
removed parts.
30-120 6 D31/37-22
Testing and adjusting HST oil pressure SEN04503-01
Adjusting 4) After finishing adjustment, check that the

a The HST main circuit pressure and the HST HST charge circuit pressure is normal
pump EPC valve output pressure cannot be according to the measurement procedure
adjusted. described above.
1. Adjusting HST charge circuit pressure 2. Adjusting HST charge circuit pressure (on
(on oil cooler bypass valve side) motor side)
a If the HST charge circuit pressure (only a If the HST charge circuit pressure (only
when the HST is in neutral) is abnormal, when traveling) is abnormal, adjust charge
adjust charge safety valve (6) of the oil relief valve (9) of the HST motor according
cooler bypass valve according to the fol- to the following procedure.
lowing procedure. a When adjusting charge relief valve (9) of
a When adjusting charge safety valve (6) of the HST pump, remove the HST motor
the oil cooler bypass valve, remove the covers (right and left).
cooling core undercover.
4 Undercover of cooling core: 15 kg
1) Fixing adjustment screw (10), loosen lock-

nut (11).
1) Fixing adjustment screw (7), loosen lock- 2) Turn adjustment screw (10) to adjust the
nut (8). pressure.
2) Turn adjustment screw (7) to adjust the
a If the adjustment screw is
pressure.
a If the adjustment screw is q turned to the right, the pressure
q turned to the right, the pressure rises.
q turned to the left, the pressure
rises.
q turned to the left, the pressure lowers.
lowers. a Quantity of adjustment per turn of
a Quantity of adjustment per turn of adjustment screw: Approx. 1.02 MPa
adjustment screw: Approx. 1.55 MPa {Approx. 10.4 kg/cm2}
{Approx. 15.38 kg/cm2} 3) Fixing adjustment screw (10), tighten lock-
3) Fixing adjustment screw (7), tighten locknut (11).
nut (8). 3 Locknut:
3 Locknut: 58.8 – 78.5 Nm {6 – 8 kgm}
58.8 – 78.5 Nm {6 – 8 kgm}
D31/37-22 30-120 7
4) After finishing adjustment, check that the

HST charge circuit pressure is normal
according to the measurement procedure
described above.
3. Initializing HST pump EPC valve

The HST pump EPC valve does not need to be
adjusted. If it is replaced, however, initialize the
related items in the tuning mode of the monitor
panel.
q Tuning code (When adjusting while track
shoe is driven idle)
1] 3001: F-PUMP LINE
2] 3002: R-PUMP LINE
q Tuning code (When adjusting while
machine is traveling actually)
1] 3003: F-PUMP RUN1
2] 3004: R-PUMP RUN1
3] 3005: F-PUMP RUN2
4] 3006: R-PUMP RUN2
30-120 8 D31/37-22
Measuring solenoid valve output oil pressure SEN04503-01
Measuring solenoid valve output a The output pressure of the parking

oil pressure 1
brake solenoid valve can be mea-
sured with the “Real-time monitoring
Necessary tools mode” of the monitor panel.
c i a l f u n c t i o n s o f m o n i t o r pa n e l
799-101-5002 Hydraulic tester (EMMS)”.
1
790-261-1204 Digital hydraulic tester q Controller: HST
799-401-3100 Adapter q Monitoring code:
L 2 91902-BRAKE PRESS
799-401-3200 Adapter
799-101-5230 Nipple
3
07002-11423 O-ring

a Measure the solenoid valve outlet pressure

under the following condition.
1. Preparation work
a If the pressures in the parking brake sole-
noid valve and slow brake solenoid valve
are not measured simultaneously, the
operation cannot be checked.
k Turn the starting switch ON, set the
work equipment lock lever in the FREE
position, and lower the blade to the
ground. Move the blade control lever
until it is not held in the FLOAT posi-
tion to release the residual pressure in
the accumulator. After the residual
pressure is released, set the work
equipment lock lever in the LOCK posi-
tion and turn starting switch OFF.
k Loosen the oil filler cap of the hydrau-
lic tank slowly to release the residual
1) Remove the inspection cover at the floor.
2) Disconnect solenoid valve outlet hoses
(2), (3), (4) and (5) of the circuit to be mea-
sured or remove oil pressure pickup plug
(6) from the valve block (1).
q Hose (2): Right HST motor EPC valve
q Hose (3): Left HST motor EPC valve
q Hose (4): Parking brake solenoid valve
q Hose (5): Work equipment lock solenoid
valve
q Plug (6): Slow brake solenoid valve
D31/37-22 30-120 9
SEN04503-01 Measuring solenoid valve output oil pressure
3) If the hoses are disconnected, insert 2. Measuring Right HST motor EPC valve and
adapters L2 and connect the hoses again. Left HST motor EPC valve
4) Install nipple [1] of hydraulic tester L1 or k Since the machine will be stopped and
nipple L3 to the plug hole and connect it to driven actually to measure the right
oil pressure gauge [2]. HST motor EPC valve and left HST
a Use the oil pressure gauge of 6 MPa motor EPC valves, work on a flat place
{60 kg/cm2}. where there is not an obstacle.
a The figure shows the measuring 1) Start the engine and set the travel mode in
instruments installed to the outlet the quick shift mode, then set the reverse
hose of work equipment lock solenoid speed setting “B”.
valve. 2) While running the engine at high idle,
change the travel speed and measure the
solenoid valve output pressure.
a If the output pressure is as shown in
Table 1, the solenoid valve is normal.
removed parts.
4) Initialization of HST motor EPC valve
If the EPC valve is replaced, initialize the
items related to it in the tuning mode of the
monitor panel. The EPC valve does not
need to be adjusted, however, in this
case.
(EMMS)”.
q Tuning code: 3024-MOTOR LINE
3. Measuring parking brake solenoid and slow

brake solenoid
operate the parking brake lever and brake
pedal and measure the solenoid valve out-
put pressure.
a The relationship between the output
pressure and operating states of the
solenoids is shown in Table 2.
removed parts.
30-120 10 D31/37-22
Measuring solenoid valve output oil pressure SEN04503-01
Table 1. Output pressures of right HST motor EPC valve and

left HST motor EPC valve (when normal)
Travel speed and Output pressure of right HST motor EPC valve
Travel mode
travel condition and left HST motor EPC valve
Stopped or traveling 1st 0 MPa {0 kg/cm2}
Quick shift mode Traveling in 2nd 1.47 ± 0.49 MPa {15 ± 5 kg/cm2}
Traveling in 3rd 2.16 ± 0.49 MPa {22 ± 5 kg/cm2}
Table 2. Output pressures of parking brake solenoid valve and slow brake solenoid valve
(when normal and abnormal)
Parking brake Output pressure of parking Output pressure of slow
Brake pedal Condition of each solenoid
lever brake solenoid valve brake solenoid valve
3.23 ± 0.49 MPa 3.23 ± 0.49 MPa
Both are normal
{33 ± 5 kg/cm2} {33 ± 5 kg/cm2}
0 MPa 3.23 ± 0.49 MPa Parking brake has trouble
{0 kg/cm2} {33 ± 5 kg/cm2} (Sticking, etc.)
FREE Released
Slow brake has trouble
0 MPa 0 MPa (Sticking, etc.).
{0 kg/cm2} {0 kg/cm2} or charge pressure is
abnormal
0 MPa 0 MPa
Both are normal
{0 kg/cm2} {0 kg/cm2}
LOCK Pressed (fully)
0 MPa 3.23 ± 0.49 MPa Slow brake has trouble
{0 kg/cm2} {33 ± 5 kg/cm2} (Sticking, etc.)
a The operation state (ON/OFF) of the solenoid valve can be checked in the monitoring mode of the mon-
itor panel (For the operating method, see “Special functions of monitor panel (EMMS)”).
q Controller: HST
q Monitoring code: 40914 D-OUT
[10]: Parking brake solenoid valve: ON
[11]: Slow brake solenoid valve: ON
(Reference: Output from HST controller to the slow brake solenoid valve is always “ON”)
4. Measuring work equipment lock solenoid

operate the work equipment lock lever and
measure the output pressure of the sole-
noid valve.
a The relationship between the output
pressure and operation of the sole-
noid valve is shown in Table 3.
removed parts.
Table 3. Output pressure of work equipment lock solenoid valve (Normal values)
Work equipment lock lever Output pressure of work equipment lock solenoid valve
Lock 0 MPa {0 kg/cm2}
Free 3.23 ± 0.49 MPa {33 ± 5 kg/cm2}
Stop engine with lever in free position and
Decreases gradually from 3.23 MPa {33 kg/cm2}.
turn starting switch ON immediately
D31/37-22 30-120 11
SEN04503-01 Testing travel deviation
Testing travel deviation 1
a Test the travel deviation under the following q Controller: HST

condition. q Monitoring code: 52503-HST L PRESS
q HST oil (Hydraulic oil) temperature: Within q Monitoring code: 52501-HST R PRESS
q Test place: Hard and even ground of con-
crete, etc.
1. Start the engine and raise the blade to about

300 mm above the ground and set the
machine in the measuring posture.
2. Set the travel speed to the 1st in the quick shift

mode.
3. After running up for 10 m with the engine

speed at high idle, measure the deviation in
the travel of 20 m.
a While measuring the travel deviation,
check the HST main circuit pressures on
the right and left sides.
30-120 12 D31/37-22
Adjusting parking brake lever SEN04503-01
Adjusting parking brake lever 1
a If any part related to the parking brake lever 4. Check that limit switch (5) operates 2.5 – 3 mm
was removed and installed or replaced, adjust when parking brake lever (1) is operated.
the parking brake lever according to the follow- q When lever is lock position (B):
ing procedure. Switch is ON
q When lever is free position (A):
1. Set parking brake lever (1) in free position (A) Switch is OFF
and adjust installed height (b) of stopper bolt
(2) so that dimension (a) of lever (1) will be a The operating condition (ON/OFF) of limit
30.7 mm. switch (5) can be checked in the “real-time
q Standard installed height (b) of stopper monitoring mode” of the monitor.
bolt = 4 mm a For the operating method, see “Special
2. Set parking brake lever (1) in lock position (B) q Controller: HST
and adjust installed height (c) of stopper bolt q Real-time monitoring code:
(3). 40911-D-IN--8-----15
q Standard installed height (c) of stopper 40912-D-IN-16-----22
bolt = 4 mm
3. Set parking brake lever (1) in free position (A)

and adjust clearance (d) between lever (4) and
2 limit switches (5).
q Clearance (d) between lever and limit
switch = 0 mm
a When adjusting, do not operate the limit
switch.
D31/37-22 30-120 13
SEN04503-01 Adjusting parking brake lever
If the parking brake lever is adjusted normally,

the following is displayed.
30-120 14 D31/37-22
Simple brake performance test procedure SEN04503-01
Simple brake performance test

procedure 1
a Perform the simple brake performance test

under the following condition.
q HST oil temperature (Hydraulic oil temper-
ature): Within operating range (40 – 60°C)
k Since the test will be carried out while the
machine is traveling, work in a sufficiently
wide place so that you can avoid an acci-
dent even if there is a trouble.
1. Start the engine and raise the blade to about

300 mm above the ground and set the
machine in the inspection posture.
2. Set the parking brake lever in the Free position

and set the gear speed to the 1st.
3. Run the engine at high idle, set the PCCS

lever in the forward position, and travel the
machine straight.
4. While the machine is traveling, press the brake

pedal and check the braking condition of the
machine.
a If the machine stops securely, the brake is
normal.
D31/37-22 30-120 15
SEN04503-01 Adjusting brake pedal
Adjusting brake pedal 1
a When adjusting the brake pedal, remove the 3) Adjust (Rotate) the installed position of the
dashboard cover, dashboard undercover and potentiometer so that the brake pedal
pedal assembly. potentiometer voltage will be the specified
Place the removed pedal assembly on the floor voltage when brake pedal (1) is pressed to
and keep connect the wiring harness connec- the stroke end.
tor between floor and pedal. q BRAKE PEDAL VOLTAGE:
3.87 ± 0.10 V
1. Adjusting brake pedal potentiometer 4) Adjust installed dimension (b) of stopper
1) Turn the starting switch ON and change (2) so that brake pedal potentiometer volt-
the monitor for display of the brake pedal age will be the specified voltage when
potentiometer voltage in the “real-time brake pedal (1) is in neutral
monitoring mode”. q BRAKE PEDAL VOLTAGE:
q Controller: HST 2.08 ± 0.10 V
q Monitoring code: q Dimension (b) = 37.0 mm (Reference
50400-BRAKE PEDAL value)
a For the operating method, see “Spe- 5) Check that the brake pedal potentiometer
cial functions of monitor panel voltage is the specified voltage when
(EMMS)”. brake pedal (1) is at 2-stage spring oper-
2) Adjust stopper (2) temporarily so that ating point (d). If not, return to adjustment
pedal height (a) will be the specified step 2).
dimension when brake pedal (1) is in neu- a 2-stage spring operating point (d) is
tral. the position where effort of a brake
q Dimension (a) = 258 mm pedal increases (148N{15.1kg} o
211N {21.5kg} [Reference value]) at
the time of operation greatly.
q BRAKE PEDAL VOLTAGE:
3.42 ± 0.18 V
30-120 16 D31/37-22
Adjusting brake pedal SEN04503-01
2. Adjusting proximity switch 2) The relationship between the position and

1) Adjust clearance (c) between proximity stroke of the brake pedal is shown in Table 1.
switch (3) and brake pedal (1).
q Clearance (c) = 2 ± 0.5 mm Table 1
2) Check that the lamp in proximity switch (3) Brake pedal Brake pedal stroke
lights up when brake pedal (1) is between Released 0 – 10%
the neutral position and 2-stage spring
2-stage spring operat-
operating point (d). 60 – 90%
ing point (d)
3) Check that the lamp in proximity switch (3)
does not light up when brake pedal (1) is Pressed (Fully) 90 – 100%
pressed to the stroke end.
3. Measuring brake pedal pressing effort

1) Press the brake pedal with the foot to
check that it operates smoothly.
2) If the brake pedal does not operate
smoothly, supply grease through grease
fitting (4) and apply grease to large spring
(5) and small spring (6).
2 Grease fitting (4): Grease (G2-LI)
2 Large spring (5) and small spring (6):
Grease (G2-LI)
3) Using push-pull scale, measure the press-
ing effort of the brake pedal at 2-stage
spring operating point (d).
q Pressing effort at 2-stage spring oper-
ating point (d): 148 N {15.1 kg}
4) Using push-pull scale A, measure the full-
stroke pressing effort of the brake pedal.
q Full-stroke pressing effort:
234 N {23.8 kg}
4. Work after finishing measurement

After finishing all adjustment, return the
removed parts and perform the related initial
adjustments in the “Tuning mode” of the moni-
tor panel.
q Tuning code: 0005-BRAKE N-SET
q Tuning code: 3007-BRAKE END
5. Testing brake pedal potentiometer

a If the initial adjustment was performed,
turn the starting switch OFF before start-
ing the measurement.
1) Turn the starting switch ON and change
the monitor for display of the brake pedal
stroke in the “real-time monitoring mode”.
q Controller: HST
q Monitoring code:
50401-BRAKE PEDAL
D31/37-22 30-120 17
SEN04503-01 Method of releasing parking brake (Procedure for emergency escape)
Method of releasing parking brake a After finishing adjustment, open the

(Procedure for emergency escape)1 valve of the volume pump to release
the residual pressure in the pump.
Necessary tools a After finishing adjustment, remove the
plug (R1/4) and connect the hose and
Symbol Part No. Name quick coupler [5].
1 790-190-1500 Pump assembly
M 799-101-5220 Nipple 2. Opening HST pump
2 a If the machine is towed after the parking
07002-11023 O-ring
brake is released, the HST motor works
as a pump to make the oil flow. Accord-
a If the engine cannot be started and the parking
ingly, open the forward travel circuit and
brake of the HST motor cannot be released,
reverse travel circuit of the HST pump.
k Fit a block to the track shoe securely.
release it according to the following procedure.
1) Remove the undercover of the HST pump.
4 Undercover: 25 kg
1. Testing pump assembly M1
k If the following work is performed while
2) Loosen locknuts (3) of towed valve (1) for
the pressure of the pump assembly is
the left pump towed valve (2) for the right
abnormal, the brake piston of the HST
pump, and then loosen plugs (4) by 2
motor may be damaged. Accordingly,
turns.
be sure to test the pump assembly.
3) Tighten locknuts (3) lightly and secure
1) Check that pump assembly M1 is con-
them so that they will not come off when
nected in the following order. the machine is towed.
[1]: Volume pump
[2]: Relief valve
[3]: T-piece
[4]: Oil pressure gauge (6 MPa {60 kg/cm2})
[5]: Hose and quick coupler
3. Connecting pump assembly M1

k Loosen the oil filler cap of the hydrau-
lic tank slowly to release the residual
1) Remove the inspection cover of the floor,
2) Remove the hose and quick coupler [5]
and install pump assembly M1 onto the
and block the volume pump [1] side with a
floor frame.
plug (R1/4).
2) Loosen plug (5) and bolt (6) of the sole-
3) Close the valve of volume pump [1] and
noid valve and remove lock plate (7) and
operate the handle to adjust relief valve [2]
then tighten plug (5) to the end. Tighten
so that it will relieve at the specified pres-
bolt (6) lightly so that it will not come off
sure.
when the machine is towed.
q Specified relief pressure:
3) Remove plug (8) and install nipple M2.
2.7 – 3.1 MPa {28 – 32 kg/cm2}
30-120 18 D31/37-22
Method of releasing parking brake (Procedure for emergency escape) SEN04503-01
4) Connect the quick coupler at the end of 2) Remove the block of the track shoe and
pump assembly M1 to nipple M2. tow the machine at speed lower than 2
km/h.
k If the supply pressure lowers
below 1.5 MPa {15 kg/cm 2 }, the
parking brake is not released com-
pletely (it works partially). Accord-
ingly, keep checking oil pressure
gauge [4] while towing the
machine. If the oil pressure lowers,
operate the handle to maintain the
oil pressure in the range of 1.5 –
3.1 MPa {15 – 32 kg/cm2}.
3) After towing the machine to a safe place,
open the valve of volume pump [1] to
release the pressure supplied to the park-
4. Releasing parking brake and towing ing brake circuit.
machine
1) Close the valve of volume pump [1] and 5. Remedy to take after towing machine
operate the handle to supply oil to the a After towing the machine to a safe place,
parking brake circuit. take the following remedy without fail to
a Increase the supply pressure until return the machine to the condition before
relief valve [2] relieves once. towing.
a Check that the supply pressure is 1) Remove pump assembly M1 and nipple
lower than the specified relief pres- M2 and install plug (8).
sure with oil pressure gauge [4]. 2) Loosen plug (5) of the 5-spool valve and
q Specified relief pressure: return lock plate (7) and then tighten plug
2.7 – 3.1 MPa {28 – 32 kg/cm2} (5) and bolt (6) to fix lock plate (7).
k If the supply pressure rises above 3) Install the inspection cover to the floor.
the specified relief pressure, the 4) Return plugs (4) of towed valves (1) and
brake piston of the HST motor may (2) of the HST pump and secure them with
be damaged. Accordingly, if the locknuts (3).
supply pressure exceeds the spec- 3 Plug and locknut:
ified relief pressure, open the valve 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
of the volume pump immediately 5) Install the undercover of the HST pump.
and adjust the relief pressure by 4 Undercover: 25 kg
the method in 1.
a If the supply pressure becomes the
specified relief pressure, the parking
brake is released.
D31/37-22 30-120 19
SEN04503-01 Testing and adjusting idler clearance
Testing and adjusting idler 3. Tighten mounting bolt (3) of guide plate (2).
clearance 1
Testing
a If the idler vibrates laterally or it slants so much
that the track shoe comes off or is worn
unevenly, the guide plate may be worn. In this
case, check according to the following proce-
dure.
1. Drive the machine forward slowly by 1 – 2 m

on a flat ground, and then stop it.
2. Measure clearance (a) between track frame (1)

and guide plate (2).
a Measure clearance (a) on inside and out-
side of the right and left idlers.
q Clearance limit (a): Max. 4 mm
Adjusting
a If the clearance exceeds the limit, adjust it
1. Loosen mounting bolt (3) of guide plate (2).

a Since 2-piece shims are used, the guide
plate does not need to be removed.
2. Remove the shims between guide plate (2)

and support (4) and adjust clearance (a).
q Adjusted clearance (a): 0.5 – 1.0 mm
q (Thickness shim) x (quantity for new
machine):
1.0 mm x 5 pieces (for each place)
30-120 20 D31/37-22
Testing and adjusting track shoe tension SEN04503-01
Testing and adjusting track shoe

tension 1
Testing
1. Drive the machine slowly on a level place, and
then stop it.
a Do not apply the brake when stopping.
2. Place straight steel bar [1] between the idler

and carrier roller and measure clearance (a)
between the bottom of the steel bar and shoe
grouser.
a As the steel bar, use an L-shape steel, etc.
which will be deflected less.
q Standard clearance (a): 20 – 30 mm 2. When tension is low
1) Using a grease pump, add grease through
grease fitting (2).
2) After adjusting, check the tension again
according to the procedure described
above.
Adjusting
a If the track shoe tension is abnormal, adjust it
a When adjusting the track shoe tension, remove
the outer covers from the track frames.
a You may supply grease until distance (b)
1. When tension is too high between the idler guide and frame end is
1) Loosen valve (1) slowly to discharge the 20 mm. If the tension is still low, the pin
grease. and bushing are worn excessively. In this
k Since the valve may jump out case, turn over or replace the pin and
because of the high-pressure bushing.
grease, do not loosen it more than
1 turn.
2) If the grease does not come out, move the
machine forward and in reverse slowly.
3) Tighten valve (1).
3 Valve: 58.8 – 88.2 Nm {6 – 9 kgm}
4) After adjusting, check the tension again
according to the procedure described
above.
D31/37-22 30-120 21
SEN04503-01 Testing work equipment oil pressure
Testing work equipment oil 3. Connect oil pressure gauge [1] of hydraulic
pressure 1
tester N1 to nipple N2.
a Use the oil pressure gauge of 40 MPa
{400 kg/cm2}.
Necessary tools

1
N
799-101-5200 Nipple
2
07002-11023 O-ring

k Before raising the blade, check that the 4. While running the engine at high idle and
side cover on the left side of the engine and relieving the blade, lift and tilt cylinders at each
front cover are closed. stroke end, measure the work equipment pres-
a The control valve piping etc. of the actual sure.
machine may be different from the pictures a When the above operation is performed,
because of the difference in the specifications the relief pressure of the main relief valve
of the optional devices etc. at the control valve section is displayed.
a Since the angle cylinder has a piston
Testing valve, its relief pressure cannot be mea-
a Test the work equipment pressure under the sured.
following condition.
q HST oil temperature (Hydraulic oil temper-
ature):
k Loosen the oil filler cap of the hydraulic
tank slowly to release the residual pressure
in the hydraulic tank.
1. Open the inspection cover on the fuel tank

side.
2. Remove the work equipment pressure pickup

plug from control valve (1) and install nipple
N2.
30-120 22 D31/37-22
Testing work equipment oil pressure SEN04503-01
Adjusting
a If the oil pressure is abnormal, adjust main
relief valve (1) of the control valve according to
the following procedure.
1. Remove the panel on the right side of the oper-

ator seat (under the blade control lever).
2. While fixing adjustment screw (2) of main relief

valve (1), loosen locknut (3).
3. Rotate adjustment screw (2) to adjust the pres-

sure.
a If the adjustment screw is
q turned to the right, the pressure
increases.
q turned to the left, the pressure
decreases.
a Change of pressure by 1 turn of adjust-
ment screw:
Approx. 12.6 MPa {128 kg/cm2}
4. While fixing adjustment screw (2), tighten lock-

nut (3).
3 Locknut: 59 – 79 Nm {6 – 8 kgm}
5. After finishing adjustment, test the oil pressure

again according to the “Testing” procedure.
D31/37-22 30-120 23
SEN04503-01 Testing work equipment PPC valve output oil pressure
Testing work equipment PPC

valve output oil pressure 1
Necessary tools

1
P 790-261-1204 Digital hydraulic tester
2 799-401-3100 Adapter

k Take care not to touch a hot part when 3. Install adapter P2 to the disconnected hose
installing or removing a testing tool. and connect again.
4. Install nipple (2) of hydraulic tester P1 to
adapter P2 and connect oil pressure gauge [1].
a Use the oil pressure gauge of 6 MPa {60
k Turn the starting switch ON, set the work
kg/cm2}.
equipment lock lever in the Free position,
and lower the blade to the ground. Move
the blade control lever until it is not held in
the Float position to release the residual
pressure in the accumulator. After the
residual pressure is released, set the work
equipment lock lever in the Lock position
and turn starting switch OFF.
a The control valve piping etc. of the actual
machine may be different from the pictures
because of the difference in the specifications
of the optional devices etc.
5. Start the engine and set the work equipment
a Before measuring the output pressure of the
lock lever in the Free position.
work equipment PPC valve, check that the out-
put pressure of the work equipment lock sole- 6. While running the engine at high idle, operate
noid valve is normal. the circuit to be measured and measure the oil
a Test the output pressure of the work equipment pressure.
PPC valve under the following condition. a When measuring, set the lever to the
q HST oil temperature (Hydraulic oil temper- stroke end.
ature): a Measure at the Lower position and Float
Within operating range (40 – 60°C) position on the lowering side of the blade.
1. Open the inspection cover on the fuel tank
side.
2. Disconnect PPC valve output hose (1) to be

measured.
a For the circuit to be measured, see “PPC
circuit connection diagram” on the follow-
ing page.
a Since the adapter cannot be connected to
the quick coupler on the control valve (2)
side, disconnect the PPC valve (3) side.
30-120 24 D31/37-22
Testing work equipment PPC valve output oil pressure SEN04503-01

suring instruments and return the removed
parts.
PPC circuit connection diagram

a The position of PPC valve ports are shown
from the bottom.
D31/37-22 30-120 25
SEN04503-01 Adjusting play of work equipment PPC valve
Adjusting play of work equipment

PPC valve 1
a If the play of the blade control lever in the lifting

and tilting directions is large, adjust it accord-
ing to the following procedure.
k Turn the starting switch ON, set the work
equipment lock lever in the Free position,
and lower the blade to the ground. Move
the blade control lever until it is not held in
the Float position to release the residual
pressure in the accumulator. After the
residual pressure is released, set the work
equipment lock lever in the Lock position
and turn starting switch OFF.
1. Remove the work equipment PPC valve from

the machine.
2. Remove bellows (1).
3. Fixing plug (2), loosen cap (3).
4. Tighten plug (2) to adjust the play of the lever.

a At this time, take care not to move piston
(4).
a Play of lever:
Max. 3 mm (at center of lever knob)
a When cap (3) is tightened, the play of the
lever is reduced a little. Count in this
reduction, when adjusting.
5. Fixing plug (2), tighten cap (3).

3 Cap: 98 – 127 Nm {10 – 13 kgm}
6. Install bellows (1).
7. Install the work equipment PPC valve to the

machine.
a After installing the blade control lever,
check that its play is proper.
30-120 26 D31/37-22
Adjusting work equipment lock lever SEN04503-01
Adjusting work equipment lock lever 1
a If any part related to the work equipment lock

lever was removed and installed or replaced,
adjust the work equipment lock lever according
1. Adjust rod (1) to standard dimension (a).

q Standard dimension (a) between rod pins:
195 mm (Reference value)
2. Set work equipment lock lever (2) in lock posi-

tion (B) and adjust clearance (b) between lever
(3) and limit switch (4).
q Clearance (b) between lever and limit
switch = 0 mm
q When adjusting, do not operate the limit
switch.
3. Check that limit switch (4) operates 2.5 – 3 mm

when work equipment lock lever (1) is oper-
ated.
q When lever is lock position (B): Switch is
OFF
q When lever is free position (A): Switch is
ON
D31/37-22 30-120 27
SEN04503-01 Testing internal leakage of work equipment cylinder
Testing internal leakage of work

equipment cylinder 1
Necessary tool

Commercially
Q Measuring cylinder
available

side cover on the left side of the engine and 4) While running the engine at high idle,
front cover are closed. operate the blade control lever to the
a Test the internal leakage of the work equip- Lower position and relieve the lift cylinder.
k Take care not to operate the lever
ment cylinder under the following condition.
q HST oil temperature (Hydraulic oil temper- to the Raise position.
ature): 5) Start measuring the oil leakage 30 sec-
Within operating range (40 – 60°C) onds after relieving is started and mea-
sure for 1 minute.
1. Testing leakage in blade lift cylinder 6) After finishing measurement, return the
1) Start the engine and ride onto a wooden removed parts.
block etc. with the track shoe (on the idler
side) to raise the front side of the machine. 2. Testing leakage in blade tilt cylinder
k Raise the front side of the machine 1) Start the engine and raise the blade to
to a height where the blade does about 1 m above the ground.
not reach the ground even if the 2) Extend the tilt cylinder to the right tilt
blade lift cylinder is extended to stroke end and stop the engine.
the lowering stroke end. k Turn the starting switch ON and set
k Set the parking brake lever in the the work equipment lock lever in
Lock position and put a block at the FREE position, and move the
the rear of the track shoe. blade control lever in the RIGHT
2) Extend the lift cylinder to the lowering TILT position to release the resid-
stroke end and stop the engine. ual pressure on the head side of
k Turn the starting switch ON and set the tilt cylinder.
k Loosen the oil filler cap of the
the work equipment lock lever in
the Free position, and move the hydraulic tank slowly to release the
blade control lever in the lower residual pressure in the hydraulic
position to release the residual tank.
pressure on the head side of the lift 3) Remove the cylinder cover, disconnect
cylinder. hose (2) on the head side, and stop the
Afte r t he re sidual pres sure is hose with a plug.
released, set the work equipment a Plug: 07376-70210 (For #02)
lock lever in the Lock position and
turn starting switch OFF.
hydraulic tank slowly to release the
residual pressure in the hydraulic
tank.
3) Remove the cylinder cover on the side to
be measured, disconnect hose (1) on the
head side, and stop it with a plug.
a Plug: 07376-70422 (For #04)
30-120 28 D31/37-22
Testing internal leakage of work equipment cylinder SEN04503-01

operate the blade control lever to the
Right position and relieve the tilt cylinder.
k Take care not to operate the lever
to the Left tilt position.
5) Start measuring the oil leakage 30 sec-
onds after relieving is started and mea-
sure for 1 minute.
6) After finishing measurement, return the
removed parts.
3. Testing leakage from blade angle cylinder

q Since the angle cylinder has a piston
valve, leakage cannot be tested.
a A test stand is necessary for testing.
D31/37-22 30-120 29
SEN04503-01 Releasing residual pressure in hydraulic circuit
Releasing residual pressure in

hydraulic circuit 1

a Before removing a hydraulic device or discon-
necting a piping of the HST circuit or work
equipment circuit, release the residual pres-
sure according to the following procedure.
1. Stop the machine on a level and hard place.
2. Lower the blade to the ground and stop the

engine.
3. After the engine stops, turn the starting switch

ON again.
4. Set the work equipment lock lever in the Free

position.
5. Operate the blade control lever to the stroke

end in each direction.
6. When the blade control lever is not held at the

Float position any more, set the work equip-
ment lock lever in the Lock position and turn
the starting switch OFF.
7. Loosen the oil filler cap (1) of the hydraulic

tank slowly to release the residual pressure in
the hydraulic tank.
30-120 30 D31/37-22
Bleeding air from hydraulic circuit SEN04503-01
Bleeding air from hydraulic circuit1 3. Bleeding air from HST pump servo section
k Since the machine will travel forward
k Stop the machine on a flat place and lower and in reverse during the following
k
work, stop the machine in a place
Before raising the blade, check that the where it can travel.
side cover on the left side of the engine and 1) Warm up the engine until the HST oil tem-
front cover are closed. perature (hydraulic oil temperature)
a If any hydraulic equipment/piping of the HST
reaches 80?.
circuit or work equipment circuit was removed/ a Air is bled more effectively when the
disconnected and installed/connected, bleed HST oil temperature (hydraulic oil
air according to the following procedure after temperature) is high.
finishing the work. 2) Set the shift mode switch in the variable
a Before and after bleeding air, check that the oil shift mode position.
level in the hydraulic tank is normal and no 3) While the 1st gear speed is selected,
bubbles are contained in the oil. press the shift-up switch twice.
4) Set the reverse travel speed set switch to
1. Bleeding air from HST pump the left once to set the reverse travel
1) Remove the inspection cover of the floor. speed to the forward travel speed.
2) Remove the oil filler cap of the hydraulic 5) Set the parking brake lever in the FREE
tank under it.
position and set the PCCS lever in the for-
ward and reverse travel positions at least
hydraulic tank slowly to release the 20 times.
residual pressure in the hydraulic q Forward o Neutral o Reverse o
tank. Neutral
3) Loosen air bleeder (1) at the top of the a Repeat the operation cycle of setting
HST pump and check that oil oozes out. the PCCS lever in the forward and
q If oil oozes out, air has been bled. reverse positions at least 20 times.
4) Tighten air bleeder (1).
5) Tighten the filler cap of hydraulic oil tank. 4. Bleeding air from cylinders
1) While running the engine at low idle,
extend and retract each cylinder to before
each stroke end 4 – 5 times.
a Stop the piston rod of each cylinder
about 100 mm before the stroke end
to avoid relieving.
2) Keep running the engine at low idle and
extend and retract each cylinder to each
stroke end 3 – 4 times.
3) Keep running the engine at high idle and
extend and retract each cylinder to each
stroke end 4 – 5 times.
5. Operating machine
2. Starting engine 1) After bleeding air, stop the engine and
Start the engine and run it at low idle for 10 leave it for 5 minutes.
minutes. a By this operation, the bubbles in the
oil in the hydraulic tank are dis-
charged.
2) Check for oil leakage. If no oil is leaking,
operate the machine.
D31/37-22 30-120 31
SEN04503-01 Adjusting play of blade center ball
Adjusting play of blade center ball1 7. Angle and tilt the blade and check that no
abnormal noise is heard and the blade moves
a After the blade is disassembled and assem- smoothly.
bled or transported, adjust the play of the cen- a If the blade does not move smoothly or
ter ball according to the following procedure. abnormal noise is heard, return to step 2
and select shims (5) again.
1. Install cap (1) and tighten mounting bolts (2)
and (3) without inserting any shim. 8. Tighten mounting bolts (2) and (3).
3 Cap mounting bolt:
2. Measure clearance (a) between cap (1) and 455 – 565 Nm {46.5 – 58 kgm}
blade (4).
3. Calculate the thickness of shims (5) to be

inserted from measured clearance (a), and
then select shims to be used.
q Thickness of shims to be inserted =
(Measured clearance (a)) + (0.2 to 1.2
mm)
q Thickness of provide shims: 1.0 mm, 2.0
mm
q Standard shim thickness (Reference):
8 mm (2 pieces of 1.0 mm shim and 3
pieces of 2.0 mm shim)
4. Loosen mounting bolt (2) and remove mount-

ing bolt (3).
5. Insert selected shims (5).
6. Tighten the mounting bolts (2) and (3) tempo-

rarily.
30-120 32 D31/37-22
Procedure for testing diodes SEN04503-01
Procedure for testing diodes 1
a Check an assembled-type diode (8 pins) and

independent diode (2 pins) in the following
manner.
a The conductive directions of the assembled-
type diode are indicated on the surface of the
diode as shown in the following figure.
2. When using analog type circuit tester

1) Switch the testing mode to resistance
range.
2) Apply the leads of the tester as explained
below and check the movement of the
pointer.
1] Put the red probe (+) of the test lead
to the anode (P) and the black probe
a The conductive directions of the single diode is (–) to the cathode (N) of diode.
indicated on the surface of the diode as shown 2] Apply the red (+) lead of the tester to
in the following figure. the cathode (N) side of the diode and
apply the black (–) lead to the anode
(P) side.
3) Determine if a specific diode is good or no
good by the way the pointer swings.
q With the connection 1] above, the
pointer is not moved. It swings, how-
ever, wh en the conn ectio n 2 ] is
employed: Normal (However, magni-
tude of the pointer's move (indicating
the resistance value) varies depend-
ing on the given tester model and the
measurement range selected).
q The pointer swings with both the con-
nections of 1] and 2]: Defective (Inter-
nal short circuit)
1. When using digital type circuit tester q The pointer does not swing with both
1) Switch the testing mode to diode range the connections of 1] and 2]: Defec-
and confirm the indicated value. tive (Internal breaking of wire)
a Voltage of the battery inside is dis-
played with conventional testing mode.
2) Put the red probe (+) of the test lead to the
anode (P) of and the black probe (–) to the
cathode (N) of diode, and confirm the indi-
cated value.
3) Determine acceptability of the diode from
the indicated value.
q Indicated value remains unchanged:
Conduction is absent (Failure)
q The indicated value changes: The
diode has conductivity (Normal) (See
a below.)
a A value between 460 to 600 is indi-
cated for silicon diodes.
D31/37-22 30-120 33
SEN04503-01 Preparation work for troubleshooting for electrical system
Preparation work for troubleshooting 6) Insert the diagnostic T-adapters in con-

for electrical system 1
nectors CN-S04 and CN-S03 of monitor
panel (7).
a When carrying out troubleshooting for an elec-
tric circuit related to the monitor panel, HST
controller and KOMTRAX terminal, expose the
related connectors according to the following
procedure.
1. Monitor panel
1) Pull out the starting key (1), remove the 4
mounting bolts (3) of each side of plastic
panel (2), and move plastic panel (2)
toward the operator's seat.
2) Remove the 7 connectors of panel
switches (4) and remove the plastic panel
(2).
3) Remove 7 panel switches (4) from the 7) Insert connectors CN-P1, CN-P2 and CN-
plastic panel (2) and insert them in their P3 and install the monitor panel mounting
respective connectors correctly. bracket (5) with the mounting bolts (6)
temporarily.
2. HST controller
1) Perform steps 1) – 3) for the “monitor
panel”.
2) Insert or connect the diagnostic T-adapt-
ers in connectors CN-ST1, CN-ST2 and
CN-ST3 of HST controller (1).
a If it is difficult to remove and install the
connectors, remove the controller for
the ease of work.
a Since each connector is fixed with a
screw, loosen the screw before dis-
connecting it.
4) Remove 6 mounting bolts (6) of monitor a When returning each connector,
panel mounting bracket (5) and move the tighten its screw to the specified
bracket (5) toward the operator's seat. torque to fix it.
3 Screw: 2.82 Nm {0.288 kgm}
5) Remove connectors CN-P1, CN-P2 and

CN-P3 and remove the monitor panel
mounting bracket (5).
30-120 34 D31/37-22
Preparation work for troubleshooting for electrical system SEN04503-01
3. KOMTRAX terminal a Removal and installation of sensor

1) Remove the operator seat mounting bolts A torque wrench is necessary for removal
and move the operator seat forward. and installation of the boost pressure and
2) Remove console cover (1) on the right temperature sensor.
side of the operator seat.
3) Connect diagnosis T-adapter to connec- 5. Supply pump IMV solenoid (FUEL REGU-
tor G01 of KOMTRAX terminal (3). LATOR)
a If the connector cannot be discon- a Disconnection and connection of connector
nected and connected easily, remove The connector of the supply pump IMV
the KOMTRAX terminal. solenoid has a special locking mecha-
a Since the connector is secured with nism. Disconnect it according to steps (a)
screws, loosen those screws before – (b) and connect it according to steps (c)
disconnecting. – (d) as shown below.
a When connecting the connector again, Disconnection:
tighten its screws to the specified (a) Unlock – (b) Disconnect connector.
torque. Connection:
3 Screw: (c) Connect connector – (d) Lock.
2.2 – 2.8 Nm {0.23 – 0.29 kgm}
6. Common rail pressure sensor (FUEL RAIL

4. Boost pressure and temperature sensor PRESS)
(BOOST PRESS & IMT) a Disconnection and connection of connector
a Disconnection and connection of connector The connector of the common rail pres-
The connector of the boost pressure and sure sensor has a special locking mecha-
temperature sensor has a special locking nism. Disconnect it according to steps (a)
mechanism. Disconnect it according to – (b) and connect it according to steps (c)
steps (a) – (b) and connect it according to – (d) as shown below.
steps (c) – (d) as shown below. Disconnection:
Disconnection: (a) Unlock – (b) Disconnect connector.
(a) Unlock – (b) Disconnect connector. Connection:
Connection: (c) Connect connector – (d) Lock.
(c) Connect connector – (d) Lock.
D31/37-22 30-120 35
SEN04503-01 Preparation work for troubleshooting for electrical system
a Precautions for disconnecting connector 7. Engine coolant temperature sensor (COOL-

The direction of the lock of the connector ANT TEMP)
varies with the tightened position of the a Disconnection and connection of connector
sensor and the lock may be in a direction The connector of the engine coolant tem-
in which it is difficult to reset (on the under- perature sensor has a special locking
side or engine side). mechanism. Disconnect it according to
In this case, pinch the lock in direction (a) steps (a) – (b) and connect it according to
with bent-nose nippers (commercially steps (c) – (d) as shown below.
available), and the lock is reset. Disconnection:
Since the lock clicks when it is reset, dis- (a) Unlock – (b) Disconnect connector.
connect the connector after a click is Connection:
heard. (c) Connect connector – (d) Lock.
a Precautions for connecting connector a Removal and installation of sensor

Take care not to connect the connector A deep socket is necessary for removal
reversely. and installation of the engine oil pressure
Engage lock (e) on the wiring harness switch.
side with triangular notch (f) on the sensor
side (Do not engage lock (e) with square
guide (g) on the opposite side of triangular
notch (f)).
30-120 36 D31/37-22
Preparation work for troubleshooting for electrical system SEN04503-01
8. Ambient pressure sensor (AMBAIR PRES-

SURE)
Engine Ne speed sensor (CRANK SENSOR)
Engine Bkup speed sensor (CAM SENSOR)
Engine oil pressure switch (OIL PRESSURE
SWITCH)
a Disconnection and connection of connectors
The connectors of the ambient pressure
sensor, engine Ne speed sensor, engine
Bkup speed sensor, and engine oil pres-
sure switch have a special locking mecha-
nism. Disconnect them according to steps
(a) – (c) and connect them according to
steps (d) – (f) as shown below.
Disconnection: (a) Slide lever – (b) Unlock –
(c) Disconnect connector.
Connection: (d) Connect connector – (e)
Lock – (f) Slide lever.
a Removal and installation of sensor

A deep socket is necessary for removal
and installation of the engine oil pressure
switch.
D31/37-22 30-120 37
SEN04503-01 How to start operation of KOMTRAX terminal
How to start operation of a For the operating method, see

KOMTRAX terminal 1
“Special functions of monitor panel
(EMMS)”.
In the case where the KOMTRAX terminal has 4) Disconnect ACC connector (2) and wait
already been installed at the plant before ship- for at least 5 seconds, and then go to the
ment: next step.
a Implement the following procedure in the case q ACC connector (2):
where the KOMTRAX terminal has already ACF (female) and ACM (male) [3-pin]
been installed at the plant before shipment (as 5) Check visually that test connector (3) is
standard equipment). connected.
q Test connector (3):
1. Notification of model, model number and TIF (female) and TIM (male) [2-pin]
serial number
Notify the model, model number and serial
number of the machine to the KOMTRAX oper-
ations administrator.
2. Registration of machine
The KOMTRAX operations administrator regis-
ters the machine using a KOMTRAX client per-
sonal computer.
a For the procedure, see “Manual for
KOMTRAX operations administrator”.
a Now the terminal is ready for use.
In the case where the KOMTRAX terminal is

retrofitted on the machine after shipment: 6) Connect ACC connector (2) and keep that
a Implement the following procedure in the case condition for 5 seconds.
where the KOMTRAX terminal is retrofitted q Check that display (b) of the monitor
after shipment of the machine (retrofitted panel or KOMTRAX terminal indi-
machine). cates “–”.
7) Disconnect test connector (3) and keep
1. Sign-up test on machine side that condition for 5 seconds.
1) Move the machine to a place where there 8) Connect test connector (3) again and
is no obstacle above. keep that condition for 5 seconds.
2) Open cover (1) under the armrest on the q If the KOMTRAX terminal detects dis-
right of the operator seat. connection or reconnection of the
connector, dot (a) blinks.
a Complete procedures 6) – 8) in 30
seconds.
Monitor panel
3) Change the display of the monitor panel to

“Real-time monitoring mode” and enter
“KOMTRAX LED display”.
q Controller: KOMTRAX
q Monitoring code: 20300
30-120 38 D31/37-22
How to start operation of KOMTRAX terminal SEN04503-01
KOMTRAX terminal a If [GPS position data detection trou-

ble] is indicated, check if there is any
external abnormality on the GPS
antenna or cable. If there is any
abnormality, repair it and repeat from
procedure 1) again.
a If [Receiving trouble] is indicated,
check if there is any external abnor-
mality on the appearance of the com-
munication antenna or cable. If there
is any abnormality, repair it then
repeat from procedure 1) again.
a If [GPS position data detection trouble
and receiving trouble] is indicated,
check if there is any external abnor-
mality on the GPS antenna or cable
9) Check that display (b) of the monitor panel and communication antenna or cable.
or KOMTRAX terminal is displaying nor- If there is any abnormality, repair it
mally. and repeat from procedure 1) again.
a If the indication is normal, “d”, “0” a If [Network trouble] is indicated,
and “–” are displayed repeatedly on check the display of [LED-C4] refer-
the monitor panel for 30 seconds after ring to “Lamp display of KOMTRAX
8) is completed. terminal”. (If CAN is not recognized,
a Go to the next step if you can check check the CAN harness of the
that the display is “Normal”. KOMTRAX terminal, and then if there
a If the display is “Abnormal”, repeat is any abnormality, repair it and
from procedure 1). repeat from procedure 1) again.)
[A]: Normal
[B]: GPS position data detection trouble
[C]: Receiving trouble
[D]: GPS position data detection trouble and receiv-
ing trouble
[E]: Network trouble
10) Turn the starting switch to the START

position, keep it more than 5 seconds, and
check that the engine does not start.
a If the engine starts or the starting
switch is returned to the OFF position,
repeat from procedure 1).
11) Turn the starting switch to the START
position again and ensure that the engine
starts.
12) Check that display (b) of the monitor panel
or KOMTRAX terminal is indicating nor-
mally.
a Go to the next step if you ensured
that the display is [Normal]. (It takes
from 90 seconds to 15 minutes before
the display turns normal.)
D31/37-22 30-120 39
SEN04503-01 How to start operation of KOMTRAX terminal
13) Disconnect ACC connector (2). 2. Application for the start of use
14) Check that display (b) of the monitor panel a Application for the start of use must be
or KOMTRAX terminal is indicating nor- made only after the sign-up test is fin-
mally in 5 seconds. ished.
a If you checked that the display is 1) Notify to the KOMTRAX operations
[Normal], that is the end of the sign- administrator of the following information
up test. concerning the machine whose sign-up
a If the display shows [Abnormal], test on the machine side is completed.
re p ea t f ro m pr oc ed u re 1 ) a ga i n (1) Information on the machine whose
because the sign-up test has not sign-up test on the machine side is
been completed successfully. completed (Model, model number
and serial number)
(2) Part number and serial number of the
KOMTRAX terminal
(3) Reading of the service meter when
the KOMTRAX terminal was installed
(0.1 h unit)
15) Connect ACC connector (2) and press

buzzer cancel switch [t] to finish the
“KOMTRAX LED display” mode.
16) Stop the engine.
2) The KOMTRAX operations administrator

registers the machine using KOMTRAX
client personal computer.
a For the procedure, see “Manual for
KOMTRAX operations administrator”.
a Now the terminal is ready for use.
30-120 40 D31/37-22
Lamp display of KOMTRAX terminal SEN04503-01
Lamp display of KOMTRAX terminal 1
CPU LED 7-segment and dot for CPU

1. LED-C1 (R signal and ACC signal status) 7. 7-segment (Number of unsent mails)
2. LED-C2 (Engine control output status) 8. Dot (GPS positioning status)
3. LED-C3 (S-NET status and C signal status)
4. LED-C4 (CAN connection status)
5. LED-C5 (Downloading and writing status)
6. LED-C6 (Downloading and writing status)
D31/37-22 30-120 41
SEN04503-01 Lamp display of KOMTRAX terminal
In the KOMTRAX system, various information and processing details are displayed on the LED of the upper
surface of the KOMTRAX terminal. Therefore, if a defect is suspected in the system, perform the following
checks.
q Check of antennas
q Check of terminal LED displays
Application for the start of use and sign-up test on the machine side must be completed in advance in order
to use KOMTRAX system.
If these have not been completed, all of the communication module LEDs are turned OFF. This does not
indicate a trouble, however.
Check of antennas
a Before checking the LED displays, check that there is no abnormality around the communication
antenna and GPS antenna.
q The communication antenna must not be off or damaged.
q The communication antenna cable must not be broken and must be connected to the KOMTRAX termi-
nal normally.
q The GPS antenna must not be off or damaged.
q The GPS antenna cable must not be broken and must be connected to the KOMTRAX terminal nor-
mally.
1. Contents of CPU LED displays

a The LED displays must be checked with the starting switch in the ON or START position or with the
engine started.
No. LED Name/Function Display (*1) Contents of display
ON Starting switch ACC signal: ON, alternator R signal: ON
Starting switch ACC signal Fast blinking Starting switch ACC signal: OFF, alternator R signal: ON
1 LED-C1
and alternator R signal status Slow blinking Starting switch ACC signal: ON, alternator R signal: OFF
OFF Starting switch ACC signal: OFF, alternator R signal: OFF
ON Engine control signal: ON
2 LED-C2 Engine control signal status
OFF Engine control signal: OFF
ON S-NET: Connected, Starting switch C signal: OFF
S-NET connection status and Fast blinking Starting switch C signal: OFF
3 LED-C3
starting switch C signal status Slow blinking (Unused)
OFF S-NET: Disconnected, Starting switch C signal: OFF
ON CAN: Connected, (Fuel sensor: Disconnected)
Fast blinking CAN: Connected, (Fuel sensor: Connected)
4 LED-C4 CAN connection status
Slow blinking CAN: Disconnected, (Fuel sensor: Connected)
OFF CAN: Disconnected, (Fuel sensor: Disconnected)
Downloading and writing mode (Special function of sys-
5 LED-C5 Either is ON
Downloading and writing tem administrator)
status Both are
6 LED-C6 Normal operation mode
OFF
*1: Types and periods of blinking

Fast blinking: Blinking at cycles of about 1 second
Slow blinking: Blinking at cycles of about 4 seconds
a The LED displays can be checked in the “Real-time monitoring mode” of the monitor panel, too.
30-120 42 D31/37-22
Lamp display of KOMTRAX terminal SEN04503-01
2. Contents of CPU 7-segment and dot displays

a The LED displays must be checked with the starting switch in the ON position.
No. Display unit Name/Function Display (*2) Contents of display
Figure indicates number of unsent mails (9 is displayed when
0 – 9: ON number is 9 or larger).
Number of unsent “ON” indicates that terminal is capturing satellite.
7 7-segment mails and satellite
capture status Figure indicates number of unsent mails (9 is displayed when
0 – 9: Fast
number is 9 or larger).
blinking
Fast blinking indicates that terminal has not captured satellite.
ON GPS positioning is completed (Position is recognized *3).
GPS connector
8 Dot GPS positioning is not completed (Position is not recognized
positioning status OFF
*3).
*2: Types and periods of blinking

Fast blinking: Blinking at cycles of about 1 second
Slow blinking: Blinking at cycles of about 4 seconds
*3: Note on GPS positioning status
It may take more than 1 minute from turning on the starting switch to the completion of positioning
even in an outdoor place where radio wave can reach.
Positioning is impossible in areas with extremely weak radio waves or areas beyond the reach of
radio waves.
a The 7-segment and dot displays can be checked in the “Real-time monitoring mode” of the monitor
panel, too.
D31/37-22 30-120 43
SEN04503-01
D31/37-22 Bulldozer
©2009 KOMATSU
All Rights Reserved
30-120 44
SEN04504-02
BULLDOZER
D31EX-22
D31PX-22
D37EX-22
D37PX-22
D31EX-22 60001 and up
D31PX-22 60001 and up
D37EX-22 60001 and up
D37PX-22 60001 and up

Special functions of monitor panel (EMMS) .................................................................................................... 2
Items to be adjusted when electric/hydraulic devices are adjusted/replaced ............................................... 62
Adjustment procedure after replacement of HST controller .......................................................................... 63
Adjustment procedure after replacement of monitor panel ........................................................................... 65
Pm-clinic service (D31EX-22, D31PX-22) .................................................................................................... 67
Pm-clinic service (D37EX-22, D37PX-22) .................................................................................................... 75
D31/37-22 30-130 1
SEN04504-02 Special functions of monitor panel (EMMS)
Special functions of monitor panel (EMMS) 1
a EMMS: Equipment Management Monitoring System
1. Buzzer cancel switch (Used to change, select or confirm modes in this chapter)
2. Information switch (Used to move the cursor or input values in this chapter)
3. Character display (Used to display information in this chapter)
Normal functions and the special functions of monitor panel (EMMS)

The monitor panel is equipped with normal functions and special functions. Various items of data are dis-
played on the character display in the middle of the monitor panel. The display items are divided by the inter-
nal setting of the monitor panel (EMMS), into automatic display items and items displayed when the monitor
panel switches are operated.
1) Normal functions: Operator mode
Functions for which the content is normally displayed or which can be displayed and operated by the
operator operating the switches.
2) Special functions: Service mode
Functions which the serviceman can display and operate with the special switches to carry out inspec-
tion, maintenance, and troubleshooting.
30-130 2 D31/37-22
Special functions of monitor panel (EMMS) SEN04504-02
Operator mode io Service mode

1 Operating mode 6 Electrical system failure history display mode
2 Action code display mode 7 Mechanical system failure history display mode
3 Failure code display mode 8 Real-time monitoring mode
4 Oil/Filter maintenance mode 9 Cylinder cut-out mode
5 Brightness adjustment mode 10 No-injection cranking mode
11 Tuning mode
12 Maintenance interval setting mode
13 Telephone number input mode
14 Model selection mode
15 Option selection mode
16 Initialize mode (factory use only)
D31/37-22 30-130 3
Function and flow of each mode
30-130 4 D31/37-22
Reference: The following Nos. correspond to those Character display portion

in the table on the previous page. Each No. in the 16 characters can be displayed on each upper and
table is put in [ ] in the title of each item in the text. lower row of the character display section, and
depending on the contents displays the combina-
Operator mode tion of the next figures, letters, and symbols.
a No. 4 – No. 5 is displayed endlessly by follow- 1) Arabic numbers: 1, 2, 3, . . .
ing the switch operation. 2) Small letters: a, b, c, . . .
a When a failure occurs, the screen changes 3) Capital letters: A, B, C, . . .
automatically to No. 2 regardless of the dis- 4) Symbols: @, ?, $, . . .
played screen. 5) Special letters:
a If the switch is not operated for over 30 sec-
onds regardless of the display screen, the
screen automatically;
q Changes to No. 1.
(If malfunction has not occurred.)
q Changes to No. 2.
(If malfunction has occurred.)
a After moving from No. 3 to No. 1 by the switch
operation, if no switch operation is performed
for longer than 10 seconds, then it automati-
cally moves to No. 2.
Service mode
a No. 6 – No. 16 is displayed endlessly by follow-
ing the switch operation. Control switch section
a By inputting and determining the ID once, it will All the display operation of the monitor panel is
be effective until the starting switch is turned operated by the buzzer cancel switch (1) and infor-
off. mation switch (2).
Each switch of [U], [t], [>], [<] is assigned to the
following function.
U : Determine and execute
t : To cancel or release
> : To right, to next, to proceed, to increase
(only when inputting Arabic numbers)
< : To left, to previous, to return, to decrease
(only when inputting Arabic numbers)
D31/37-22 30-130 5
t Operator mode (Outline) [2] Action code display mode

When abnormal situations occur, the monitor panel
[1] Operating mode display (Default) automatically displays the action code depending
When turning the starting switch ON, the service on the extent of the abnormality in order to remind
meter is displayed in the upper row. the operator of proper remedy.
a If this function is selected, the engine speed is a When action code [E03] or [E04] is displayed,
displayed in the lower row. it and “CHECK RIGHT NOWÅh, “CALL + phone
q Turn ON and OFF the display with the [>] and No.” are displayed alternately.
[<] switches. a When action code [E01] or [E02] is displayed,
a For details, see Operation and maintenance “CHECK RIGHT NOW” and “CALL + phone
manual. No.” is not displayed.
a The phone No. is displayed only when it is set.
<Reference>
An action code is displayed only when a serious
fault occurs.
Even if an action code is not displayed, a fault may
have occurred. If you feel any abnormality, be sure
to check for a failure code in the “Electrical system
failure history display mode” and “Mechanical sys-
tem failure history display mode” of the service
mode.
30-130 6 D31/37-22
Action code table

Action Remedy requested for
Display method of trouble Examples of abnormality
code an operator
• Only action code is displayed. • Backup alarm does not sound. • Automatic function stops or nor-
• Fan speed is always at maxi- mal function stops partially, but
E01 mum. machine can work.
• Contact your Komatsu distribu-
tor for repair.
• Action code is displayed. • Gear is not shifted up or down. • Stop engine and start it again,
• Warning lamp flashes • Exhaust gas color is bad when and you can operate machine
• Alarm buzzer sounds. temperature is low. without limiting function. You
E02
• Defective coolant temperature must take care, however.
sensor • Contact your Komatsu distribu-
tor for repair.
• The action code is displayed. • Engine boost pressure is abnor- • Move machine to safe place.
• Warning lamp flashes mal. • Contact your Komatsu distribu-
E03
• Alarm buzzer sounds. • Usable gear speeds are limited. tor for repair.
• Engine speed does not rise fully.
• The action code is displayed. • Engine cannot be controlled. • Stop machine immediately.
E04 • Warning lamp flashes • Machine cannot travel. • Contact your Komatsu distribu-
• Alarm buzzer sounds. • Machine stops. tor for repair.
D31/37-22 30-130 7
[3] Failure code display mode

By pressing the [>] switch once while the action
code is displayed on the monitor panel, the present
failure code is displayed.
q [>]: To display failure code.
a The failure codes which have been detected in

the past are separated into electrical and
mechanical systems and recorded as failure
history (refer to service mode for a detail).
a If there are several failures, other failure codes
are displayed by pressing the [>] switch.
a After displaying all the failure codes by press-
ing the [>] switch, press [>] switch further to
return to the operating mode.
Press the [>] switch again, and the failure code
is displayed from the beginning.
a If there is no switch operation for longer than
10 seconds in the operating mode, it automati-
cally switches to the action code display
screen.
a The following information is displayed in the
failure code display mode.
A: Failure code
B: Controller code (Controller that detected
failure code)
MON: Monitor panel
ENG: Engine controller
HST: HST controller
C: Displayed message (System having trou-
ble)
a Refer to “Failure code table” for details of dis-
played failure codes.
a Be careful of the partial difference in the dis-
played information for the failure code display
mode and the failure history display mode (ser-
vice mode).
30-130 8 D31/37-22
Failure code table

Appli-
Cau- Cau-
Failure cable Action History
Defective part Trouble Message tion tion
codes equip- code classification
lamp buzzer
ment
Mechanical
6091NX HST charge filter element Clogging HST — — q q
system
Mechanical
AA10NX Air cleaner Clogging MON — — — —
system
Mechanical
AB00MA Alternator Malfunction MON — — q —
system
Mechanical
B@BAZG Engine oil Lowering of oil pressure ENG — — q q
system
Mechanical
B@BCNS Coolant Overheating ENG — — q q
system
Mechanical
B@CRNS HST oil Overheating HST — — q q
system
Mechanical
B@CRZG HST oil Lowering of oil pressure HST — — q q
system
CONTROL- Electrical
CA111 Engine controller Abnormality in controller ENG E04 q q
LER system
Abnormal engine NE, Bkup ENG Electrical
CA115 Abnormal speed sensor signal ENG E04 q q
speed SPEED system
Electrical
CA122 Charge pressure sensor too high Excessively high voltage detected ENG E03 ENGINE q q
system
Electrical
CA123 Charge pressure sensor too low Excessively low voltage detected ENG E03 ENGINE q q
system
Decelerator pedal sensor too DECEL Electrical
CA131 Excessively high voltage detected ENG E03 q q
high PEDAL system
DECEL Electrical
CA132 Decelerator pedal sensor too low Excessively low voltage detected ENG E03 q q
PEDAL system
Coolant temperature sensor too WATER Electrical
high TEMP system
Coolant temperature sensor too WATER Electrical
CA145 Excessively low voltage detected ENG E02 q q
low TEMP system
Charge temperature sensor too Electrical
CA153 Excessively high voltage detected ENG E01 ENGINE — —
high system
Charge temperature sensor too Electrical
CA154 Excessively low voltage detected ENG E01 ENGINE — —
low system
SENSOR Electrical
CA187 Sensor power source 2 too low Excessively low voltage detected ENG E03 q q
VOLTAGE system
Atmospheric pressure sensor too Electrical
CA221 Excessively high voltage detected ENG E03 ENGINE q q
high system
Atmospheric pressure sensor too Electrical
CA222 Excessively low voltage detected ENG E03 ENGINE q q
low system
SENSOR Electrical
CA227 Sensor power source 2 too high Excessively high voltage detected ENG E03 q q
VOLTAGE system
Mechanical
CA234 Engine overspeed Excessively high speed ENG — — q q
system
Abnormal power source for Ne ENG Electrical
speed sensor SPEED system
Electrical
CA271 IMV/PCV1 short circuit Short circuit ENG E03 ENGINE q q
system
Electrical
CA272 IMV/PCV1 disconnection Disconnection ENG E03 ENGINE q q
system
Disconnection and short circuit in Electrical
CA322 Disconnection or short circuit ENG E03 ENGINE q q
injector #1 system
injector #3 system
D31/37-22 30-130 9
Appli-
Cau- Cau-
lamp buzzer
ment
injector #2 system
injector #4 system
Abnormal circuit for injector sys- Electrical
CA351 Abnormal circuit ENG E03 ENGINE q q
tem system
SENSOR Electrical
CA352 Sensor power source 1 too low Excessively low voltage detected ENG E03 q q
VOLTAGE system
SENSOR Electrical
CA386 Sensor power source 1 too high Excessively high voltage detected ENG E03 q q
VOLTAGE system
FUEL Electrical
CA428 Water detection sensor too high Excessively high voltage detected ENG E01 — —
FILTER system
FUEL Electrical
CA429 Water detection sensor too low Excessively low voltage detected ENG E01 — —
FILTER system
Abnormal engine oil pressure ENG OIL Electrical
CA435 Abnormal signal circuit ENG E02 q q
switch PRESS SW system
BATTERY Electrical
CA441 Power supply voltage too low Excessively low voltage detected ENG E04 q q
VOLTAGE system
BATTERY Electrical
CA442 Power supply voltage too high Excessively high voltage detected ENG E04 q q
VOLTAGE system
Excessively high pressure Electrical
CA449 Common rail pressure too high 2 ENG E03 ENGINE q q
detected system
Common rail pressure sensor too Electrical
CA451 Excessively high voltage detected ENG E03 ENGINE q q
high system
Common rail pressure sensor too Electrical
CA452 Excessively low voltage detected ENG E03 ENGINE q q
low system
Excessively high pressure Electrical
CA553 Common rail pressure too high 1 ENG E02 ENGINE q q
detected system
Electrical
CA559 Supply pump no pressure 1 No pressure feeding detected ENG E02 ENGINE q q
system
Abnormal engine Ne speed sen- ENG Electrical
CA689 Abnormality in signal ENG E03 q q
sor SPEED system
Abnormal engine Bkup speed ENG Electrical
CA731 Abnormal phase ENG E03 q q
sensor phase SPEED system
Loss of all data of engine control- CONTROL- Electrical
CA757 Loss of all data ENG E04 q q
ler LER system
Abnormal engine Bkup speed ENG Electrical
CA778 Abnormal Bkup signal ENG E03 q q
sensor SPEED system
Abnormal CAN communication
Electrical
CA1633 (Engine controller – HST control- Abnormal communication ENG E03 DATA LINK q q
system
ler)
Decelerator pedal sensor power DECEL Electrical
source too high PEDAL system
Decelerator pedal sensor power DECEL Electrical
source too low PEDAL system
Electrical
CA2249 Supply pump no pressure 2 No pressure feeding detected ENG E03 ENGINE q q
system
Electrical
CA2311 Abnormal IMV solenoid Abnormal resistance ENG E03 ENGINE q q
system
Disconnection in air intake heater HEATER Electrical
CA2555 Disconnection ENG E01 — —
relay RELAY system
Short circuit in air intake heater HEATER Electrical
CA2556 Short circuit ENG E01 — —
relay RELAY system
N SAFETY Electrical
D130KA Neutral safety relay Disconnection HST E02 q q
RELAY system
30-130 10 D31/37-22
Appli-
Cau- Cau-
lamp buzzer
ment
N SAFETY Electrical
D130KB Neutral safety relay Short circuit HST E02 q q
RELAY system
“Defective communication
CAN communication (Monitor Electrical
DAFRKR (Abnormality in objective compo- MON E03 DATA LINK q q
panel – HST controller) system
nent system)”
CAN communication (Monitor Electrical
DAFRMC (Abnormality in objective compo- MON E03 DATA LINK q q
panel – Engine controller) system
nent system)”
Electrical
DAJ000 HST controller Memory error HST — — — —
system
BATTERY Electrical
DAJ0KK HST controller Lowing of source voltage HST E04 q q
VOLTAGE system
MACHINE Electrical
DAJ0KQ HST controller Machine code error HST E03 q q
CODE system
CONTROL- Electrical
DAJ0KT HST controller Memory error HST E03 q q
LER system
HST controller sensor 5V power SENSOR Electrical
DAJ5KK Lowing of source voltage/Input HST E04 q q
supply No. 1 VOLTAGE system
HST controller sensor 5V power SENSOR Electrical
DAJ6KK Lowing of source voltage/Input HST E03 q q
supply No. 2 VOLTAGE system
CAN communication (HST con- Electrical
DAJRKR (Abnormality in objective compo- HST E03 DATA LINK q q
troller – Monitor panel) system
nent system)”
CAN communication (HST con- Electrical
DB2RKR (Abnormality in objective compo- HST E03 DATA LINK q q
troller – Engine controller) system
nent system)”
SHIFT UP Electrical
DD12KA Shift up switch Disconnection HST E02 q q
SW system
SHIFT UP Electrical
DD12KB Shift up switch Short circuit HST E02 q q
SW system
SHIFT Electrical
DD13KA Shift down switch Disconnection HST E02 q q
DOWN SW system
SHIFT Electrical
DD13KB Shift down switch Short circuit HST E02 q q
DOWN SW system
TRAVEL Electrical
DD14KB Travel lock limit switch 1 Short circuit HST E03 q q
LOCK system
Electrical
DD1NL4 Fan rotation selector switch Disagreement of ON/OFF signals HST E01 FAN SW — —
system
R SPEED Electrical
DDDCKB Reverse travel speed switch Short circuit HST E01 — —
SW system
BRAKE Electrical
DDP6KA Brake oil pressure sensor Disconnection HST E02 q q
PRESS system
BRAKE Electrical
DDP6KB Brake oil pressure sensor Short circuit HST E02 q q
PRESS system
BRAKE Electrical
DDP6MA Brake oil pressure sensor Malfunction HST E02 q q
PRESS system
TRAVEL Electrical
DDQ2KA Travel lock limit switch 1 Disconnection HST E03 q q
LOCK system
SHIFT Electrical
DDT0L4 Shift mode switch Disagreement of ON/OFF signals HST E01 — —
MODE SW system
TRAVEL Electrical
DDU1FS Travel lock limit switches 1 and 2 Fixing HST E03 q q
LOCK system
TRAVEL Electrical
DDU1KA Travel lock limit switch 2 Disconnection HST E03 q q
LOCK system
Short circuit with power supply TRAVEL Electrical
DDU1KY Travel lock limit switch 2 HST E03 q q
line LOCK system
D31/37-22 30-130 11
Appli-
Cau- Cau-
lamp buzzer
ment
Electrical
DGS1KA HST oil temperature sensor Disconnection HST E01 OIL TEMP — —
system
Electrical
DGS1KX HST oil temperature sensor Out of input signal range HST E01 OIL TEMP — —
system
HST Electrical
DHH5KA Left HST pump pressure sensor Disconnection HST E02 q q
PRESS system
HST Electrical
DHH5KB Left HST pump pressure sensor Short circuit HST E02 q q
PRESS system
HST Electrical
DHH6KA Right HST pump pressure sensor Disconnection HST E02 q q
PRESS system
HST Electrical
DHH6KB Right HST pump pressure sensor Short circuit HST E02 q q
PRESS system
Electrical
DK10KA Fuel dial sensor Disconnection HST E03 FUEL DIAL q q
system
Electrical
DK10KB Fuel dial sensor Short circuit HST E03 FUEL DIAL q q
system
Electrical
DK30KA Steering angle sensor 1 Disconnection HST E03 ST LEVER q q
system
Electrical
DK30KB Steering angle sensor 1 Short circuit HST E03 ST LEVER q q
system
Electrical
DK30KX Steering angle sensor Out of input signal range HST E04 ST LEVER q q
system
Electrical
DK30KZ Steering angle sensor Disconnection or short circuit HST E04 ST LEVER q q
system
Electrical
DK30L8 Steering angle sensor Disagreement of analog signals HST E03 ST LEVER q q
system
Electrical
system
Electrical
system
BRAKE Electrical
DK40KA Brake pedal sensor Disconnection HST E03 q q
PEDAL system
BRAKE Electrical
DK40KB Brake pedal sensor Short circuit HST E03 q q
PEDAL system
Electrical
DK55KX Directional potentiometer Out of input signal range HST E04 FR LEVER q q
system
Electrical
DK55KZ Directional potentiometer Disconnection or short circuit HST E04 FR LEVER q q
system
Electrical
DK55L8 Directional potentiometer Disagreement of analog signals HST E03 FR LEVER q q
system
Electrical
DK56KA Directional potentiometer 1 Disconnection HST E03 FR LEVER q q
system
Electrical
DK56KB Directional potentiometer 1 Short circuit HST E03 FR LEVER q q
system
Electrical
DK57KA Directional potentiometer 2 Disconnection HST E03 FR LEVER q q
system
Electrical
DK57KB Directional potentiometer 2 Short circuit HST E03 FR LEVER q q
system
TRAVEL Electrical
DLM0KX HST motor speed sensor Out of input signal range HST E03 q q
SPEED system
TRAVEL Electrical
DLM1KA Left HST motor speed sensor Disconnection HST E01 — —
SPEED system
Electrical
DLM1KB Left HST motor speed sensor Short circuit HST — — — —
system
30-130 12 D31/37-22
Appli-
Cau- Cau-
lamp buzzer
ment
Electrical
DLM1MA Left HST motor speed sensor Malfunction HST — — — —
system
TRAVEL Electrical
DLM2KA Right HST motor speed sensor Disconnection HST E01 — —
SPEED system
Electrical
DLM2KB Right HST motor speed sensor Short circuit HST — — — —
system
Electrical
DLM2MA Right HST motor speed sensor Malfunction HST — — — —
system
FAN Electrical
DLM3KA Fan speed sensor Disconnection HST E01 — —
SPEED system
FAN Electrical
DLM3KB Fan speed sensor Short circuit HST E02 q q
SPEED system
BRAKE Electrical
DN21FS Brake pedal and proximity switch Fixing HST E03 q q
PEDAL system
Electrical
DV00KB Caution buzzer Short circuit MON E01 BUZZER — —
system
BACK Electrical
DV20KB Back alarm buzzer Short circuit HST E01 — —
ALARM system
P BRAKE Electrical
DW4BKA Parking brake solenoid valve Disconnection HST E04 q q
SOL system
P BRAKE Electrical
DW4BKB Parking brake solenoid valve Short circuit HST E04 q q
SOL system
Short circuit with power supply P BRAKE Electrical
DW4BKY Parking brake solenoid valve HST E03 q q
line SOL system
FAN CLN Electrical
DW7BKA Fan reverse solenoid valve Disconnection HST E01 — —
SOL system
FAN CLN Electrical
DW7BKB Fan reverse solenoid valve Short circuit HST E01 — —
SOL system
Short circuit with power supply FAN CLN Electrical
DW7BKY Fan reverse solenoid valve HST E03 q q
line SOL system
SLOW
Electrical
DW7EKA Slow brake solenoid valve Disconnection HST E04 BRAKE q q
system
SOL
SLOW
Electrical
DW7EKB Slow brake solenoid valve Short circuit HST E04 BRAKE q q
system
SOL
SLOW
Short circuit with power supply Electrical
DW7EKY Slow brake solenoid valve HST E03 BRAKE q q
line system
SOL
Electrical
DWN5KA Fan EPC solenoid valve Disconnection HST E01 FAN EPC — —
system
Electrical
DWN5KB Fan EPC Solenoid valve Short circuit HST E01 FAN EPC — —
system
Short circuit with power supply Electrical
DWN5KY Fan EPC solenoid valve HST E02 FAN EPC q q
line system
LF HST pump EPC solenoid HST PUMP Electrical
DXA4KA Disconnection HST E03 q q
valve EPC system
LF HST pump EPC solenoid HST PUMP Electrical
DXA4KB Short circuit HST E03 q q
valve EPC system
LF HST pump EPC solenoid Short circuit with power supply HST PUMP Electrical
DXA4KY HST E04 q q
valve line EPC system
LR HST pump EPC solenoid HST PUMP Electrical
valve EPC system
LR HST pump EPC solenoid HST PUMP Electrical
valve EPC system
D31/37-22 30-130 13
Appli-
Cau- Cau-
lamp buzzer
ment
LR HST pump EPC solenoid Short circuit with power supply HST PUMP Electrical
DXA5KY HST E04 q q
RF HST pump EPC solenoid HST PUMP Electrical
valve EPC system
RF HST pump EPC solenoid HST PUMP Electrical
valve EPC system
RF HST pump EPC solenoid Short circuit with power supply HST PUMP Electrical
DXA6KY HST E04 q q
RR HST pump EPC solenoid HST PUMP Electrical
valve EPC system
RR HST pump EPC solenoid HST PUMP Electrical
valve EPC system
RR HST pump EPC solenoid Short circuit with power supply HST PUMP Electrical
DXA7KY HST E04 q q
HST
Left HST motor EPC solenoid Electrical
DXK1KA Disconnection HST E02 MOTOR q q
valve system
EPC
HST
Left HST motor EPC solenoid Electrical
DXK1KB Short circuit HST E02 MOTOR q q
valve system
EPC
HST
Left HST motor EPC solenoid Short circuit with power supply Electrical
DXK1KY HST E04 MOTOR q q
valve line system
EPC
HST
Right HST motor EPC solenoid Electrical
DXK2KA Disconnection HST E02 MOTOR q q
valve system
EPC
HST
Right HST motor EPC solenoid Electrical
DXK2KB Short circuit HST E02 MOTOR q q
valve system
EPC
HST
Right HST motor EPC solenoid Short circuit with power supply Electrical
DXK2KY HST E04 MOTOR q q
valve line system
EPC
a Failure codes:
The failure code table is written in alphabetical order and also starting from small number.
The failure code in parentheses is not recorded in the failure history for both electrical system and
mechanical system.
a Applicable equipment:
Applicable equipment indicates in which controller system the failure has occurred.
MON : Monitor panel system
ENG : Engine controller system
HST : HST controller system
a Action codes:
Action codes indicate what is displayed in the operator mode when a failure is detected.
a History classification:
History classification indicates in which system, either electrical system or mechanical system in the fail-
ure history display mode, a failure has been recorded.
30-130 14 D31/37-22
[4] Oil/filter maintenance mode (MAINTE- q Table of maintenance item

NANCE MONITOR)
Code Display Maintenance items
1. If buzzer cancel switch [U] is pressed on the
normal display screen, the maintenance mode 01 01: ENG OIL Engine oil
is selected and the filter/oil maintenance mode 02 02: ENG FILT Engine oil filter
screen is displayed first. 03 03: FUEL FILT Fuel main filter
41 41: P FUEL FILT Fuel pre filter
04 04: HYD FILT Hydraulic oil filter
06 06: CORR RES Corrosion resistor (*)
18 18: BYPS FILT Bypass filter (*)
07 07: DAMP OIL Damper filter (*)
08 08: FNL OIL Final drive oil
10 10: HYD OIL Hydraulic oil
19 19: POWL OIL Power train oil (*)
20 20: POWL FILT Power train oil filter (*)
21 21: HST FILT HST charge filter
* Set ineffective on this machine.
2. Replacement time display of filter and oil (dis-
played automatically) 3. Reset of replacement time (selection menu)
When the replacement interval for the various The monitor panel can reset the interval time
filters or oils approaches, the monitor panel by operating the switch, if various filters and oil
automatically displays the information to maintenances are finished.
remind an operator of maintenance. a For details, see Operation and mainte-
nance manual.
a Replacement interval time setting can be
operated by the maintenance mode in the
service mode.
D31/37-22 30-130 15
[5] Brightness adjustment mode (BRIGHT- t Service mode

NESS ADJUST)
In this mode, the display condition of the monitor Procedure for switching to service mode and
panel can be adjusted. screen display
a For details, see Operation and maintenance a When using the service mode, change the
manual. screen by the following special operation.
1. Confirming the screen display

Check that the monitor panel is in operator
mode and the screen is displaying either of the
“operating modeÅh, “action codeÅh, or “failure
codeÅh.
2. Displaying ID input initial screen

Press the following 2 switches at the same
time for longer than 5 seconds to display the ID
input screen.
q [t] switch and [<] switch
a If the switch is pressed for longer than 5
seconds, the character display section
a The following items are displayed in the bright- becomes next figure. After confirming this
ness adjustment mode. display, release the switch.
Order Display Item
BRIGHTNES Adjustment of back light of

1
GAUGE LCD gauge
BRIGHTNES Adjustment of back light of

2
CHARACTER DISP character display portion.
CONTRAST Adjustment of LCD con-

3 trast of character display
CHARACTER DISP
portion.
q Screen during adjustment
3. Input and determination of ID

After displaying ID input screen, operate [>],
[<], [U], and [t] switch and input 4 digits ID.
a ID: 6491
q [ > ]:Number at the cursor increases.
q [ < ]:Number at the cursor decreases
q [U]:Number at the cursor is determined
q [ t ]:Cursor moves to left end or the dis-
play returns to operator mode screen.
a If the ID input screen is left without switch
operation for longer than 60 seconds, it
automatically returns to the operator mode
q [>]: To increase adjustment value screen.
q [<]: To decrease adjustment value
q [U]: To determine and return to previous
screen
a The state when [U] is pressed is
recorded.
30-130 16 D31/37-22
a Displayed service menu:

Reference: No.1 – 5 are used in “Operator modeÅh
Order Display Function
Electrical system failure
6 ELECTRIC FAULT
history display mode
Mechanical system failure
7 MACHINE FAULT
history display mode
REAL-TIME
8 Real-time monitoring mode
MONITOR
CYLINDER
9 Cylinder cut-out mode
CUT-OUT
10 NO INJECTION No injection cranking mode
11 TUNING Tuning mode
4. Displaying service menu selection screen
After confirming all 4 digits of ID, display the MAINTENANCE Maintenance interval
12
MONITOR change mode
service menu selection screen in the service
mode. 13 TEL Phone No. input mode
a By inputting and determining the ID once, 14 MACHINE Model selection mode
it will be effective until the starting switch 15 OPTIONAL SELECT Option selection mode
is turned off.
Initialize mode (exclusive
16 INITIALIZE
function for factory)
a The service menu is displayed in the

places marked with [*].
5. Selection of the service menu

If the [>] switch or [<] switch is pressed on the
service menu selection screen, the service
menu is displayed endlessly in the order of the
following table, then select the menu that is
6. Finishing mode and function
used.
The current mode and function can be finished
q [>]: To proceed to next service menu.
by either of the following method, regardless of
q [<]: To return to previous service menu.
the current function and hierarchy.
q When continuing operations in another
mode or function:
Press the [t] switch and return to the
mode screen to be used or menu screen
to be used.
a If you return to the operator mode
screen by mistake, repeat the proce-
dure from step 1 above (however
there is no need to input the ID again).
q When completing all operations:
Turn the starting switch OFF.
D31/37-22 30-130 17
[6] Electrical system failure history display 3. Displayed failure history data
mode (ELECTRIC FAULT) With the electrical system failure history dis-
The monitor panel retains the data for problems play mode, the following data can be dis-
that occurred in the electrical system in the past as played.
failure history. They can be displayed as follows. 1: Record number (recorded up to a maxi-
mum of 20 items)
1. Selection of the service menu A: Failure code (4-digits device code + 2-dig-
Select electrical system failure history display its symptom code)
mode (ELECTRIC FAULT) in the service menu 2: Number of occurrences (number of occur-
selection screen. rences of same code in the past)
a The total number of failure history data 3: Elapsed time 1 (time elapsed on service
items recorded in memory is displayed in meter since first occurrence)
the [* *] portion. 4: Elapsed time 2 (time elapsed on service
meter since last occurrence)
a Failure codes for problems that are still
existing are shown on a flashing display.
a Refer to failure code table of operator
mode for details of displayed failure
codes.
a Note that with the electrical system failure
history display mode and failure code dis-
play mode (operator mode), the displayed
data are partially different.
a If the fault history is not recorded, “–” is
displayed on the display section of 1/A/2/
3/4.
2. Failure history data display

With the service menu selected, press the [U]
switch and display the failure history data
recorded in memory.
q [U]: Conduct the service menu.
4. Switching failure history display

If the [>] switch or [<] switch is pressed during
the display of failure history, the display
switches to another failure histor y data
recorded.
q [>]: To proceed to data for next record
number
q [<]: Go back to data for previous record
number
30-130 18 D31/37-22
5. Deleting individual failure history data 3) When the ALL CLEAR execution screen is
1) With the failure history data to be deleted displayed, operate each switch of [<], [>]
displayed, press the [U] switch and dis- and [U].
play the individual deletion screen. q [ <]: Select YES (move cursor)
q [U]: Display the deletion screen q [ >]: Select NO (move cursor)
2) When the individual deletion screen is dis- q [U]: Execute YES or NO
played, operate each switch of [<], [>] and a An information which is active cur-
[U]. rently (display is flashing) cannot be
q [ < ]: Select YES (move cursor) deleted.
q [ > ]: Select NO (move cursor)
q [U]: Execute YES or NO
a An information which is active cur-
rently (display is flashing) cannot be
deleted.
4) The screen changes to the fault history

screen. Check that the number of records
in ** is “0Åh.
6. Deletion of all the failure history information

1) With the failure history data displayed,
press the [>] switch or [<] switch and dis-
play ALL CLEAR menu screen.
a The ALL CLEAR menu is displayed at
the end of failure history data.
2) When the ALL CLEAR menu is displayed,

press the [U] switch and display the ALL
CLEAR execution screen.
q [U]: Execute ALL CLEAR menu
D31/37-22 30-130 19
[7] Mechanical system failure history display 3. Displayed failure history data
mode (MACHINE FAULT) With the mechanical system failure history dis-
The monitor panel retains the data for problems play mode, the following data can be dis-
that occurred in the mechanical system in the past played.
as failure history. They can be displayed as follows. 1: Record number
A: Failure code (4-digits device code + 2-dig-
1. Selection of the service menu its symptom code)
Select mechanical system failure history dis- 2: Number of occurrences (number of occur-
play mode (MACHINE FAULT) in the service rences of same code in the past)
menu selection screen. 3: Service meter at first occurrence
a The total number of failure history data 4: Service meter at last occurrence
items recorded in memory is displayed in a Failure codes for problems that are still
the [* *] portion. existing are shown on a flashing display.
a Refer to failure code table of operator
mode for details of displayed failure
codes.
a Note that with the mechanical system fail-
ure history display mode and failure code
display mode (operator mode), the dis-
played data are partially different.
a If the fault history is not recorded, “–” is
displayed on the display section of 1/A/2/
3/4.
2. Failure history data display

With the service menu selected, press the [U]
switch and display the failure history data
recorded in memory.
q [U]: Conduct the service menu.
4. Switching failure history display

If the [>] switch or [<] switch is pressed during
the display of failure history, the display
switches to another failure histor y data
recorded.
q [>]: To proceed to data for next record
number
q [<]: Go back to data for previous record
number
5. Deleting failure history data (not permitted)

a The failure history data for the mechanical
system cannot be deleted.
30-130 20 D31/37-22
[8] Real time monitoring mode (REAL-TIME q [>]: To proceed to next monitoring
MONITOR) system and function
The monitor panel can monitor the condition of the q [<]: Go back to data for previous
machine in real time through the signals from the monitoring system and function
sensors installed to various parts of the machine. a Monitoring system and function to be
In the real time monitoring mode, the following 2 displayed:
types of display can be shown.
No. Display System and function
q 1 item independent display (for each controller)
q 2 items simultaneous display (code input) 1 MONITOR PANEL Monitor panel system
2 HST HST controller system
1. Selection of the service menu 3 ENGINE Engine controller system
Select real time monitoring mode (REAL-TIME
4 KOMTRAX KOMTRAX terminal system
MONITOR) in the service menu selection
screen. 2 items simultaneous monitor-
5 2 ITEMS
ing
a Monitoring system and function is dis-

played in the “*” section.
2. Display and selection of monitoring system

and function
1) With the service menu selected, press the
[U] switch to display the monitoring sys-
tem and function selection screen. 3. Setting 1 item individual monitoring
q [U]: Execute the service menu. 1) In the monitoring system and function
selection screen, select the monitoring
system (example: ENGINE) to be used.
2) If the [>] switch or [<] switch is pressed on

the monitoring system and function selec-
tion screen, the monitoring system and
device is displayed endlessly in the follow-
ing order, then select the system or func-
tion that is used.
D31/37-22 30-130 21
2) With the monitoring system selected, 4. Display data for 1 item individual monitoring
press the [U] switch and display the mon- On the 1 item individual monitoring display
itoring display and item selection screen. screen, the following data are displayed.
q [U]: Implement 1 system individual A: Item display
monitoring B: Monitoring code (5-digit)
3) With the monitoring display and item 1: Monitoring data (including unit)
selection screen displayed, press the [>] a For details, see “Monitoring code tableÅh.
switch or [<] switch and select items to
monitor.
q [>]: To proceed to the next monitoring
item
q [<]: Return to the previous monitoring
item
a The monitored items are scroll-dis-
played due to internal setting.
a If the switch is kept pressed, the mon-
itoring items scroll at high speed.
a In the monitoring display and item
selection screen, the information of
the monitored items are displayed on
real time.
5. Setting 2 items simultaneous monitoring
1) Select 2 items simultaneous monitoring (2
ITEMS) in the monitoring system and
function selection screen.
2) With 2 items simultaneous monitoring
selected, press the [U] switch to display
the monitoring code input screen.
q [U]: Implement 2 system individual
monitoring
4) To hold or cancel monitoring data display:

If the [U] switch is pressed during moni-
toring, the monitoring data display is held
and the [U] mark flashes. If the [U]
switch is pressed again, hold is canceled
and it becomes active again.
q [U]: Hold and release of data display
30-130 22 D31/37-22
3) In the monitoring code input screen, oper- 6. Display data for 2 items simultaneous monitor-
ate the switches [>], [<], [U] and [t], to ing
input two monitoring codes directly. On the 2 item simultaneous monitoring display
q [ > ]: Number at the cursor increases. screen, the following data are displayed.
q [ < ]: Number at the cursor decreases A : Monitoring code 1
q [U]: Number at the cursor is deter- 1 : Monitoring data 1 (including unit)
mined B : Monitoring code 2
q [ t]: Cursor moves to the left end / To 2 : Monitoring data 2 (including unit)
return to the monitoring system a For details, see “Monitoring code tableÅh.
and function selection screen.
4) When both of the monitoring codes have

been confirmed, the screen switches to
the 2 items simultaneous monitoring dis-
play screen.
5) To hold or cancel monitoring data display:

If the [U] switch is pressed during moni-
toring, the monitor data is held and the
[U] mark flashes.
If the [U] switch is pressed again, hold is
canceled and it becomes active again.
q [U]: Hold and release of data
D31/37-22 30-130 23
Monitoring code table

MONITOR PANEL [Monitor panel system]
Display Monitoring
Monitoring item Item display Data display range Unit
order code
D39
1 Machine model code MACHINE CODE 00205 –
(Example of display)
01010101
2 Monitor panel input signal 1 D–IN– –0– – – – – –7 40921 (8 digits of 0/1. 0: OFF/1: ON
See detail.)
01010101
3 Monitor panel input signal 2 D–IN– –8–10 40922 (8 digits of 0/1. 0: OFF/1: ON
See detail.)
4 Fuel sensor voltage FUEL SENSOR 04200 0 – 500 mV
5 Alternator R signal input voltage R SIGNAL 04303 0 – 500 mV

6 Application ver. 1 VERSION (APP) 20221 –
(8 digits/symbols)

7 Application data ver. 1 VERSION (DATA) 20222 –
(8 digits/symbols)

8 Program No. VERSION 20228 –
(8 digits/symbols)

9 Assembly No. RART NUMBER 20227 –
(8 digits/symbols)

10 Serial No. SERIAL NUMBER 20402 –
(7 digits)
Display example of bit information

a Bit information is displayed in parts “[ ]” and
“OFF” is indicated with “0” and “ON” with “1Åh.
a An unused item is indicated with “0Åh.
a In detailed information, the condition where the
bit is turned ON (Åg1” is displayed) is shown.
Detailed information of 40921 (D–IN– –0– – – – – –7)

[0] Starting switch C signal: Start position
[1] Front lamp and rear lamp: ON
[2] Preheater: ON
[3] (Unused)
[4] (Unused)
[5] (Unused)
[6] Air cleaner clogging sensor: ON (Clogged)
[7] Information switch: < (Left)
Detailed information of 40922 (D–IN– –8–10)

[8] Information switch: > (Right)
[9] Buzzer cancel switch: U (Left)
[10] Buzzer cancel switch: t (Right)
30-130 24 D31/37-22
HST CONTROLLER [HST controller system]

Display Monitoring Data display
Monitoring item Item display Unit
order code range
D39
1 Machine model code MACHINE CODE 00204 (Example of dis- –
play)
2 HST oil temperature HST TEMP 04401 -99.9 – 999.9 °C
3 HST oil temperature sensor voltage HST TEMP 04402 0 – 5.00 V
Travel speed (Faster one of right
4 VEHICLE SPEED 40010 0 – 99.9 km/h
and left)
5 Right travel speed R SPEED 40002 0 – 99.9 km/h
6 Left travel speed L SPEED 40003 0 – 99.9 km/h
7 Right travel speed R SPEED 40963 0 – 9999 Hz
8 Left travel speed L SPEED 40964 0 – 9999 Hz
9 HST right circuit pressure HST R PRESS 52501 0 – 99.9 MPa
10 HST left circuit pressure HST L PRESS 52503 0 – 99.9 MPa
HST right circuit pressure sensor
11 HST R PRESS 52500 0 – 5.00 V
voltage
HST left circuit pressure sensor
12 HST L PRESS 52502 0 – 5.00 V
voltage
13 Brake pressure BRAKE PRESS 91902 0.00 – 9.99 MPa
14 Brake pressure sensor voltage BRAKE PRESS 91903 0 – 5000 mV
15 FR lever stroke FR LEVER 50204 -100.0 – 100.0 %
16 FR potentiometer 1 voltage FR LEVER 1 50202 0 – 5.00 V
17 FR potentiometer 2 voltage FR LEVER 2 50203 0 – 5.00 V
18 Steering stroke S/T LEVER 50303 -100.0 – 100.0 %
19 Steering potentiometer 1 voltage S/T LEVER 1 50300 0 – 5.00 V
20 Steering potentiometer 2 voltage S/T LEVER 2 50301 0 – 5.00 V
21 Brake pedal stroke BREAK PEDAL 50401 0.0 – 100.0 %
22 Brake potentiometer voltage BREAK PEDAL 50400 0 – 5.00 V
23 Throttle dial command speed FUEL DIAL 03003 0 – 9999 rpm
24 Throttle dial voltage FUEL DIAL 03002 0 – 5.00 V
Right forward pump capacity
25 RF PUMP 52404 0.0 – 95.0 cc/r
command value
Left forward pump capacity
26 LF PUMP 52405 0.0 – 95.0 cc/r
command value
Right reverse pump capacity
27 RR PUMP 52406 0.0 – 95.0 cc/r
command value
Left reverse pump capacity
28 LR PUMP 52407 0.0 – 95.0 cc/r
command value
Right forward pump output current
29 RF PUMP 52400 0 – 9999 mA
command value
Left forward pump output current
30 LF PUMP 52401 0 – 9999 mA
command value
Right reverse pump output current
31 RR PUMP 52402 0 – 9999 mA
command value
Left reverse pump output current
32 LR PUMP 52403 0 – 9999 mA
command value
Right forward pump output current
33 RF PUMP FB 52408 0 – 9999 mA
sensed value
D31/37-22 30-130 25

order code range
Left forward pump output current
34 LF PUMP FB 52409 0 – 9999 mA
sensed value
Right reverse pump output current
35 RR PUMP FB 42410 0 – 9999 mA
sensed value
Left reverse pump output current
36 LR PUMP FB 52411 0 – 9999 mA
sensed value
37 Motor capacity command value MOTOR 52300 0 – 160 cc/r
Right motor output current
38 R MOTOR 52301 0 – 9999 mA
command value
Left motor output current command
39 L MOTOR 52302 0 – 9999 mA
value
Right motor output current sensed
40 R MOTOR FB 52303 0 – 9999 mA
value
Left motor output current sensed
41 L MOTOR FB 52304 0 – 9999 mA
value
42 Theoretical traction force TRACTION 60000 0 – 99.9 ton
43 Fan speed FAN SPEED 10007 0 – 9999 rpm
44 Fan speed FAN SPEED 40965 0 – 9999 Hz
Fan EPC output current command
45 FAN EPC 31623 0 – 9999 rpm
value
Fan EPC output current sensed
46 FAN EPC FB 31624 0 – 9999 mA
value
47 R signal input voltage R SIGNAL 04303 0 – 50.0 V
48 Battery relay drive voltage BR HOLD 60600 0 – 50.0 V
49 Neutral safety relay drive voltage N-SAFETY 50901 0 – 50.0 V
50 Backup alarm drive voltage BACK ALARM 70401 0 – 50.0 V
Controller unswitched power supply
51 PWR IN BATT 03207 0 – 50.0 V
voltage (VB)
Controller load drive power supply
52 PWR IN BRY 03202 0 – 50.0 V
voltage (VIS)
53 Key ACC input voltage PWR CNT KEY 03201 0 – 50.0 V
01010101
54 HST controller switch input 1 D–IN– –0– – – – – –7 40910 (8 digits of 0/1. 0: OFF/1: ON
See detail.)
01010101
55 HST controller switch input 2 D–IN– –8– – – – – –15 40911 (8 digits of 0/1. 0: OFF/1: ON
See detail.)
01010101
56 HST controller switch input 3 D–IN–16– – – – –23 40912 (8 digits of 0/1. 0: OFF/1: ON
See detail.)
01010101
57 HST controller switch input 4 D–IN–23– – – – –31 40913 (8 digits of 0/1. 0: OFF/1: ON
See detail.)
01010101
58 HST controller D-OUT output D–OUT–0– – – – – –7 40918 (8 digits of 0/1. 0: OFF/1: ON
See detail.)
01010101
59 HST controller SOL OUT output D–OUT–8– – – – –15 40914 (8 digits of 0/1. 0: OFF/1: ON
See detail.)
60 1000 rpm service meter 1000rpm SMR 31105 0 – 9999999 h
30-130 26 D31/37-22

order code range
61 Forward odometer FORWARD ODO M 53501 0 – 9999999 m
62 Reverse odometer BACKWARD ODO M 53502 0 – 9999999 m
********
63 Application ver. 1 VERSION (APP) 20235 –
(8 digits/symbols)
********
64 Application data ver. 1 VERSION (DATA) 20236 –
(8 digits/symbols)
********
65 Program No. VERSION 20238 –
(8 digits/symbols)
********
66 Assembly No. PART NUMBER 20237 –
(8 digits/symbols)
********
67 Serial No. SERIAL NUMBER 20406 –
(7 digits/symbols)
Detailed information of 40910 Detailed information of 40911

(D–IN– – 0 – – – – – – 7) (D–IN– – 8 – – – – – 15)
[0] Travel lever shift-up switch (NO): ON [8] Starting switch C signal: Start position
[1] (Unused) [9] (Unused)
[3] HST filter switch: ON (Filter is clogged) [11] (Unused)
[4] Travel lever shift-down switch (NC): OFF [12] Travel lock switch 2 (NO): Lock
[5] Travel lever shift-down switch (NO): ON [13] (Unused)
[6] Travel lever shift-up switch (NC): OFF [14] (Unused)
D31/37-22 30-130 27
Detailed information of 40912 Detailed information of 40918

(D–IN–16 – – – – – 23) (D–OUT– 0 – – – – – – 7)
[16] Reverse travel speed set switch: Deceleration [0] (Unused)
(Left) [1] (Unused)
[17] Reverse travel speed set switch: Acceleration [2] (Unused)
(Right) [3] Neutral safety relay: ON
[18] Travel lock switch (NO): Lock [4] (Unused)
[19] Travel lock switch (NC): Free [5] Backup alarm: ON
[21] (Unused) [7] Battery relay: ON
[22] (Unused)
[23] (Unused)
Detailed information of 40914

(D–OUT–8 – – – – – 15)
Detailed information of 40913 [8] Fan reverse solenoid valve: ON
(D–IN–24 – – – – – 31) [9] (Unused)
[24] Shift mode switch: Quick shift mode (Right) [10] Parking brake solenoid valve: ON
[25] Shift mode switch: Variable shift mode (Left) [11] Slow brake solenoid valve: ON
[26] Fan rotation selector switch: Reverse (Right) [12] (Unused)
[27] Fan rotation selector switch: Forward (Left) [13] (Unused)
[30] (Unused)
[31] (Unused)
30-130 28 D31/37-22
ENGINE [Engine controller system]

Display Monitoring
order code
1 Engine speed 1 ENG SPEED 01002 0 – 4000 rpm
2 Engine coolant temperature COOLANT TEMP 04107 -40 – 210 °C
Engine coolant temperature sensor
3 COOLANT TEMP 04105 0.00 – 5.00 V
voltage
4 Decelerator pedal operating degree DECEL PEDAL 31701 0 – 100 %
5 Decelerator pedal sensor voltage DECEL PEDAL 31702 0.00 – 5.00 V
6 Selected machine model name MACHINE ID 00201 – –
7 Build version BUILD VER 20216 – –
8 Calibration data version CAL VER 20217 – –
9 Controller internal temperature ECMINT TEMP 18900 -40 – 210 °C
10 Hardware serial No. ECM S/N 20400 0 – 49999999 –
11 Converted torque TORQUE RATIO 36700 0 – 100 %
12 Engine mode selection POWER MODE 17500 0–4 –
13 Common rail pressure RAIL PRESS 36400 0 – 400 MPa
Common rail pressure sensor
14 RAIL PRESS 36401 0.00 – 5.00 V
voltage
Final common rail pressure
15 PRESS COMMAND 36200 0 – 400 MPa
command PFIN
Final injection timing command
16 INJECT TIMING 36300 -180.0 – 180.0 CA
TFIN
17 Ambient pressure AMBIENT PRESS 37400 -99.9 – 999.9 kPa
18 Ambient pressure sensor voltage AMBIENT PRESS 37401 0.00 – 5.00 V
19 Boost pressure 1 CHG PRESS-A 36500 -99.9 – 99.9 kPa
20 Boost pressure sensor voltage 1 CHG PRESS-A 36501 0.00 – 5.00 V
21 Battery voltage POWER PATE 03203 0.0 – 480.0 V
22 Momentary fuel consumption FUEL RATE 37300 0.0 – 999.9 L/h
Final accelerator pedal operating
23 FINAL THROTTLE 31706 0 – 100 %
degree
24 Intake air temperature INTAKE TEMP 18400 -50 – 200 °C
Intake air temperature sensor
25 INTAKE TEMP 18401 0.00 – 5.00 V
voltage
26 Boost temperature CHG TEMP 18500 -50 – 200 °C
27 Boost temperature sensor voltage CHG TEMP 18501 0.00 – 5.00 V
28 Idle validation switch 1 IVS 1 18300 0 or 1 –
29 Idle validation switch 2 IVS 2 18301 0 or 1 –
Final injection command (Weight
30 INJECT COMMAND 18600 0 – 1000 mg
unit)
31 Engine output torque OUTPUT TORQUE 18700 -24000 – 24000 Nm
32 WIF sensor state WATER IN FUEL 18800 0 or 1 –
D31/37-22 30-130 29
KOMTRAX [KOMTRAX terminal system]

Display Monitoring
order code
1 LED display LED STATUS 20300 o_ _o 7. (Example) –
Examples of display of LED information

a The LED information is displayed by “_ (Under
bar)” for OFF and “o” for ON in the place [ ] at
[1] to [4].
Detailed information of 20300 (LED STATUS)

[1] LED-C1
[2] LED-C2
[3] LED-C3
[4] LED-C4
[5] 7-Segments
[6] Dot
30-130 30 D31/37-22
[9] Cylinder cut-out mode (CYLINDER CUT- 3. Setting cut-out cylinder

OUT) In the reduced cylinder mode execution
As one method of troubleshooting for the engine, screen, operate the switches [>], [<], [U] and
the monitor panel has a reduced cylinder mode that [t] to select the cut-out cylinder.
can set the desired cylinder to the no injection con- q [ > ]: Selector cursor moves to the right.
dition. q [ < ]: Selector cursor moves to the left.
q [U]: Determine the cylinder.
1. Starting engine q [ t]: To return to the service menu selec-
Use this function while the engine is running, tion screen.
because a defective cylinder is determined a When the [U] switch is used to confirm
depending on the engine speed in the reduced the cut-out cylinder, communication is car-
cylinder mode. ried out between the monitor panel and
engine controller. During this time, the cyl-
2. Selection in the service menu inder No. flashes.
1) Select the reduced cylinder mode (CYLIN- After completion of the communication,
DER CUT-OUT) in the service menu the segment under the cylinder No.
selection screen. becomes black to show that the cylinder
has been cut out.
a A single cylinder or multiple cylinders can
be cut out.
2) With the cylinder cut-out mode selected,

press the [U] switch and display the
reduced cylinder mode execution screen.
q [U]: Execute the service menu. 4. Canceling cylinder cut-out
a The cylinder No. and the engine Cancellation of cylinder cut-out is done by the
speed are displayed on the upper same procedure as setting cut-out cylinder.
line, and the final injection amount a When the [U] switch is used to confirm
command is displayed on the lower the cancellation of the cut-out cylinder,
communication is carried out between the
line. monitor panel and engine controller. Dur-
a When being switched to the reduced ing this time, the cylinder No. flashes.
cylinder mode execution screen, the After completion of the communication,
cursor of cylinder selection is always the segment under the cylinder No.
displayed under the No.1 cylinder. becomes white to show that the cylinder
cut-out has been canceled.
D31/37-22 30-130 31
[10] No injection cranking mode 3. Setting is rejected during engine running

(NO INJECTION) During engine running, if the setting of no
The monitor panel has the function of no injection in jec tio n c r ank ing i s attem pted , “ STOP
cranking, which is used for cranking after long-term ENGINE” is displayed with blinking in the lower
storage, stopping fuel injection of all the cylinders line, and setting is rejected.
without starting the engine. a No injection cranking function cannot be
a The function of no injection cranking must be used during engine running.
operated under the condition that the engine is
stopped.
1. Selection in the service menu

In the service menu selection screen, select no
injection cranking mode (NO INJECTION).
4. Canceling no injection cranking

If the [t] switch is pressed on the no injection
cranking execution screen, the screen returns
to the service menu selection screen and the
no injection cranking is cancelled.
q [t]: To return to the service menu selec-
2. Establishment of no injection cranking tion screen.
With the no injection cranking selected, press
the [U] switch to display no injection cranking
execution screen.
q [U]: Execute the service menu.
a If “CRANKING READY” is displayed on
the lower line, the none injection cranking
is set.
a If the starting switch is operated to the
START position under this condition, the
engine cranks but will not start.
30-130 32 D31/37-22
[11] Tuning mode (TUNING)

Various devices can be set and tuned with this mode. The changes of the screen in this function are outlined
below.
1. Selecting service menu

Select the tuning mode (TUNING) on the ser-
vice menu selection screen.
D31/37-22 30-130 33
2. Tuning pattern selection 3. Tuning item selection (Tuning code input)

1) While the service menu is selected, press 1) While the tuning code input (ID INPUT) is
the [U] switch to display the tuning pat- displayed on the tuning pattern selection
tern. screen, press the [U] switch.
q [U]: Execute the service menu. q [U]: Execute the tuning pattern.
2)
Press the [>] switch or [<] switch, and the 2) Operate the [>], [<], [U] and [t] switches
tuning patterns are displayed repeatedly to input the code of a tuning item to be
in the following order. Select a tuning pat- used.
tern to be used. a For the tuning codes, see “Tuning
q [>]: Go to the next tuning pattern. mode tableÅh.
q [<]: Return to the previous tuning pat- q [>]: Number at the cursor increases.
tern. q [<]: Number at the cursor decreases.
<Displayed tuning pattern> q [U]: Number at the cursor is deter-
mined.
No. Display Tuning pattern
q [t]: Cursor moves to left end or the
1 ID INPUT Tuning code input display returns to tuning pattern
2 TUNING 1 Tuning 1 (Steering lever, brake pedal) selection screen.
3 TUNING 2 Tuning 2 (HST pump, HST motor) 3) Determine all of the 4 digits of the tuning
code and display the tuning screen.
a The display of tuning 1 (TUNING 1) is a The following is displayed on the tun-
shown below as an example. ing screen.
a: Tuning code
b: Tuning item
c: Related information
30-130 34 D31/37-22
a For the detailed information and 2) The tuning items in the group can be
actual tuning procedure, see “Tuning changed repeatedly by pressing the [>]
mode table and tuning procedureÅh. switch or [<] switch.
a If a wrong code is input, the following q [>]: Go to the next tuning item.
is displayed and screen returns to the q [<]: Return to the previous tuning
tuning code input screen. In this case, item.
input again. a For the change order of the tuning
items in tuning 1 and tuning 2, see
“ Tu n i n g m o d e ta b l e a n d t u n i n g
procedureÅh.
4. Tuning item selection (Tuning 1 and tuning 2)

a The tuning items which are often tuned
simultaneously are arranged in the groups
of tuning 1 and tuning 2 and can be
changed in order without inputting the tun-
ing codes.
1) While tuning 1 (TUNING 1) or tuning 2
(TUNING 2) is selected on the tuning pat-
tern selection screen, press the [U]
switch to display the first tuning screen of
the change order.
q [U]: Execute the tuning pattern.
a When tuning 1 (TUNING 1) is
selected, the following screen is dis-
played.
a For the actual tuning procedure, see

“ Tu n i n g m o d e ta b l e a n d t u n i n g
procedureÅh.
D31/37-22 30-130 35
5. Tuning mode table and adjustment procedure

Tuning Automatic selection
No. Display Item Related information
item ID TUNING1 TUNING2
1 0005 BRAKE N-SET Brake potentiometer neutral set Potentiometer voltage A6
Steering lever left counter-rotation set
2 1010 S/T H.L-SET Potentiometer voltage A2
(Operating effort difference)
Steering lever right counter-rotation set
3 1011 S/T H.R-SET Potentiometer voltage A4
(Operating effort difference)
4 1012 S/T N-SET Steering lever neutral set Potentiometer voltage A1
5 1013 S/T M.L-SET Steering lever left max. set Potentiometer voltage A3
6 1014 S/T M.R-SET Steering lever right max. set Potentiometer voltage A5
Forward pump set
7 3001 F-PUMP LINE Command current B1
(For running track shoe idle)
Reverse pump set
8 3002 R-PUMP LINE Command current B2
(For running track shoe idle)
Forward pump start/max. capacity set
9 3003 F-PUMP RUN1 Command current
(For travel)
Reverse pump start/max. capacity set
10 3004 R-PUMP RUN1 Command current
(For travel)
11 3005 F-PUMP RUN2 Forward pump medium capacity set (For travel) Command current
12 3006 R-PUMP RUN2 Reverse pump medium capacity set (For travel) Command current
13 3007 BREAK END Brake potentiometer max. set Potentiometer voltage A7
Engine speed
EST oil temperature
14 3016 STALL CHECK Stall pressure test mode (Hydraulic oil temperature)
Right HST main circuit pressure
Left HST main circuit pressure
15 3019 SHIFT LIMIT Gear speed limit mode Limit gear speed
16 3024 MOTOR LINE Motor set (For running track shoe idle) Command current B3
17 3032 FAN MODE Fan test mode selection Mode name
18 3033 FAN AMP SET Fan set Command current
Forward pump start adjustment value change Adjustment direction
19 3035 F-PUMP MAP1
(For right and left separately) adjustment value
Reverse pump start adjustment value change Adjustment direction
20 3036 R-PUMP MAP1
(For right and left separately) adjustment value
Forward pump start adjustment value change
21 3037 F-PUMP MAP2 Travel speed adjustment value
(For right and left simultaneously)
Reverse pump start adjustment value change
22 3038 R-PUMP MAP2 Travel speed adjustment value
(For right and left simultaneously)
23 — — Service meter set (*) Service meter value
*: Refer to the “SERVICE NEWSÅh.
<Automatic selection of adjustment item>

a For items having numbers in the “Automatic selection” column of the above table, once TUNING 1 or
TUNING 2 is selected on the ID INPUT/TUNING 1/TUNING 2 selection screen, those items can be
selected automatically in the order within the group by operating the information switch.
<Items to be adjusted after disassembly and assembly>
q When HST controller assembly is replaced (Either of the following):
a Perform the following adjustment after selecting the machine model.
1) TUNING 1: [A1] [A2] [A3] [A4] [A5] [A6] [A7] and TUNING 2: [B1] [B2] [B3] and ID INPUT: [3033]
2) TUNING 1: [A1] [A2] [A3] [A4] [A5] [A6] [A7] and ID INPUT: [3003] [3004] [3005] [3006] [3024] [3033]
q When HST pump assembly or HST pump EPC valve is replaced (Either of the following)
1) ID INPUT: [3001] [3002]
2) ID INPUT: [3003] [3004] [3005] [3006]
q When HST motor assembly or HST motor EPC valve is replaced: ID INPUT: [3024]
q When hydraulic fan, fan motor, control valve, fan EPC or work equipment pump is replaced: ID INPUT:
Items of [3033]
q When PCCS lever assembly is replaced: ID INPUT: [1012] [1010] [1013] [1011] [1014]
q When brake linkage is adjusted or brake potentiometer is replaced: ID INPUT [0005] [3007]
30-130 36 D31/37-22
t Details of each item [1010] Steering lever left counter-rotation set

a The 4-digit number in [ ] is the adjustment (Operating effort difference) (Changed in nor-
code. mal order: A2)
q This code is used to adjust the left counter-
[0005]: Brake potentiometer neutral set (Changed rotation (operating effort difference) position of
in normal order: A6) the steering potentiometer of the PCCS lever.
q This code is used to adjust the neutral position q The signal output of the steering potentiometer
of the brake pedal potentiometer. is displayed by voltage on the lower line (Dis-
q The signal output of the brake pedal potenti- play range: 0 – 5000).
ometer is displayed by voltage on the lower
line. (Display range: 0 – 5000)
q Adjustment method:
i) Set the PCCS lever in the left counter-
q Adjustment method: rotation (operating effort difference) posi-
i) Check that the brake pedal is in neutral (it tion.
is not pressed). ii) Set buzzer cancel switch in the [U] posi-
ii) Set buzzer cancel switch in the [U] position and check that the caution buzzer
tion and check that the caution buzzer sounds.
sounds. a The display of the lower line does not
a The display of the lower line does not change after adjustment.
change after adjustment. a Even if this code is turned OFF, the setting
a Even if this code is turned OFF, the setting is effective.
is effective. a This code is not used to adjust the steer-
a This adjustment is performed to make the ing performance, etc.
HST controller recognize the neutral posi- a The adjustment value cannot be adjusted
tion of the brake pedal potentiometer. It is higher than 2,000 mV to prevent wrong
not performed to adjust the effect of the setting (The caution buzzer does not
brake. sound).
D31/37-22 30-130 37
[1011] Steering lever right counter-rotation set [1012] Steering lever neutral set (Changed in nor-
(Operating effort difference) (Changed in normal order: A1)
mal order: A4) a This code is used to adjust the neutral position
q This code is used to adjust the right counter- of the steering potentiometer of the PCCS
rotation (operating effort difference) position of lever.
the steering potentiometer of the PCCS lever. a The signal output of the steering potentiometer
q The signal output of the steering potentiometer is displayed by voltage on the lower line (Dis-
is displayed by voltage on the lower line (Dis- play range: 0 – 5000).
play range: 0 – 5000).
q Adjustment method: i) Set the PCCS lever in the neutral position.
i) Set the PCCS lever in the right counter- ii) Set buzzer cancel switch in the [U] posi-
rotation (operating effort difference) position and check that the caution buzzer
tion. sounds.
ii) Set buzzer cancel switch in the [U] posi- a The display of the lower line does not
tion and check that the caution buzzer change after adjustment.
sounds. a Even if this code is turned OFF, the setting
a The display of the lower line does not is effective.
change after adjustment. a This code is not used to adjust the steer-
a Even if this code is turned OFF, the setting ing performance, etc.
is effective. a The adjustment value cannot be adjusted
a This code is not used to adjust the steer- lower than 2,000 mV or higher than 3,000
ing performance, etc. mV to prevent wrong setting (The caution
a The adjustment value cannot be adjusted buzzer does not sound).
lower than 3,000 mV to prevent wrong set-
ting (The caution buzzer does not sound).
30-130 38 D31/37-22
[1013] Steering lever left max. set (Changed in nor- [1014] Steering lever right max. set (Changed in
mal order: A3) normal order: A5)
q This code is used to adjust the left maximum q This code is used to adjust the right maximum
position of the steering potentiometer of the position of the steering potentiometer of the
PCCS lever. PCCS lever.
q The signal output of the steering potentiometer q The signal output of the steering potentiometer
is displayed by voltage on the lower line (Dis- is displayed by voltage on the lower line (Dis-
play range: 0 – 5000). play range: 0 – 5000).
q Adjustment method: q Adjustment method:

i) Set the PCCS lever to the left steering i) Set the PCCS lever to the right steering
stroke end. stroke end.
ii) Set buzzer cancel switch in the [U] posi- ii) Set buzzer cancel switch in the [U] posi-
tion and check that the caution buzzer tion and check that the caution buzzer
sounds. sounds.
a The display of the lower line does not a The display of the lower line does not
change after adjustment. change after adjustment.
a Even if this code is turned OFF, the setting a Even if this code is turned OFF, the setting
is effective. is effective.
a This code is not used to adjust the steer- a This code is not used to adjust the steer-
ing performance, etc. ing performance, etc.
a The adjustment value cannot be adjusted a The adjustment value cannot be adjusted
higher than 2,000 mV to prevent wrong lower than 3,000 mV to prevent wrong set-
setting (The caution buzzer does not ting (The caution buzzer does not sound).
sound).
D31/37-22 30-130 39
[3001] Forward pump set (For running track shoe a When stopping (interrupting) the track
idle) (Changed in normal order: B1) shoe during adjustment, return the
q This code is used to adjust the command cur- PCCS lever to the neutral position.
rent of the forward pump while the track shoe (Operations of steering with the
is running idle. PCCS lever, brake pedal, fuel control
q The command current of the forward pump is dial, and decelerator pedal are not
displayed on the lower line. accepted during adjustment. Take
care.)
v) After adjustment is finished, set the PCCS
lever in the neutral position and set the
parking brake lever in the LOCK position.
a When starting adjustment again after
interrupting it, perform the procedures
from ii).
a Even if this code is turned OFF, the setting
is effective.
a If adjustment is interrupted and an error is
displayed, check the following devices.
q When the track shoe does not move:
HST pump
q When the track shoe moves:
q Adjustment method: HST motor speed sensor
i) Jack up the rear frame bottom of the
machine and brace the blade in the lower- <Display example of error>
ing direction to float the whole track shoe
so that it can run idle.
k Since the track shoe will run idle
during adjustment, check that it is
floated securely above the ground.
ii) Run the engine at high idle.
iii) Check that the parking brake lever is in
the LOCK position and the PCCS lever is
in the neutral position and [P] is flashing in
the gear speed/set travel speed/shift
mode indicator section.
iv) Set the parking brake lever in the FREE
ward travel position, and adjustment
starts. a The arrowed letters indicate the abnormal
k If adjustment starts, the pump sides.
command current increases and q R: Right side
the track shoe starts running auto- q L: Left side
matically. (The track shoe starts q LR: Both right and left sides
running idle, then stops and starts
again. Take care.)
a The caution buzzer keeps sounding
during adjustment.
a The command current of the forward
pump increases to 805 mA, then the
track shoe stops.
a When adjustment is finished, [SET-
TING NOW!!] is displayed on the
lower line.
30-130 40 D31/37-22
[3002] Reverse pump set (For running track shoe a When stopping (interrupting) the track
idle) (Changed in normal order: B2) shoe during adjustment, return the
q This code is used to adjust the command cur- PCCS lever to the neutral position.
rent of the reverse pump while the track shoe (Operations of steering with the
is running idle. PCCS lever, brake pedal, fuel control
q The command current of the reverse pump is dial, and decelerator pedal are not
displayed on the lower line. accepted during adjustment. Take
care.)
from ii).
is effective.
a If adjustment is interrupted and an error is
displayed, check the following devices.
q When the track shoe does not move:
HST pump
q When the track shoe moves:
q Adjustment method: HST motor speed sensor
machine and brace the blade in the lower- <Display example of error>
starts. a The arrowed letters indicate the abnormal
k If adjustment starts, the pump sides.
command current increases and q R: Right side
the track shoe starts running auto- q L: Left side
matically. (The track shoe starts q LR: Both right and left sides
running idle, then stops and starts
again. Take care.)
during adjustment.
a The command current of the reverse
track shoe stops.
lower line.
D31/37-22 30-130 41
[3003] Forward pump start/max. capacity set (For a If the PCCS lever, fuel control dial,
travel) decelerator pedal, or brake pedal is
q This code is used to adjust the command cur- operated during adjustment, the
rent of the start and maximum capacity of the machine moves as operated. In this
forward pump while the machine is traveling. case, however, adjustment is inter-
q The command current of the forward pump is rupted, the caution buzzer stops
displayed on the lower line. sounding, and gear speed/set travel
speed/shift mode indicator section
stops flashing and lights up.
a When moving the machine after inter-
rupting adjustment, operate it as usu-
ally. The travel speed at the time of
interruption is kept, however.
from i).
is effective.
q Adjustment method: a If adjustment is interrupted and an error is
i) Move the machine to a wide and flat place displayed, adjust the following parts.
where it can travel straight for at least q When machine does not move:
30 m. HST pump
k Since the machine will travel q When machine moves:
straight forward during adjust- HST motor speed sensor
ment, work in a place where there
is not an obstacle through length <Display example of error>
of at least 30 m.
starts.
k If adjustment starts, the pump
command current increases and
the machine starts traveling for-
ward automatically. (The machine a The arrowed letters indicate the abnormal
starts traveling forward, then stops sides.
and starts again. Take care.) q R: Right side
a The caution buzzer keeps sounding q L: Left side
during adjustment. q LR: Both right and left sides
machine stops.
lower line.
30-130 42 D31/37-22
[3004] Reverse pump start/max. capacity set (For a If the PCCS lever, fuel control dial,
• This code is used to adjust the command cur- operated during adjustment, the
rent of the start and maximum capacity of the machine moves as operated. In this
reverse pump while the machine is traveling. case, however, adjustment is inter-
• The command current of the reverse pump is rupted, the caution buzzer stops
from i).
is effective.
q Adjustment method: a If adjustment is interrupted and an error is
i) Move the machine to a wide and flat place displayed, adjust the following parts.
where it can travel straight for at least q When machine does not move:
30 m. HST pump
k Since the machine will travel q When machine moves:
straight in reverse during adjust- HST motor speed sensor
is not an obstacle through length <Display example of error>
of at least 30 m.
starts.
ward automatically. (The machine a The arrowed letters indicate the abnormal
starts traveling forward, then stops sides.
and starts again. Take care.) q R: Right side
a The caution buzzer keeps sounding q L: Left side
during adjustment. q LR: Both right and left sides
machine stops.
lower line.
D31/37-22 30-130 43
[3005] Forward pump medium capacity set (For a If the PCCS lever, fuel control dial,
q This code is used to adjust the command cur- operated during adjustment, the
rent of the medium capacity of the forward machine moves as operated. In this
pump while the machine is traveling. case, however, adjustment is inter-
q The command current of the forward pump is rupted, the caution buzzer stops
from i).
is effective.
i) Move the machine to a wide and flat place
where it can travel straight for at least
15 m.
k Since the machine will travel
straight forward during adjust-
is not an obstacle through length
of at least 15 m.
starts.
ward automatically. (The machine
starts traveling forward, then stops
and starts again. Take care.)
during adjustment.
machine stops.
lower line.
30-130 44 D31/37-22
[3006] Reverse pump medium capacity set (For a If the PCCS lever, fuel control dial,
q This code is used to adjust the command cur- operated, the machine moves as
rent of the medium capacity of the reverse operated. In this case, however,
pump while the machine is traveling. adjustment is interrupted, the caution
q The command current of the reverse pump is buzzer stops sounding, and caution
displayed on the lower line. lamp lights up.
from i).
is effective.
i) Move the machine to a wide and flat place
where it can travel straight for at least
15 m.
k Since the machine will travel
straight in reverse during adjust-
is not an obstacle through length
of at least 15 m.
position and set the PCCS lever in the
reverse travel position, and adjustment
starts.
the machine starts traveling in
r e v e r s e a u t o m a t i c a l l y. ( T h e
machine starts traveling reverse,
then stops and starts again. Take
care.)
during adjustment.
a The command current of the reverse
machine stops.
lower line.
D31/37-22 30-130 45
[3007] Brake potentiometer max. set (Changed in [3016] Stall pressure test mode
normal order: A7) q This code is used to test the right and left HST
q This code is used to adjust the maximum posi- main circuit pressures, engine speed, and HST
tion of the brake pedal potentiometer. oil temperature (hydraulic oil temperature),
q The signal output of the brake pedal potenti- while the HST is stalled.
ometer is displayed by voltage on the lower q Right HST main circuit pressure, left HST main
line. circuit pressure, engine speed or HST oil tem-
(Display range: 0 – 5000) perature are displayed on the lower line.
q Adjustment method: q How to use:

i) Press and hold the brake pedal at the k Check that the HST oil temperature
stroke end. (hydraulic oil temperature) is in the
ii) Set buzzer cancel switch in the [U] posi- range from 40 to 60ºC while the HST is
tion and check that the caution buzzer stalled. (Do not stall the HST while the
sounds. oil temperature is out of the specified
a The display of the lower line does not range.)
change after adjustment. k Before selecting this code, check that
a Even if this code is turned OFF, the setting the parking brake lever is in the LOCK
is effective. position and the PCCS lever is in the
a This code is used to make the HST con- neutral position.
troller recognize the maximum position of a If this code is selected, the HST is stalled
the brake pedal potentiometer. It is not automatically. (The HST is stalled only
used to adjust the brake performance. when the PCCS lever is set in the FOR-
WARD or REVERSE position, however.)
q Travel speed: 3rd (Min. delivery of
HST motor)
q Parking brake solenoid valve: OFF
q Slow brake solenoid valve: OFF
k The following errors are set in this
code for safety. If one of them is turned
ON, the command current to the HST
pump EPC valve is stopped.
q No. 1: When the machine is set in this
mode, it is moving or PCCS lever is
not in neutral position.
q No. 2: The parking brake lever is not
q No. 3: After the machine is set in this
mode, it is moved.
q No. 4: The parking brake release
pressure is increased.
30-130 46 D31/37-22
i) While the engine is running, select an item [3019] Gear speed limit mode
to be displayed by operating information q This code is used to prevent shifting the gear
switch (5). to the 3rd position.
q [>]: Next code q The usable gear speeds are displayed on the
q [<]: Previous code lower line.
a The following items can be displayed.
No. Display Item Unit
1 R-PRES Right HST main circuit pressure MPa
2 L-PRES Left HST main circuit pressure MPa
3 ENG-REV Engine speed rpm
4 HST TEMP HST oil temperature °C
ii) Check that the parking brake lever is in

the LOCK position.
a Stall the HST while the parking brake
lever is in the LOCK position.
iii) Set the PCCS lever in the FORWARD or
REVERSE position to stall the HST and q Using method:
test the necessary items. i) Select use of the highest gear speed by
a If the PCCS lever is set in the FOR- operating information switch.
WARD or REVERSE position, the q [3RD]: Permit use of 3rd gear speed.
HST stalls. If the PCCS lever is q [2ND]: Limit use of 3rd gear speed.
returned, stalling of the HST stops. ii) Set the buzzer cancel switch in the [U]
a The displayed item can be changed position to enter the setting.
even while the HST is stalled. a If the gear speed is limited, it is not shifted
k While the HST is stalled, the oil to the 3rd position, even if the shift-up
temperature rises sharply and switch is operated.
locally. Accordingly, do not stall a The setting becomes effective when the
the HST continuously for more starting switch is turned OFF and ON.
than 30 seconds. Accordingly, the a The setting is effective in both quick shift
following restriction function is mode and variable shift mode.
installed.
a If stalling of the HST starts, the gauge
displays (hereinafter, referred to as
the gauges) of gear speed, set travel
speed and shift indicator section go
off one cell by one. If stalling is
stopped, the gauges are lighted one
cell by one.
If all the gauges are put out, stalling of
the HST is stopped automatically.
When starting stalling again, return
the PCCS lever to the neutral position
once, and then start again.
D31/37-22 30-130 47
[3024] Motor set (For running track shoe idle) v) After adjustment is finished, set the PCCS
(Changed in normal order: B3) lever in the neutral position and set the
q This code is used to adjust the command cur- parking brake lever in the LOCK position.
rent of the motor while the track shoe is run- a When starting adjustment again after
ning idle. interrupting it, perform the procedures
q The command current of the motor is dis- from ii).
played on the lower line. a Even if this code is turned OFF, the setting
is effective.
a If adjustment stops automatically and an
error is displayed, check the following
items.
q When track shoe does not move:
HST pump
q When track shoe moves:
1) HST motor speed sensor
2) Hose between motor EPC and
motor
3) (Is engine running at high idle?)
4) (Is hydraulic oil temperature abnor-
mally low?)
q Adjustment method: <Display example of error>

machine and brace the blade in the lower-
position and set the PCCS lever in the for- a The arrowed letters indicate the abnormal
ward travel position, and adjustment sides.
starts. q R: Right side
k If adjustment starts, the motor q L: Left side
command current increases and q LR: Both right and left sides
the track shoe starts running auto-
matically. Take care.
during adjustment.
a The motor command current changes
and then the track shoe stops.
lower line.
a When stopping (interrupting) the track
shoe during adjustment, return the
PCCS lever to the neutral position.
(Operations of steering with the
PCCS lever, brake pedal, fuel control
dial, and decelerator pedal are not
accepted during adjustment. Take
care.)
30-130 48 D31/37-22
[3032] Fan test mode selection [3033] Fan set

q This code is used to select the normal control q This code is used to adjust the fan command
mode, fan 100% mode or fan 70% mode. current while the fan is running.
q The mode to be selected is displayed on the q The fan command current is displayed on the
lower line. lower line.
q How to use q Adjustment method

i) Operate the information switch to select a k Before selecting this code, adjust the
mode. HST oil temperature (hydraulic oil tem-
ii) Set buzzer cancel switch in the [U] posi- perature) to 50 – 60°C.
tion to settle the setting. k Keep the work equipment lowered to
q The following modes can be selected. the ground and set the work equipment
lock lever in the LOCK position during
Order Display Item
this adjustment.
1 OFF Normal control mode i) Start the engine, set the fuel control dial in
2 100% Fan 100% mode the high idle position.
3 70% Fan 70% mode ii) Set the buzzer cancel switch in the [U]
position, and adjustment starts.
a In the fan 100% mode or fan 70% mode, iii) The fan command current changes from
the cooling fan speed is forcibly set to 800 mA to 300 mA and adjustment is fin-
100% or 70% of the maximum speed. ished.
a When the hydraulic oil temperature is a When adjustment is finished, [SET-
below 45°C and the coolant temperature is TING NOW!!] is displayed on the
below 60°C, the fan EPC current is set to lower line.
1,000 mA and the fan speed is lowered a Even if this code is turned OFF, the
below 200 rpm even in the fan 100% setting is effective.
mode or fan 70% mode. In this case,
increase the hydraulic oil temperature
above 55°C and the engine coolant tem-
perature above 65°C and then check
again.
is effective as long as the starting switch is
in the ON position.
a Accordingly, when returning the fan into
the normal control mode, set it in the nor-
mal control mode again or turn the starting
switch OFF.
D31/37-22 30-130 49
[3035] Forward pump start adjustment value vi) Set the buzzer cancel switch in the [U]
change (For right and left separately) position and check that the caution buzzer
q This code is used to adjust the forward pump sounds and [SETTING NOW!!] is dis-
command value finely when the right and left played on the lower line.
track shoes do not start forward simulta- a Even if this code is turned OFF, the setting
neously (the machine swings in either direc- is effective.
tion) after performing adjustments of [B1] or
[3003] [3005].
q The correction value of the right or left side to
be adjusted is displayed on the lower line.
q Adjustment method
i) Operate the information switch to select
the side which starts earlier (RIGHT/
LEFT).
q Press the [>] or [<] button to select
[RIGHT] or [LEFT].
ii) Set the buzzer cancel switch in the [U]
position to settle the selected correction
direction.
If the selection is settled, [AD:] is
added next to [RIGHT/LEFT] on the lower
line.
Once adjustment is completed, it cannot
be returned. Accordingly, be sure to
record the value on the right side of
[DA:] before starting iii).
iii) Operate the information switch to
decrease the value by 1. (Decrease the
value by 1)
q [>]: Increase value (Start earlier)
q [<]: Decrease value (Start later)
k If the value is changed largely, the
machine starts sharply. Take care.
a If you changed the value largely by mis-
take at a time, turn the starting switch OFF
and then start adjustment again.
iv) Check that the right and left track shoes
start forward simultaneously.
v) Repeat steps iii) and iv) until the right and
left track shoes start simultaneously.
30-130 50 D31/37-22
[3036] Reverse pump start adjustment value vi) Set the buzzer cancel switch in the [U]
change (For right and left separately) position and check that the caution buzzer
q This code is used to adjust the reverse pump sounds and [SETTING NOW!!] is dis-
command value finely when the right and left played on the lower line.
track shoes do not start reverse simulta- a Even if this code is turned OFF, the setting
neously (the machine swings in either direc- is effective.
tion) after performing adjustments of [B2] or
[3004] [3006].
q The correction value of the right or left side to
be adjusted is displayed on the lower line.
q Adjustment method
i) Operate the information switch to select
the side which starts earlier (RIGHT/
LEFT).
q Press the [>] or [<] button to select
[RIGHT] or [LEFT].
ii) Set the buzzer cancel switch in the [U]
position to settle the selected side.
If the selection is settled, [AD:] is
added next to [RIGHT/LEFT] on the lower
line.
a Once adjustment is completed, it cannot
be returned. Accordingly, be sure to
record the value on the right side of
[DA:] before starting iii).
iii) Operate the information switch to
decrease the value by 1.
iv) Check that the right and left track shoes
start reverse simultaneously.
v) Repeat steps iii) and iv) until the right and
left track shoes start simultaneously.
D31/37-22 30-130 51
[3037] Forward pump start adjustment value v) Set the buzzer cancel switch in the [U]
change (For right and left simultaneously) position and check that the caution buzzer
q This code is used to adjust the forward pump sounds and [SETTING NOW!!] is dis-
command value finely when remarkably large played on the lower line.
shocks are made at the starting and stopping a Even if this code is turned OFF, the setting
moments of forward travel after performing is effective.
adjustments of [B1] or [3003] [3005]. a This code is not used to adjust the starting
q The travel speed and correction value are dis- acceleration performance but used to
played on the lower line. adjust the shocks made at the moments
when the machine starts and stops.
q Adjustment method
k Once adjustment is completed, it can-
not be returned. Accordingly, be sure
to record the value on the right side of
[DA:****] before starting adjustment.
i) Operate the information switch to
ii) Check that shocks are not made at the
moments when the machine starts and
stops forward travel.
iii) Repeat i) and ii) until shocks are not
made.
iv) Select the variable gear shift mode, set
the gear speed display to the minimum (2
gauge segments), drive the machine to
forward, and check that the travel speed is
“0.6 km/h” or higher (the value on the right
of [SPD:1] on the lower line, is 600 or
higher).
If the travel speed is below “0.6 km/hÅh,
time lag in start and other negative effects
are made. Accordingly, return the adjusted
value until the travel speed lowers below
“0.6 km/hÅh.
30-130 52 D31/37-22
[3038] Reverse pump start adjustment value v) Set the buzzer cancel switch in the [U]
change (For right and left simultaneously) position and check that the caution buzzer
q This code is used to adjust the reverse pump sounds and [SETTING NOW!!] is dis-
command value finely when remarkably large played on the lower line.
shocks are made at the starting and stopping a Even if this code is turned OFF, the setting
moments of reverse travel after performing is effective.
adjustments of [B2] or [3004] [3006]. a This code is not used to adjust the starting
q The travel speed and correction value are dis- acceleration performance but used to
played on the lower line. adjust the shocks made at the moments
when the machine starts and stops.
[ – ] Service meter set

Refer to the “SERVICE NEWS” about this item.
q Adjustment method
k Once adjustment is completed, it can-
not be returned. Accordingly, be sure
to record the value on the right side of
[DA:] before starting adjustment.
i) Operate the information switch to
ii) Check that shocks are not made at the
moments when the machine starts and
stops reverse travel.
iii) Repeat i) and ii) until shocks are not
made.
iv) Select the variable gear shift mode, set
the gear speed display to the minimum (2
gauge segments), drive the machine to
reverse, and check that the travel speed is
“0.6 km/h” or higher (the value on the right
of [SPD:1] on the lower line, is 600 or
higher).
If the travel speed is below “0.6 km/hÅh,
time lag in start and other negative effects
are made. Accordingly, return the adjusted
value until the travel speed lowers below
“0.6 km/hÅh.
D31/37-22 30-130 53
[12] Maintenance interval setting mode (MAIN- a Displayed maintenance item and
TENANCE MONITOR) function:
Monitor panel can set the maintenance intervals for
Maintenance items
various oil and filters which become the base of Code Display
and functions
replacement time display for oil and filter. Also the
monitor panel can activate or deactivate the display 01 01: ENG OIL Engine oil
function. 02 02: ENG FILT Engine oil filter
03 03: FUEL FILT Fuel main filter
1. Selection of the service menu
41 41: P FUEL FILT Fuel pre-filter
Select the maintenance interval setting mode
(MAINTENANCE MONITOR) in the service 04 04: HYD FILT Hydraulic oil filter
menu selection screen. 06 06: CORR RES Corrosion resistor (*)
18 18: BYPS FILT Bypass filter (*)
07 07: DAMP OIL Damper filter (*)
08 08: FNL OIL Final drive oil
10 10: HYD OIL Hydraulic oil
19 19: POWL OIL Power train oil (*)
20 20: POWL FILT Power train oil filter (*)
21 21: HST FILT HST charge filter
Setting default value for all
– INITIALIZE
items
Setting validity or invalidity for
– ALL ITEMS
all items
* Set ineffective on this machine.
2. Displaying and selecting the maintenance item
and function a The maintenance items which have
1) With the service menu selected, press the their respective codes are changed
[U] switch to display the maintenance separately and the functions which
item and function selection screen. have no codes are used to change all
q [U]: Conduct the service menu. the items simultaneously.
2) If [>] switch or [<] switch is pushed while

the maintenance item and function selec-
tion screen is displayed, the maintenance
item and function will be displayed end-
lessly in the order shown by the below
table. Select the item or the function which
will be used.
q [>]: To proceed to next maintenance
item and function.
q [<]: To return to the previous mainte-
nance item and function.
30-130 54 D31/37-22
3. Display contents of the maintenance item 2) With the interval change screen displayed,
(Items with code No.) press the [U] switch to display the interval
If the maintenance item is selected, the follow- time input screen.
ing contents are displayed. q [U]: Select interval time input screen.
1: Code (2 digits) a The current set interval is displayed
A: Maintenance item on the screen.
2: Remaining time to set replacement time 3) On the interval change screen, operate
3: Number of times of replacement up to the switches [>], [<], [U] and [t] to input
present the interval time.
q [ > ]: Number at the cursor increases.
q [ < ]: Number at the cursor decreases.
q [U]: Number at the cursor is deter-
mined.
q [t ]: Cursor moves to left end or the
display returns to interval
change screen.
a The time must always be input with 4
digits. For the time with less than 4
digits, input 0s in place of the vacant
number.
4. Changing the interval time by maintenance

item (Items with code No.)
1) With the item to change the interval time
(ex: P FUEL FILT) selected on the mainte-
nance item and the function selection
screen, press the [U] switch to display the
interval change screen.
q [U]: Execute the function to change
maintenance item.
4) When the interval time is completely

determined, the screen to confirm the
changes is displayed. Then, operate the
switches [<], [>] and [U].
q [ <]: Select YES (move cursor)
q [ >]: Select NO (move cursor)
a With this screen displayed, if the [>]

switch is operated, the screen
switches to the setting screen for
enable or disable the maintenance
item.
D31/37-22 30-130 55
5. Set the function activation or deactivation by 4) When the change confirmation screen is
maintenance item (items with code No.). displayed, operate each [<], [>] and [U]
1) With the item (ex: 41: FUEL P FILT) to switches.
change the enable or disable of the func- q [ <]: Select YES (move cursor)
tion selected on the maintenance item and q [ >]: Select NO (move cursor)
function selection screen, press the [U] q [U]: Execute YES or NO
switch to display the interval change
screen.
q [U]: Execute the function to change
maintenance item.
a If the timer which has been OFF is

turned ON, the interval is set to the
value before it was turned OFF and
the rest of set time of the timer is
2) After the screen to change intervals is dis- reset. The number of resetting times
played, press the [>] switch to display the is set to the value before it was turned
activation or deactivation setting screen. OFF.
q [>]: Switch to activation/deactivation
setting screen. 6. Setting default values of interval time for all
a If the function is activated, it is dis- items (INITIALIZE)
played like the upper line. And if it is 1) With all item default value setting (INI-
deactivated, it is displayed like the TIALIZE) selected on the maintenance
lower line. item and function selection screen, press
3) After the activate or deactivate setting the [U] switch to display the all item
screen is displayed, check the present default value setting screen.
setting status and the contents of change. q [U]: Execute the function to set the
Then operate the switches [U] or [t]. default values of all the items.
q [U]: Switch to the change confirma-
tion screen
q [t]: To return to the maintenance
i te m an d fu nc ti on s e le ct io n
screen.
q [< ]: Switch to the interval change
screen.
30-130 56 D31/37-22
2) After the all item default value setting 2) After the all items activation or deactiva-
screen is displayed operate [<], [>] and tion setting screen is displayed, press the
[U] switches. [>] switch or the [<] switch to display the
q [ < ]: Select YES (move cursor) activation setting or deactivation setting
q [ > ]: Select NO (move cursor) screen.
q [U]: Execute YES or NO q [>]: Switch to activation setting
screen.
q [<]: Switch to deactivation setting
screen.
a To deactivate all the items, display the
lower line setting screen (OFF), and
to activate all the items, display the
lower line setting screen (ON).
a All the items are set to their respec-

tive default values, regardless of the
ON or OFF state of each item.
a The rest of the set time of the timer is
set to the [default value – elapsed
time after the previous replacement].
a The number of resetting times is kept
at the value before the default was 3) Confirm the setting screen, press the [U]
set. switch or the [t] switch to display the
a Each item is set turned ON. change confirmation screen.
q [U]: To switch to the change confir-
7. Setting the function activation or deactivation mation screen.
for all the items (ALL ITEMS) q [t ]: To return to the maintenance
1) With the activation or deactivation setting i te m an d fun c ti on s el ec t io n
for all items selected (ALL ITEMS) on the screen.
maintenance item and function selection a If deactivation of all the items (OFF) is
screen, press the [U] switch to display the set, it will stop the maintenance func-
all items activation or deactivation setting tion of all the items, regardless of the
screen. setting of each maintenance item.
q [U]: Implement the function to set a If activation of all the items (ON) is
activation or deactivation of all set, the maintenance function of all
the items. the items starts to work regardless of
the setting of each maintenance item
and the interval is set to the previous
time before the interval has been
deactivated.
The timer is reset simultaneously.
a The number of resetting times is set
to the value before it was turned OFF.
D31/37-22 30-130 57
4) When the change confirmation screen is

displayed, operate each [<], [>] and [U]
switches.
q [ < ]: Select YES (move cursor)
q [ > ]: Select NO (move cursor)
Table of oil and filter replacement time set items
Replacement frequency
Order System and function Code Display Remarks
(Default value)
1 Engine oil 01 ENG OIL 0500h
2 Engine oil filter 02 ENG FILT 0500h
3 Fuel main filter 03 FUEL FILT 1000h
4 Fuel pre filter 41 P FUEL FILT 0500h
5 Hydraulic oil filter 04 HYD FILT 2000h
6 Corrosion resistor 06 CORR RES 1000h *1
7 Bypass filter 18 BYPS FILT 1000h *1
8 Damper filter 07 DAMP OIL 1000h *1
9 Final drive oil 08 FNL OIL 1000h
10 Hydraulic oil 10 HYD OIL 2000h
11 Power train oil 19 POWL OIL 1000h *1
12 Power train oil filter 20 POWL FILT 500h *1
13 HST charge filter 21 HST FILT 2000h
All item simultaneous
14 Setting default value for all items (None) INITIALIZE —
setting function
All item simultaneous
15 Setting enable or disable for all items (None) ALL ITEMS —
setting function
*1: Set ineffective on this machine.
30-130 58 D31/37-22
[13] Telephone No. input mode (TEL) 3) When all of the 12 digits are determined,
The telephone No. to be set in the monitor panel inputting is completed and the screen
can be input/change/reset by switch operation. returns to the service menu selection
a When action code “E03” or “E04” is displayed, screen.
the telephone No. and “CALL” are also dis-
played. [14] Machine model selection mode (MACHINE)
1. Service menu selection This mode is a function of making the monitor panel
While the service menu selection screen is dis- and HST controller recognize the machine model.
played, select the telephone No. input mode k If the machine model is different from the
(TEL). setting of the controller, the machine may
move unexpectedly or an error is made.
Accordingly, be sure to perform correct set-
ting for the machine.
k If any data is determined carelessly in this
mode, the memory in the controller is ini-
tialized. Accordingly, do not operate unnec-
essarily.
a If any data is determined with a machine differ-
ent from the machine that the HST controller
has recognized, all the data need to be initial-
ized again.
a The machine currently recognized by the mon-
itor panel and HST controller can be verified in
the real-time monitoring mode.
2. Telephone No. input Controller: MONITOR PANEL
1) While the service menu is selected, press Monitoring code: 00204 MACHINE CODE
the [U] switch to display the telephone Controller: HST
No. input screen. Monitoring code: 00205 MACHINE CODE
q [U]: Execute the service menu.
1. Service menu selection
While the service menu selection screen is dis-
played, select the machine selection mode
(MACHINE).
a The currently set telephone No. is dis-

played on the screen.
2) Operate the [>], [<], [U] and [t] switches
to input a telephone No.
q [ > ]: Number at the cursor increases. a The machine currently set in the monitor
q [ < ]: Number at the cursor decreases. panel is displayed on the screen.
q [U]: Number at the cursor is deter-
mined.
q [ t]: Cursor moves to left end or the
display returns to service menu
select screen.
a Input 12 digits as the telephone No.
a To make a blank, select “*Åh.
D31/37-22 30-130 59
2. Machine model selection and setting 3. Check of setting

1) While the service menus is selected, hold 1) Turn the starting switch OFF and keep it in
down the [U] switch for 3 seconds to dis- the OFF position for at least 15 seconds.
play the machine selection screen. a If the starting switch is not kept OFF
q [U] (Holding down for 3 seconds): for 15 seconds, the HST controller
Execute the service menu. does not save data.
a The machine currently set in the mon- 2) Turn the starting switch ON.
itor panel is displayed on the screen. a At this time, the machine setting
becomes effective.
3) In the real-time monitoring mode, verify
the machine saved in the monitor panel
and HST controller.
a The HST controller may not be inter-
changeable between machines. If a
machine that is not applicable is
selected, its setting is not accepted.
2) While the machine selection and setting

screen is displayed, press the [>] switch or
[<] switch, and the machines are dis-
played repeatedly in the order shown in
the following table. Select a machine to be
used.
q [>]: Go to the next machine.
q [<]: Return to the previous machine.
<Displayed machine>
Display Model
D51 D51 (Default)
D39 D39
D37 D37
D31 D31
3) While a machine is selected on the

machine selection screen, press the [U]
switch to determine the setting.
q [U]: Determine the setting.
q [t]: Return to the service menu
selection screen.
4) After the setting is determined, the screen
changes to the service menu screen.
Check that the set machine is displayed.
30-130 60 D31/37-22
[15] Optional selection mode (OPTIONAL SELECT) [16] Initializing mode (INITIALIZE)
a Do not use this mode. a This mode is exclusive for the plant, and is not
used for field service.
D31/37-22 30-130 61
SEN04504-02 Items to be adjusted when electric/hydraulic devices are adjusted/replaced
Items to be adjusted when

electric/hydraulic devices are
adjusted/replaced 1
a If any of the following electric/hydraulic devices

are adjusted or replaced, perform the following
system adjustment.
k If the system is not adjusted, the machine
may not operate normally but may move
unexpectedly. Accordingly, be sure to
adjust the system.
*1: See Testing and adjusting, Part 3, page 63. *8: See Testing and adjusting, Part 3, page 39.
*7: See Testing and adjusting, Part 3, page 37.
a For the system adjustment, see “Special functions of monitor panel (EMMS)Åh, “Service modeÅh, “Tuning
modeÅh.
a For the using method of “Special functions of monitor panel (EMMS)Åh, see Testing and adjusting, Part 3, page 2.
a For the using method of “Service modeÅh, see Testing and adjusting, Part 3, page 16.
a For the using method of “Tuning modeÅh, see Testing and adjusting, Part 3, page 33.
a For the using method of each tuning item, see the page of the corresponding ID.
30-130 62 D31/37-22
Adjustment procedure after replacement of HST controller SEN04504-02
Adjustment procedure after 2) Select “TUNING1” and initialize the steer-

replacement of HST controller 1
ing lever and brake potentiometer.
(1012, 1010, 1013, 1011, 1014, 0005,
a After the machine is assembled or the HST 3007)
controller is replaced, adjust the system
adjust the system.
a Precautions for replacing HST controller:
When replacing the HST controller, stop the
machine on a safe place and turn the starting
switch OFF.
1. Selecting machine model

1) Turn the starting switch ON, set the moni-
tor panel in “Machine model selection
mode” in the service mode, and select the 3) Turn the starting switch OFF.
machine model.
3. Adjusting HST pump and HST motor
1) Jack up the rear part of the machine frame
and brace the blade against the ground to
float all the track shoes above the ground
so that the tracks can be rotated with no
load.
k Since the tracks are rotated with
no load during adjustment, check
that the tracks are floated above
the ground.
2) Run the engine at high idle.
3) Set the monitor panel in “Adjustment
mode” in the service mode, select
“TUNING2Åh, and initialize the HST pump
2) Turn the starting switch OFF. and HST motor. (3001, 3002, 3024)
2. Adjusting steering lever and brake potentiome-

ter
1) Turn the starting switch ON again and set
the monitor panel in “Adjustment mode” in
the service mode.
4) Turn the starting switch OFF.
D31/37-22 30-130 63
SEN04504-02 Adjustment procedure after replacement of HST controller
4. Initializing fan a For the using method of ÅgElectrical

1) Adjust the HST oil temperature (hydraulic system failure history display modeÅh,
oil temperature) to 50 – 60 °C. see Testing and adjusting, Part 3,
2) Run the engine at high idle. page 18.
3) Set the monitor panel in “Adjustment
mode” in the service mode, select “ID
INPUTÅh, select fan initialization (3033),
and adjust the fan.
4) Turn the starting switch OFF.
5. Checking failure code

1) Turn the starting switch ON again and set
the monitor panel in “Electrical system
fault history display mode” in the service
mode.
2) Check to see if there is any failure code
being indicated. If there is not any, delete
all the recorded failure codes.
a If there is any failure code being indi-
cated, remove the cause of the failure
by troubleshooting and then perform
steps 1) and 2).
a For the system adjustment, use
ÅgMachine model selection modeÅh,
ÅgTuning modeÅh, and ÅgElectrical sys-
tem failure history display modeÅh of
ÅgService modeÅh of “Special functions
of monitor panel (EMMS)Åh.
a For the using method of “Special
functions of monitor panel (EMMS)Åh,
see Testing and adjusting, Part 3,
page 2.
a For the using method of “Service
modeÅh, see Testing and adjusting,
Part 3, page 16.
a For the using method of ÅgMachine
model selection modeÅh, see Testing
and adjusting, Part 3, page 59
a For the using method of “Tuning
modeÅh, see Testing and adjusting,
Part 3, page 33.
a For the using method of each tuning
item, see the page of the correspond-
ing ID.
30-130 64 D31/37-22
Adjustment procedure after replacement of monitor panel SEN04504-02
Adjustment procedure after 3. Setting phone No.

replacement of monitor panel 1
Set the monitor panel in “Phone No. setting
mode” in the service mode and set the phone No.
a After the monitor panel is replaced, adjust the
system according to the following procedure.
adjust the system.
a Precautions before replacement of monitor
panel:
If the monitor panel is replaced, the saved val-
ues of the service meter, oil and filter mainte-
nance mode and phone No. are reset.
Accordingly, check and record the service
meter reading, time before maintenance and
phone No. before replacing the monitor panel.
a Precautions for replacing monitor panel:
When replacing the monitor panel, stop the 4. Checking failure code
machine on a safe place and turn the starting 1) Set the monitor panel in “Electrical system
switch OFF. fault history display mode” in the service
mode.
1. Selecting machine model 2) Check to see if there is any failure code
1) Turn the starting switch ON, set the moni- being indicated. If there is not any, delete
tor panel in “Machine model selection all the recorded failure codes.
mode” in the service mode, and select the a If there is any failure code being indicated,
machine model. remove the cause of the failure by trouble-
shooting and then perform steps 1) and 2).
a Precautions after replacement of monitor
panel:
If the monitor panel is replaced, the service
meter for the oil and filter maintenance function
restarts from 0. As a result, the replacement
time shown on the monitor panel may be differ-
ent from the actual operating time. Accordingly,
ap pl y the ti me b ef or e t he m ai nt en an c e
recorded before the replacement until the first
maintenance after the replacement.
a For the system adjustment, use ÅgMachine
model selection modeÅh, ÅgTuning modeÅh, and
ÅgElectrical system failure history display
modeÅh of ÅgService modeÅh of “Special functions
2) Turn the starting switch OFF. of monitor panel (EMMS)Åh.
a For the using method of “Special functions of
2. Setting service meter monitor panel (EMMS)Åh, see Testing and
Set the service meter to the value recorded adjusting, Part 3, page 2.
before replacement. a For the using method of “Service modeÅh, see
a Referring to “Service NewsÅh, set the ser- Testing and adjusting, Part 3, page 16.
vice meter. a For the using method of ÅgMachine model
selection modeÅh, see Testing and adjusting,
Part 3, page 59
a For the using method of “Tuning modeÅh, see
Testing and adjusting, Part 3, page 33.
a For the using method of each tuning item, see
the page of the corresponding ID.
a For the using method of ÅgElectrical system fail-
ure history display modeÅh, see Testing and
adjusting, Part 3, page 18.
D31/37-22 30-130 65
SEN04504-02 Adjustment procedure after replacement of monitor panel
30-130 66 D31/37-22
Pm-clinic service (D31EX-22, D31PX-22) SEN04504-02
Pm-clinic service (D31EX-22, D31PX-22) 1
D31/37-22 30-130 67
SEN04504-02 Pm-clinic service (D31EX-22, D31PX-22)
Pm-clinic measuring points for D31EX, PX-22 (1/2)
[1] Engine speed (*1) [4] Blow-by pressure (*2)
[2] Exhaust gas temperature (*2) [5] Engine oil pressure (*5)
[3] Boost pressure (*3)

Reference pages for measurement procedure des-
ignated
*1. Engine speed: Testing and adjusting, Part 1,

page 6.
*2. Exhaust gas temperature:
*3. Boost pressure: Testing and adjusting, Part 1,
page 7.
*4. Blow-by pressure: Testing and adjusting, Part 1,
page 15.
*5. Engine oil pressure: Testing and adjusting,
Part 1, page 17.
30-130 68 D31/37-22
Reference pages for measurement procedure designated

*6. HST charge circuit pressure: Testing and adjusting HST oil pressure, Part 2, page 4.
*7. Solenoid valve output pressure: Measuring solenoid valve output oil pressure, Part 2, page 9.
*8. Fan circuit pressure, Fan speed: Measuring fan circuit pressure and fan speed, Part 1, page 26.
*9. Work equipment pump relief pressure: Testing work equipment oil pressure, Part 2, page 22.
*10. Work equipment PPC valve output pressure: Testing work equipment PPC valve output oil pressure,
Part 2, page 24.
D31/37-22 30-130 69
5DWHGVSHHG
30-130 70 D31/37-22
D31/37-22 30-130 71
Pm Clinic Serial No.

D31EX/PX-22
Undercarriage check sheet
Work order No. Date Service meter Serviceman

/ / h
q Measure the bushing temperature immediately after operations

Left side of machine
Measurement
Pass Fail
results
Right side of machine

Measurement
Pass Fail
results
q Opening of track link

Left track A: Clearance between links
Pin No. 1.2
Right track A: Clearance between links

Pin No. 1.2
30-130 72 D31/37-22
D31EX-22 (Wet type/Normal)
Y Komatsu
Undercarriage Inspection Customer name:
T20606 Address:
Model D31EX-22 Serial# Equip# Work Order No

Location SMR Wet,AR,HD or Dry WET
Soil condition Dealer Shoe width (mm)
Working condition Inspector Shoe type SINGLE
Insp.Date(yyyy/mm/dd) (yyyy/m/d) Wear type NORMAL
New 100% Measured Wear SMR Hours on Comments/Observation
Wear mm % New Rebuilt Parts:
LH 617.2 637.2
LINK PITCH Regular
M L L=l/4 RH 617.2 637.2
LH 154.30 159.30
master pin
l
Master
RH 154.30 159.30
LH 90.0 80.0
H
RH 90.0 80.0
LINK HEIGHT
New Turned
BUSHING d1
LH 54.0 43.8
New Turned
d
d RH 54.0 43.8
D is the smallest
of d1, d2 and, d3
GROUSER HIGHT LH 47.0 20.0
H
RH 47.0 20.0
CARRIER LH 142.0 128.0
Front
RH 142.0 128.0
D LH 142.0 128.0
Rear
RH 142.0 128.0
LH 14.0 22.0
IDLER Front
RH 14.0 22.0
H
LH 14.0 22.0
Rear
RH 14.0 22.0
1 LH 170.0 152.0
2 LH 170.0 152.0
3 LH 170.0 152.0
4 LH 170.0 152.0
5 LH 170.0 152.0
6 LH 170.0 152.0
7 LH 170.0 152.0
TRACK ROLLER 8 LH 170.0 152.0
9 LH 170.0 152.0
D 10 LH 170.0 152.0
1 RH 170.0 152.0
h2 h1 2 RH 170.0 152.0
3 RH 170.0 152.0
D=2(h1-h2) 4 RH 170.0 152.0
5 RH 170.0 152.0
6 RH 170.0 152.0
7 RH 170.0 152.0
8 RH 170.0 152.0
9 RH 170.0 152.0
10 RH 170.0 152.0
SPROCKET h1 LH 0.0 6.0
H is the smallest of
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
D31/37-22 30-130 73
D31PX-22 (Wet type/Normal)
Y Komatsu
T20606 Address:
Model D31PX-22 Serial# Equip# Work Order No

LH 617.2 637.2
LINK PITCH R
M L L=l/4 RH 617.2 637.2
LH 154.30 159.30
master pin
l
M
RH 154.30 159.30
LH 90.0 80.0
H
RH 90.0 80.0
LINK HEIGHT
New Turned
BUSHING d1
LH 54.0 43.8
New Turned
d
d RH 54.0 43.8
D is the smallest
of d1, d2 and, d3
H
RH 47.0 20.0
Front
RH 142.0 128.0
D LH 142.0 128.0
Rear
RH 142.0 128.0
LH 14.0 22.0
IDLER Front
RH 14.0 22.0
H
LH 14.0 22.0
Rear
RH 14.0 22.0
1 LH 170.0 152.0
2 LH 170.0 152.0
3 LH 170.0 152.0
4 LH 170.0 152.0
5 LH 170.0 152.0
6 LH 170.0 152.0
7 LH 170.0 152.0
9 LH 170.0 152.0
D 10 LH 170.0 152.0
1 RH 170.0 152.0
h2 h1 2 RH 170.0 152.0
3 RH 170.0 152.0
D=2(h1-h2) 4 RH 170.0 152.0
5 RH 170.0 152.0
6 RH 170.0 152.0
7 RH 170.0 152.0
8 RH 170.0 152.0
9 RH 170.0 152.0
10 RH 170.0 152.0
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
30-130 74 D31/37-22
Pm-clinic service (D37EX-22, D37PX-22) 1
D31/37-22 30-130 75
[1] Engine speed (*1) [4] Blow-by pressure (*4)
[2] Exhaust gas temperature (*2) [5] Engine oil pressure (*5)
[3] Boost pressure (*3)

Reference pages for measurement procedure des-
ignated
*1. Engine speed: Testing and adjusting, Part 1,

page 6.
*2. Exhaust gas temperature:
*3. Boost pressure: Testing and adjusting, Part 1,
page 7.
*4. Blow-by pressure: Testing and adjusting, Part 1,
page 15.
*5. Engine oil pressure: Testing and adjusting,
Part 1, page 17.
30-130 76 D31/37-22
Reference pages for measurement procedure designated

*6. HST charge circuit pressure: Testing and adjusting HST oil pressure, Part 2, page 4.
*7. Solenoid valve output pressure: Measuring solenoid valve output oil pressure, Part 2, page 9.
*8. Fan circuit pressure, Fan speed: Measuring fan circuit pressure and fan speed, Part 1, page 26.
*9. Work equipment pump relief pressure: Testing work equipment oil pressure, Part 2, page 22.
*10. Work equipment PPC valve output pressure: Testing work equipment PPC valve output oil pressure,
Part 2, page 24.
D31/37-22 30-130 77
+LJKLGOH+67VWDOO
([KDXVW
WHPSHUDWXUH

^` ^`
30-130 78 D31/37-22
D31/37-22 30-130 79
Pm Clinic Serial No.

D37EX/PX-22
Undercarriage check sheet
Work order No. Date Service meter Serviceman

/ / h
q Measure the bushing temperature immediately after operations

Left side of machine
Measurement
Pass Fail
results
Right side of machine

Measurement
Pass Fail
results
q Opening of track link

Left track A: Clearance between links
Pin No. 1.2
Right track A: Clearance between links

Pin No. 1.2
30-130 80 D31/37-22
D37EX-22 (Wet type/Normal)

Y Komatsu
T20606 Address:
Model D37EX-22 Serial# Equip# Work Order No

LH 617.2 629.2
LINK PITCH Regular
M L L=l/4 RH 617.2 629.2
LH 154.30 157.30
master pin
l
Master
RH 154.30 157.30
LH 90.0 80.0
H
RH 90.0 80.0
LINK HEIGHT
New Turned
BUSHING d1
LH 54.0 43.8
New Turned
d
d RH 54.0 43.8
D is the smallest
of d1, d2 and, d3
H
RH 47.0 20.0
Front
RH 142.0 128.0
D LH 142.0 128.0
Rear
RH 142.0 128.0
LH 14.0 22.0
IDLER Front
RH 14.0 22.0
H
LH 14.0 22.0
Rear
RH 14.0 22.0
1 LH 170.0 152.0
2 LH 170.0 152.0
3 LH 170.0 152.0
4 LH 170.0 152.0
5 LH 170.0 152.0
6 LH 170.0 152.0
7 LH 170.0 152.0
9 LH 170.0 152.0
D 10 LH 170.0 152.0
1 RH 170.0 152.0
h2 h1 2 RH 170.0 152.0
3 RH 170.0 152.0
D=2(h1-h2) 4 RH 170.0 152.0
5 RH 170.0 152.0
6 RH 170.0 152.0
7 RH 170.0 152.0
8 RH 170.0 152.0
9 RH 170.0 152.0
10 RH 170.0 152.0
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
D31/37-22 30-130 81
D37PX-22 (Wet type/Normal)
Y Komatsu
T20606 Address:
Model D37PX-22 Serial# Equip# Work Order No

LH 617.2 629.2
LINK PITCH R
M L L=l/4 RH 617.2 629.2
LH 154.30 157.30
master pin
l
M
RH 154.30 157.30
LH 90.0 80.0
H
RH 90.0 80.0
LINK HEIGHT
New Turned
BUSHING d1
LH 54.0 43.8
New Turned
d
d RH 54.0 43.8
D is the smallest
of d1, d2 and, d3
H
RH 47.0 22.0
Front
RH 142.0 128.0
D LH 142.0 128.0
Rear
RH 142.0 128.0
LH 14.0 22.0
IDLER Front
RH 14.0 22.0
H
LH 14.0 22.0
Rear
RH 14.0 22.0
1 LH 170.0 152.0
2 LH 170.0 152.0
3 LH 170.0 152.0
4 LH 170.0 152.0
5 LH 170.0 152.0
6 LH 170.0 152.0
7 LH 170.0 152.0
9 LH 170.0 152.0
D 10 LH 170.0 152.0
1 RH 170.0 152.0
h2 h1 2 RH 170.0 152.0
3 RH 170.0 152.0
D=2(h1-h2) 4 RH 170.0 152.0
5 RH 170.0 152.0
6 RH 170.0 152.0
7 RH 170.0 152.0
8 RH 170.0 152.0
9 RH 170.0 152.0
10 RH 170.0 152.0
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
30-130 82 D31/37-22
D31/37-22 30-130 83
D31/37-22 Bulldozer
©2014 KOMATSU
All Rights Reserved
30-130 84 D31/37-22
SEN04505-01
BULLDOZER 1SHOP MANUAL
D31EX-22
D31PX-22
D37EX-22
D37PX-22
D31EX-22 60001 and up
D31PX-22 60001 and up
D37EX-22 60001 and up
D37PX-22 60001 and up
40 Troubleshooting 40
100 Failure code table and fuse locations

Failure code table ........................................................................................................................................... 2
Before carrying out troubleshooting for electrical system (E-mode) ............................................................... 8
D31/37-22 40-100 1
SEN04505-01 Failure code table
Failure code table 1
Appli-
Cau- Cau-
Failure cable Action History Reference
codes equip- code classification document No.
lamp buzzer
ment
6091NX HST charge filter Clogging HST — — q q Mechanical

element system
Mechanical
AA10NX Air cleaner Clogging MON — — — — system
Mechanical
AB00MA Alternator Malfunction MON — — q —
system
Mechanical
B@BAZG Engine oil Lowering of oil pressure ENG — — q q
system
Mechanical
B@BCNS Coolant Overheating ENG — — q q system
Mechanical
B@CRNS HST oil Overheating HST — — q q
system
Mechanical
B@CRZG HST oil Lowering of oil pressure HST — — q q
system
CONTROL- Electrical
CA111 Engine controller Abnormality in controller ENG E04 q q
LER system
Abnormal engine NE, Abnormal speed sensor ENG Electrical
CA115 ENG E04 q q
Bkup speed signal SPEED system
Charge pressure sensor Excessively high voltage Electrical
CA122 ENG E03 ENGINE q q
too high detected system
Charge pressure sensor Excessively low voltage Electrical
too low detected system
CA131 Decelerator pedal Excessively high voltage ENG E03 DECEL q q Electrical
sensor too high detected PEDAL system Troubleshoot-
ing by failure
CA132 Decelerator pedal Excessively low voltage ENG E03 DECEL q q Electrical code (Display
sensor too low detected PEDAL system of code), Part 1
Coolant temperature Excessively high voltage WATER Electrical SEN04507-01
CA144 sensor too high detected ENG E02 TEMP q q system
Coolant temperature Excessively low voltage WATER Electrical
CA145
sensor too low detected ENG E02 TEMP q q system
CA153 Charge temperature Excessively high voltage ENG E01 ENGINE — — Electrical
sensor too high detected system
Charge temperature Excessively low voltage Electrical
CA154 sensor too low detected ENG E01 ENGINE — — system
CA187 Sensor power source 2 Excessively low voltage ENG E03 SENSOR q q Electrical
too low detected VOLTAGE system
Atmospheric pressure Excessively high voltage Electrical
CA221 sensor too high detected ENG E03 ENGINE q q system
Atmospheric pressure Excessively low voltage Electrical
CA222 sensor too low detected ENG E03 ENGINE q q system
Sensor power source 2 Excessively high voltage SENSOR Electrical
CA227 ENG E03 q q
too high detected VOLTAGE system
Mechanical
CA234 Engine overspeed Excessively high speed ENG — — q q
system
Abnormal power source Excessively low voltage ENG Electrical
CA238 ENG E03 q q
for Ne speed sensor detected SPEED system
CA271 IMV/PCV1 short circuit Short circuit ENG E03 ENGINE q q Electrical
system
IMV/PCV1 Electrical
CA272 Disconnection ENG E03 ENGINE q q
disconnection system
Disconnection and short Disconnection or short Electrical
CA322 circuit in injector #1 circuit ENG E03 ENGINE q q system
Disconnection and short Disconnection or short Electrical
circuit in injector #3 circuit system
Disconnection and short Disconnection or short Electrical Troubleshoot-
CA331 ENG E03 ENGINE q q ing by failure
circuit in injector #2 circuit system
code (Display
Disconnection and short Disconnection or short Electrical of code), Part 2
circuit in injector #4 circuit system SEN04508-02
Abnormal circuit for Electrical
CA351 Abnormal circuit ENG E03 ENGINE q q
injector system system
Sensor power source 1 Excessively low voltage SENSOR Electrical
CA352 ENG E03 q q
40-100 2 D31/37-22
Failure code table SEN04505-01
Appli- Cau- Cau-

codes equip- code lamp buzzer classification document No.
ment
Sensor power source 1 Excessively high voltage SENSOR Electrical
CA386 ENG E03 q q
Water detection sensor Excessively high voltage FUEL FIL- Electrical
CA428 ENG E01 — —
too high detected TER system
Water detection sensor Excessively low voltage FUEL FIL- Electrical
CA429 too low detected ENG E01 TER — — system
Abnormal engine oil ENG OIL Electrical
CA435 Abnormal signal circuit ENG E02 q q
pressure switch PRESS SW system
Power supply voltage Excessively low voltage BATTERY Electrical
CA441 ENG E04 q q
CA442 Power supply voltage Excessively high voltage ENG E04 BATTERY q q Electrical
Common rail pressure Excessively high pressure Electrical
too high 2 detected system
CA451 Common rail pressure Excessively high voltage ENG E03 ENGINE q q Electrical
sensor too high detected system
Common rail pressure Excessively low voltage Electrical
CA452 sensor too low detected ENG E03 ENGINE q q system
Common rail pressure Excessively high pressure Electrical
too high 1 detected system
Supply pump no No pressure feeding Electrical
pressure 1 detected system
Troubleshoot-
Abnormal engine Ne ENG Electrical ing by failure
CA689 Abnormality in signal ENG E03 q q
speed sensor SPEED system code (Display
of code), Part 2
Abnormal engine Bkup ENG Electrical
CA731 speed sensor phase Abnormal phase ENG E03 SPEED q q system
SEN04508-02
CA757 Loss of all data of Loss of all data ENG E04 CONTROL- q q Electrical
engine controller LER system
Abnormal engine Bkup ENG Electrical
CA778 speed sensor Abnormal Bkup signal ENG E03 SPEED q q system
Abnormal CAN
communication (Engine Abnormal communication Electrical
CA1633 controller – HST ENG E03 DATA LINK q q system
controller)
Decelerator pedal
CA2185 sensor power source Excessively high voltage ENG E03 DECEL q q Electrical
detected PEDAL system
too high
Decelerator pedal
CA2186 sensor power source Excessively low voltage ENG E03 DECEL q q Electrical
detected PEDAL system
too low
Supply pump no No pressure feeding Electrical
pressure 2 detected system
Electrical
CA2311 Abnormal IMV solenoid Abnormal resistance ENG E03 ENGINE q q
system
Disconnection in air HEATER Electrical
CA2555 intake heater relay Disconnection ENG E01 RELAY — —
system
Short circuit in air intake Short circuit HEATER Electrical
CA2556 heater relay ENG E01 RELAY — — system
N SAFETY Electrical
D130KA Neutral safety relay Disconnection HST E02 q q
RELAY system
N SAFETY Electrical
D130KB Neutral safety relay Short circuit HST E02 q q
RELAY system
CAN communication "Defective communication
Electrical
DAFRKR (Monitor panel – HST (Abnormality in objective MON E03 DATA LINK q q
system
controller) component system)"
CAN communication "Defective communication Troubleshoot-
Electrical
DAFRMC (Monitor panel – Engine (Abnormality in objective MON E03 DATA LINK q q system
ing by failure
controller) component system)" code (Display
of code), Part 3
Electrical SEN04509-00
DAJ000 HST controller Memory error HST — — — —
system
BATTERY Electrical
DAJ0KK HST controller Lowing of source voltage HST E04 VOLTAGE q q system
MACHINE Electrical
DAJ0KQ HST controller Machine code error HST E03 CODE q q system
CONTROL- Electrical
DAJ0KT HST controller Memory error HST E03 q q
LER system
D31/37-22 40-100 3
Appli-
Cau- Cau-
Failure Defective part Trouble cable Action Message tion tion History Reference
lamp buzzer
ment
HST controller sensor Lowing of source voltage/ SENSOR Electrical
DAJ5KK HST E04 q q
5V power supply No. 1 Input VOLTAGE system
HST controller sensor Lowing of source voltage/ SENSOR Electrical
DAJ6KK HST E03 q q
5V power supply No. 2 Input VOLTAGE system
Electrical
DAJRKR (HST controller – (Abnormality in objective HST E03 DATA LINK q q system
Monitor panel) component system)"
Electrical
DB2RKR (HST controller – (Abnormality in objective HST E03 DATA LINK q q
system
Engine controller) component system)"
SHIFT UP Electrical
DD12KA Shift up switch Disconnection HST E02 q q
SW system
DD12KB Shift up switch Short circuit HST E02 SHIFT UP q q Electrical

SW system
SHIFT Electrical
DD13KA Shift down switch Disconnection HST E02 q q
DOWN SW system
SHIFT Electrical
DD13KB Shift down switch Short circuit HST E02 q q
DOWN SW system
TRAVEL Electrical
DD14KB Travel lock limit switch 1 Short circuit HST E03 q q
LOCK system
Fan rotation selector Disagreement of ON/OFF Electrical Troubleshoot-
DD1NL4 switch HST E01 FAN SW — —
signals system ing by failure
Reverse travel speed R SPEED Electrical code (Display
DDDCKB switch Short circuit HST E01 SW — — system of code), Part 3
SEN04509-00
DDP6KA Brake oil pressure Disconnection HST E02 BRAKE
q q
Electrical
sensor PRESS system
DDP6KB Brake
oil pressure BRAKE Electrical
sensor Short circuit HST E02 PRESS q q system
DDP6MA Brake
oil pressure BRAKE Electrical
sensor Malfunction HST E02 PRESS q q system
TRAVEL Electrical
DDQ2KA Travel lock limit switch 1 Disconnection HST E03 LOCK q q system
Disagreement of ON/OFF SHIFT Electrical
DDT0L4 Shift mode switch HST E01 — —
signals MODE SW system
Travel lock limit TRAVEL Electrical
DDU1FS switches 1 and 2 Fixing HST E03 LOCK q q system
TRAVEL Electrical
DDU1KA Travel lock limit switch 2 Disconnection HST E03 q q
LOCK system
DDU1KY Travel lock limit switch 2 Short circuit with power HST E03 TRAVEL q q Electrical
supply line LOCK system
DGS1KA HST
oil temperature Electrical
sensor Disconnection HST E01 OIL TEMP — — system
DGS1KX HST
oil temperature Electrical
Out of input signal range HST E01 OIL TEMP — —
sensor system
DHH5KA Left
HST pump HST Electrical
Disconnection HST E02 q q
pressure sensor PRESS system
Left HST pump HST Electrical
DHH5KB pressure sensor Short circuit HST E02 q q
PRESS system
DHH6KA Right HST pump

HST Electrical
DHH6KB Right HST pump Short circuit HST E02 HST q q Electrical
Electrical Troubleshoot-
DK10KA Fuel dial sensor Disconnection HST E03 FUEL DIAL q q system ing by failure
code (Display
Electrical of code), Part 4
DK10KB Fuel dial sensor Short circuit HST E03 FUEL DIAL q q
system SEN04510-00
Electrical
system
Electrical
system
Electrical
DK30KX Steering angle sensor Out of input signal range HST E04 ST LEVER q q
system
Disconnection or short Electrical
DK30KZ Steering angle sensor HST E04 ST LEVER q q
circuit system
40-100 4 D31/37-22
Appli-
Cau- Cau-
lamp buzzer
ment
Disagreement of analog Electrical
DK30L8 Steering angle sensor HST E03 ST LEVER q q
signals system
Electrical
system
Electrical
DK31KB Steering angle sensor 2 Short circuit HST E03 ST LEVER q q system
BRAKE Electrical
DK40KA Brake pedal sensor Disconnection HST E03 q q
PEDAL system
BRAKE Electrical
DK40KB Brake pedal sensor Short circuit HST E03 q q
PEDAL system
DK55KX Directional Out of input signal range HST E04 FR LEVER q q Electrical
potentiometer system
Directional Disconnection or short Electrical
DK55KZ potentiometer HST E04 FR LEVER q q
circuit system
DK55L8 Directional Disagreement of analog HST E03 FR LEVER q q Electrical

potentiometer signals system
DK56KA Directional
Electrical
potentiometer 1 Disconnection HST E03 FR LEVER q q system
Directional Electrical
DK56KB potentiometer 1 Short circuit HST E03 FR LEVER q q
system Troubleshoot-
Directional Electrical ing by failure
DK57KA potentiometer 2 Disconnection HST E03 FR LEVER q q system code (Display
of code), Part 4
SEN04510-00
DK57KB Directional Short circuit HST E03 FR LEVER q q Electrical
potentiometer 2 system
DLM0KX HST
motor speed TRAVEL Electrical
sensor Out of input signal range HST E03 SPEED q q system
DLM1KA Left HST motor speed Disconnection HST E01 TRAVEL — — Electrical
sensor SPEED system
DLM1KB Left
HST motor speed Electrical
sensor Short circuit HST — — — — system
Left HST motor speed Electrical
DLM1MA sensor Malfunction HST — — — — system
Right HST motor speed TRAVEL Electrical
DLM2KA sensor Disconnection HST E01 SPEED — — system
DLM2KB Right HST motor speed Short circuit

Electrical
HST — — — —
sensor system
DLM2MA Right HST motor speed Malfunction HST — — — — Electrical

sensor system
Electrical
DLM3KA Fan speed sensor Disconnection HST E01 FAN SPEED — —
system
Electrical
DLM3KB Fan speed sensor Short circuit HST E02 FAN SPEED q q
system
Brake pedal and BRAKE Electrical
DN21FS proximity switch Fixing HST E03 q q
PEDAL system
Electrical
DV00KB Caution buzzer Short circuit MON E01 BUZZER — — system
BACK Electrical
DV20KB Back alarm buzzer Short circuit HST E01 — —
ALARM system
DW4BKA Parking brake solenoid Disconnection HST E04

P BRAKE
q q
Electrical
valve SOL system
DW4BKB Parking
brake solenoid Short circuit P BRAKE Electrical
valve HST E04 SOL q q system
Troubleshoot-
ing by failure
code (Display
DW4BKY Parking
brake solenoid Short circuit with power P BRAKE Electrical
HST E03 q q of code), Part 5
valve supply line SOL system
SEN04511-00
DW7BKA Fan
reverse solenoid FAN CLN Electrical
Disconnection HST E01 — —
valve SOL system
Fan reverse solenoid FAN CLN Electrical
DW7BKB valve Short circuit HST E01 — —
SOL system
DW7BKY Fan reverse solenoid

Short circuit with power FAN CLN Electrical
HST E03 q q
valve supply line SOL system
Slow brake solenoid SLOW Electrical

DW7EKA valve Disconnection HST E04 BRAKE q q system
SOL
D31/37-22 40-100 5
Appli- Cau- Cau-

lamp buzzer
ment
SLOW
Slow brake solenoid Electrical
DW7EKB Short circuit HST E04 BRAKE q q
valve system
SOL
SLOW
Slow brake solenoid Short circuit with power Electrical
DW7EKY valve supply line HST E03 BRAKE q q system
SOL
Electrical
DWN5KA Fan EPC solenoid valve Disconnection HST E01 FAN EPC — —
system
Electrical
DWN5KB Fan EPC solenoid valve Short circuit HST E01 FAN EPC — —
system
Short circuit with power Electrical
DWN5KY Fan EPC solenoid valve HST E02 FAN EPC q q
supply line system
LF HST pump EPC HST PUMP Electrical
solenoid valve EPC system
DXA4KB LF HST pump EPC Short circuit HST E03 HST PUMP q q Electrical
DXA4KY LF HST pump EPC Short circuit with power HST E04 HST PUMP q q Electrical
solenoid valve supply line EPC system
DXA5KA LR
HST pump EPC HST PUMP Electrical
LR HST pump EPC HST PUMP Electrical
DXA5KB solenoid valve Short circuit HST E03 EPC q q system
LR HST pump EPC Short circuit with power HST PUMP Electrical
DXA5KY solenoid valve supply line HST E04 EPC q q system
DXA6KA RF HST pump EPC

HST PUMP Electrical
Disconnection HST E03 q q Troubleshoot-
solenoid valve EPC system ing by failure
code (Display
DXA6KB RF HST pump EPC Short circuit HST E03 HST PUMP q q Electrical
of code), Part 5
SEN04511-00
DXA6KY RF
HST pump EPC Short circuit with power HST PUMP Electrical
HST E04 q q
solenoid valve supply line EPC system
DXA7KA RR HST pump EPC Disconnection HST E03 HST PUMP q q Electrical
RR HST pump EPC HST PUMP Electrical
DXA7KB solenoid valve Short circuit HST E03 q q
EPC system
RR HST pump EPC Short circuit with power HST PUMP Electrical
DXA7KY solenoid valve supply line HST E04 EPC q q system
Left HST motor EPC HST Electrical

DXK1KA solenoid valve Disconnection HST E02 MOTOR q q system
EPC
HST
DXK1KB Left
HST motor EPC q q Electrical
solenoid valve Short circuit HST E02 MOTOR
system
EPC
HST
DXK1KY Left HST motor EPC Short circuit with power HST E04 MOTOR q q Electrical
solenoid valve supply line system
EPC
HST
Right HST motor EPC Electrical
DXK2KA solenoid valve Disconnection HST E02 MOTOR q q system
EPC
HST
DXK2KB Right
HST motor EPC Electrical
solenoid valve
Short circuit HST E02 MOTOR q q
system
EPC
HST
DXK2KY Right HST motor EPC
Short circuit with power Electrical
HST E04 MOTOR q q
solenoid valve supply line system
EPC
a Failure codes:
The failure code table is written in alphabetical order and also starting from small number.
The failure code in parentheses is not recorded in the failure history for both electrical system and
mechanical system.
a Applicable equipment:
Applicable equipment indicates in which controller system the failure has occurred.
MON : Monitor panel system
ENG : Engine controller system
HST : HST controller system
40-100 6 D31/37-22
a Failure codes:
Failure codes indicate what is displayed in the operator mode when a failure is detected.
a History classification:
History classification indicates in which system, either electrical system or mechanical system in the fail-
ure history display function, a failure has been recorded.
D31/37-22 40-100 7
SEN04505-01 Before carrying out troubleshooting for electrical system (E-mode)
Before carrying out troubleshooting for electrical system (E-mode) 1
Connection table of fuse box

a This connection table shows the devices to which each power supply of the fuse box supplies power (A switch
power supply is a device which supplies power while the starting switch is at the ON position and a constant
power supply is a device which supplies power while the starting switch is at position (ON/OFF)).
a When carrying out troubleshooting related to the electrical system, you should check the fuse box to see
if the power is supplied normally.
Fuse box A (CN-F01)

Type of power supply Capacity of
Fuse No. Destination of power
(Power source) fuse
1
20 A Headlamp and rear lamp
(Between terminals 1 and 1A)
2
10 A Horn
3
10 A PPC lock
4
30 A Air conditioner (Cab specification)
Switch power supply (Between terminals 4 and 4A)
(Battery relay terminal M) 5
10 A HST controller (Solenoid power supply)
(Between terminals 5 and 5B)
6
10 A Center brake
(Between terminals 6 and 6B)
7 Switch power supply of fuse box B
30 A
(Between terminals 7 and 7B) (Cab specification)
8 Switch power supply of fuse box B
30 A
(Between terminals 8 and 8B) (Cab specification)
9
15 A Starting switch (terminal B)
Constant power supply (Between terminals 9 and 9C)
(Battery relay terminal B) 10
30 A Engine controller (Main power supply)
(Between terminals 10 and 10C)
11
20 A Spare power supply (No destination)
(Between terminals 11 and 11D)
12
15 A Preheat
Switch power supply (Between terminals 12 and 12D)
(Battery relay terminal M) 13
10 A Foot heater (If equipped)
14
15 A Air suspension seat
15
10 A HST controller (Main power supply)
(Between terminals 15 and 15E)
16
10 A Monitor panel
Constant power supply 17
5A Spare fuse (No destination)
(Battery relay terminal B) (Between terminals 17 and 17E)
18
10 A Service connector (CN-DT12 connector)
19
10 A Constant power supply of fuse box B
Switch power supply
20
(Starting switch terminal 5A Engine controller (ACC signal)
(Between terminals 20 and 20F)
ACC)
40-100 8 D31/37-22
Before carrying out troubleshooting for electrical system (E-mode) SEN04505-01
Fuse box B (FUSE) [Cab specification]

Type of power supply Fuse
(Power source) capacity
Constant power supply 1
10A Radio (Constant power supply)
(Fuse box CN-F01 (19)) (Between terminals 1 and F)
2
20A Additional working lamp
(Between terminals 2 and B)
3
20A Lighter, 12 V socket
Switch power supply 4

10A Room lamp, radio
(Fuse box F01- (7) (8)) (Between terminals 4 and B)
5
10A Front wiper and washer, rear wiper and washer
6
10A Left and right door wiper and washer
Locations and Nos. of fuses
D31/37-22 40-100 9
SEN04505-01 Before carrying out troubleshooting for electrical system (E-mode)
Slow blow fuse (CN-106)

Type of power supply Fuse
(Power source) capacity
1
Switch power supply 120A Preheater relay
(Between terminals 1 and 3)
(Battery relay terminal
M) 2
120A Safety relay
(Between terminals 2 and 4)
Locations and Nos. of slow blow fuse

Inside of side cover at the engine left side.
40-100 10 D31/37-22
Before carrying out troubleshooting for electrical system (E-mode) SEN04505-01
D31/37-22 40-100 11
SEN04505-01
D31/37-22 Bulldozer
©2014 KOMATSU
All Rights Reserved
40-100 12
SEN04506-01
D31EX-22
D31PX-22
D37EX-22
D37PX-22
D31EX-22 60001 and up
D31PX-22 60001 and up
D37EX-22 60001 and up
D37PX-22 60001 and up
200 General information on troubleshooting

Points to remember when troubleshooting ..................................................................................................... 2
Sequence of events in troubleshooting ........................................................................................................... 3
Testing before troubleshooting........................................................................................................................ 4
Classification and procedures of troubleshooting ........................................................................................... 5
Information contained in troubleshooting table ............................................................................................... 8
Connection table for connector pin numbers ................................................................................................ 10
T- branch box and T- branch adapter table ................................................................................................... 46
D31/37-22 40-200 1
SEN04506-01 Points to remember when troubleshooting
Points to remember when troubleshooting 1
k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are
securely fitted.
k When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to under-
stand the structure and function. 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 symp-
toms.
1. When carrying out troubleshooting, do not hurry to disassemble the components.

If components are disassembled immediately after any failure occurs:
q Parts that have no connection with the failure or other unnecessary parts will be disassembled.
q It will become impossible to find the cause of the failure.
It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the
confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to
carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed pro-
cedure.
2. Points to ask user or operator
1) Have any other problems occurred apart from the problem that has been reported?
2) Was there anything strange about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there problems with the machine condition before this?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the failure? When were these repairs carried out?
6) Has the same kind of failure occurred before?
3. Check before troubleshooting
1) Are abnormal symptoms detected in the machine?
2) Make checks before starting day's work.
3) Make checks of other items.
4) Check other maintenance items which can be visually checked and are considered necessary.
4. Confirming failure
Confirm the extent of the failure by yourself, and judge whether to treat it as a real failure or as a
problem of handling, operation, etc.
a When operating the machine to reenact the troubleshooting symptoms, do not carry out any inves-
tigation or measurement that may make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in items 2 – 4 to narrow down the causes of
failure, then use the troubleshooting table or flowchart (matrix) to find out the failure part
exactly.
a The basic procedure for troubleshooting is as follows.
1] Start from the simple points.
2] Start from the most likely points.
3] Investigate other related parts or information.
6. Measures to remove root cause of failure
Even if the immediate failure is repaired, the same failure may occur again, unless the root cause
of the failure is repaired. To prevent this, always investigate why the cause of the failure
occurred. Then, remove the root cause.
40-200 2 D31/37-22
Sequence of events in troubleshooting SEN04506-01
Sequence of events in troubleshooting 1
D31/37-22 40-200 3
SEN04506-01 Testing before troubleshooting
Testing before troubleshooting 1
Item Criteria Remedy
1. Check of level and type of fuel — Add fuel
2. Check for foreign matter in fuel

— Clean or drain
Check fuel filter and fuel pre-filter for clogging
3. Check of fuel filter for clogging — Replace
4. Check of level and type of oil in engine oil pan Between H and L Add oil
Lubricating oil and coolant
Between FULL and

5. Check of coolant level Add coolant
LOW
6. Check of air cleaner for clogging No red Clean or replace
7. Check of level and type of hydraulic oil Between H and L Add oil
8. Check of level and type of HST oil Between H and L Add oil
9. Check of engine oil filter for clogging — Replace
10. Check of hydraulic oil filter for clogging — Replace
11. Check of HST oil filter for clogging — Replace
Retighten or
12. Check of battery terminal cables for looseness and corrosion —
replace
Electrical parts
13. Check of alternator terminal cables for looseness and Retighten or

—
corrosion replace
14. Check of starting motor terminal cables for looseness and Retighten or
—
corrosion replace
15. Check of operation of instruments — Repair or replace

mechanical equipment
16. Check for abnormal noise and smell — Repair

Hydraulic and
17. Check for oil leakage — Repair
18. Bleeding air — Bleed air
19. Check of effect of brake — Repair or adjust
20. Check of battery voltage (with engine stopped) 20 – 30 V Charge or replace
21. Check of battery electrolyte level Between U.L and L.L Add or replace
Electrical equipment
22. Check wires for discoloration, burn, and removal of cover — Replace
23. Check for removed wire clamp and drooping wire — Repair
24. Check wiring for wetting with water (Check connectors and Disconnect and dry
—
terminals for wetting with water, in particular) connectors
25. Check of slow-blow fuses and fuses for disconnection and
— Replace
corrosion
26. Check of alternator voltage (with engine at medium speed or After several-minute
Repair or replace
higher) operation: 27.5 – 29.5 V
27. Check of operating sound of battery relay (Starting switch
— Replace
OFF o ON)
40-200 4 D31/37-22
Classification and procedures of troubleshooting SEN04506-01
Classification and procedures of troubleshooting 1
Classification of troubleshooting
Mode Contents
Failure code Troubleshooting by failure code (Display of code)
E-mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical system
S-mode Troubleshooting of engine
Procedure for troubleshooting

If a phenomenon looking like a trouble occurs in the machine, select a proper troubleshooting No. according
to the following procedure, and then go to the corresponding troubleshooting section.
1. Procedure for troubleshooting to be taken when action code is displayed on machine monitor:
If an action code is displayed on the machine monitor, display the failure code in the failure code display
mode (for the electrical system and the mechanical system) of the machine monitor (EMMS).
Carry out troubleshooting in [Display of failure code] according to the displayed failure code.
a Each failure code “flashes” when the trouble corresponding to it is detected. Even if a failure code
“lights up” when the starting switch is turned ON, the trouble corresponding to that failure code
may not have been repaired (Some troubles can be detected by simply turning the starting switch
ON).
a If a failure code is recorded, be sure to perform the operation for reproducing it to see if the trouble
corresponding to it has been repaired (For the method of reproducing the failure code, see the trou-
bleshooting in [Display of code]).
2. Procedure for troubleshooting to be taken when failure code is recorded:

If an action code is not displayed on the machine monitor, check for a failure code in the failure code dis-
play mode (for the electrical system and the mechanical system) of the machine monitor (EMMS).
If a failure code is recorded, carry out troubleshooting in [Display of code] according to that failure code.
a Each failure code “flashes” when the trouble corresponding to it is detected. Even if a failure code
“lights up” when the starting switch is turned ON, the trouble corresponding to that failure code
may not have been repaired (Some troubles can be detected by simply turning the starting switch
ON).
a If a failure code is recorded, be sure to perform the operation for reproducing it to see if the trouble
corresponding to it has been repaired (For the method of reproducing the failure code, see the trou-
bleshooting in [Display of code]).
3. Procedure of troubleshooting to be taken when action code is not displayed and failure code is
not recorded:
If a failure code is not recorded in the machine monitor (EMMS), a trouble that the machine cannot find
out by itself may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from
the table of “Phenomena looking like troubles and troubleshooting Nos.“, and then carry out trouble-
shooting related to that phenomenon in the “E-mode“, “H-mode“, or “S-mode“.
D31/37-22 40-200 5
SEN04506-01 Classification and procedures of troubleshooting
Phenomena looking like troubles and troubleshooting Nos.

Troubleshooting
No. Phenomena looking like trouble Code
E-mode H-mode S-mode
display
Phenomena related to action codes and failure codes
1 Action codes are displayed on machine monitor Check failure code
2 If failure code display function is checked, failure codes are displayed q
Phenomena related to engine
3 Starting performance is poor S-1
4 Engine does not start E-1 S-2
5 Engine does not pick up smoothly S-3
6 Engine stops during operations H-4 S-4
7 Engine does not rotate smoothly S-5
8 Engine lacks output (or lacks power) S-6
9 Exhaust smoke is black (incomplete combustion) S-7
10 Oil consumption is excessive (or exhaust smoke is blue) S-8
11 Oil becomes contaminated quickly S-9
12 Fuel consumption is excessive S-10
13 Oil is in coolant (or coolant spurts back, or coolant level goes down) S-11
14 Oil pressure drops S-12
15 Oil level rises (water, fuel in oil) S-13
16 Coolant temperature becomes too high (overheating) S-14
17 Abnormal noise is made S-15
18 Vibration is excessive S-16
19 Engine is not preheated E-2
Phenomena related to power train
Right and left travel systems do not operate forward and in reverse
20 H-1
(No travel systems operate)
Right or left travel system does not operate forward and in reverse
21 H-2
(Only right or left travel system does not operate)
Right or left travel system does not operate forward or in reverse
22 H-3
(Only 1 system does not operate)
23 Speed or power of travel is low H-4
24 Gear is not shifted H-5
25 Large shocks are made when machine starts and stops travel H-6
26 Hydraulic drift of travel is large H-8
27 Engine stalls or engine speed lowers extremely during travel H-9
28 Abnormal sound comes out from around HST pump and motor H-10
29 HST oil temperature (Hydraulic oil temperature) rises too high H-20
Phenomena related to steering
30 Machine deviates largely during travel H-7
Phenomena related to work equipment
31 Work equipment does not operate at all H-11
32 Speed or power of whole work equipment is low H-12
33 Speed or power of lifting blade is low H-13
34 Speed or power of tilting blade is low H-14
35 Speed or power of angling blade is low H-15
40-200 6 D31/37-22
Classification and procedures of troubleshooting SEN04506-01
Troubleshooting
No. Phenomena looking like trouble Code
E-mode H-mode S-mode
display
36 Time lag in lifting blade is large H-16
37 Hydraulic drift of lifting blade is large H-17
38 Hydraulic drift of tilting blade is large H-18
Abnormal sound comes out from around work equipment pump and
39 H-19
control valve
Others
40 Fan speed is abnormal (High, low, or 0 rpm) H-21
41 Abnormal sound is heard from around fan H-22
42 When starting switch is turned ON, any item does not light up E-3
43 Charge level caution flashes while engine is running E-4
44 Emergency warning items flash while engine is running E-5
45 Preheating pilot lamp does not light up during preheating operation E-6
46 The coolant temperature gauge does not indicate correctly E-7
47 The HST oil temperature gauge does not indicate correctly E-8
48 Fuel level gauge does not indicate properly E-9
Gear speed, set travel speed, and shift mode indicator does not dis-
49 E-10
play normally
50 Multi-information unit does not display normally E-11
51 Caution lamp does not flash or does not go off E-12
52 Caution buzzer does not sound or does not stop E-13
53 Reverse travel speed setting switch does not function E-14
54 Shift mode switch does not function E-15
55 Buzzer cancel switch does not function E-16
56 Information switch does not function E-17
57 The fan cleaning does not operate or cannot be reset E-18
58 Backup alarm does not sound E-19
59 The horn does not sound or does not stop E-20
60 Work equipment does not move E-21
61 Headlamp or rear lamp does not light up E-22
62 Foot heater does not operate E-23
63 Air conditioner does not operate [Cab specification] E-24
Windshield wiper and window washer do not operate [Cab specifica-
64 E-25
tion]
65 KOMTRAX system does not operate normally E-26
D31/37-22 40-200 7
SEN04506-01 Information contained in troubleshooting table
Information contained in troubleshooting table 1
Action code Failure code

Monitor Trouble Problem that appears on machine
Monitor display
display
Contents of
State where the monitor panel or controller detects the trouble
trouble
Action of Action taken by machine monitor or controller to protect system or devices when engine con-
controller troller detects trouble
Problem that
Problem that appears on machine as result of action taken by machine monitor or controller
appears on
(shown above)
machine
Related
Information related to detected trouble or troubleshooting
information
Cause Standard value in normal state/Remarks on troubleshooting
<Described contents>
• Standard value in normal state to judge assumed cause
(good or not)
• Remarks required to judge whether the cause is good
1
<Phenomenon of defective wiring harness>
• Disconnection in wiring
The connector connection is defective or the wiring harness
is disconnected.
• Grounding fault
A harness not connected to ground (earth) circuit comes
into contact with the ground (earth) circuit.
• Hot short circuit
2 A harness not connected to the power (24 V) circuit comes
into contact with the power (24 V) circuit.
• Short circuit
Possible causes Possible causes of trouble A harnesses of an independent circuit abnormally comes
and standard is assumed to be detected into contact with one of another circuit.
value in normal (The order number indicates
state a serial number, not a priority <Notes on troubleshooting>
sequence.) (1) Method of indicating connector number and handling T-
branch
For troubleshooting, insert or connect T-branch adapter
3
as shown below unless especially specified.
• When “male” or “female” is not indicated for a con-
nector number, disconnect the connector, and insert
the T-branch adapter in both the male and female.
• When “male” and “female” is indicated for a connec-
tor number, disconnect the connector, and insert the
T-branch adapter in only either the male or female.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (–)
4 leads as shown below unless especially specified.
• Connect the plus (+) lead to a pin or harness indi-
cated in the front.
• Connect the minus (–) lead to a pin or harness indi-
cated in the rear.
40-200 8 D31/37-22
Information contained in troubleshooting table SEN04506-01
Related circuit diagram
This is the excerpted circuit diagram related to trouble

• Connector No.: Indicates (Model – No. of pins) (Color)
• “Connector No. and pin No.” from each branching/
merging point: Shows the ends of branch or source of
merging within the parts of the same wiring harness.
• Arrow (io): Roughly shows the location on the
machine.
D31/37-22 40-200 9
SEN04506-01 Connection table for connector pin numbers
Connection table for connector pin numbers (Rev. 2009.04)
a The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
40-200 10 D31/37-22
Connection table for connector pin numbers SEN04506-01
D31/37-22 40-200 11
40-200 12 D31/37-22
D31/37-22 40-200 13
40-200 14 D31/37-22
D31/37-22 40-200 15
40-200 16 D31/37-22
D31/37-22 40-200 17
40-200 18 D31/37-22
D31/37-22 40-200 19
40-200 20 D31/37-22
D31/37-22 40-200 21
40-200 22 D31/37-22
D31/37-22 40-200 23
40-200 24 D31/37-22
D31/37-22 40-200 25
40-200 26 D31/37-22
D31/37-22 40-200 27
40-200 28 D31/37-22
D31/37-22 40-200 29
40-200 30 D31/37-22
D31/37-22 40-200 31
40-200 32 D31/37-22
D31/37-22 40-200 33
40-200 34 D31/37-22
D31/37-22 40-200 35
40-200 36 D31/37-22
D31/37-22 40-200 37
40-200 38 D31/37-22
D31/37-22 40-200 39
40-200 40 D31/37-22
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40-200 42 D31/37-22
D31/37-22 40-200 43
40-200 44 D31/37-22
D31/37-22 40-200 45
T- branch box and T- branch adapter table (Rev. 2009.03)
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4350 T-box (for DRC 60, ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
40-200 46 D31/37-22
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol

799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 — q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 — q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT (Brown) 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q
D31/37-22 40-200 47
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430* 2 P q q
Socket for engine (CRI-T3) PCV
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* 2 A q q
Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 3 — q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190* 3 1,2,3L q q
Commonrail pressure
799-601-4230* 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
799-601-4340* 2 2,PA q q
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380* 4 1,2,3,4T q
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 — q
799-601-4280* Box for controller (PUMP) 121 — q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
Multi-adapter for
799-601-9890 3, — q
DT2 – 4 and DTM2
4,
“ * ” Shows not T-adapter but socket.
40-200 48 D31/37-22
D31/37-22 40-200 49
SEN04506-01
D31/37-22 Bulldozer
©2009 KOMATSU
All Rights Reserved
40-200 50
SEN04507-01
D31EX-22
D31PX-22
D37EX-22
D37PX-22
D31EX-22 60001 and up
D31PX-22 60001 and up
D37EX-22 60001 and up
D37PX-22 60001 and up
310 Troubleshooting by failure code

(Display of code), Part 1
Failure code [6091NX] HST charge filter element: Clogging .......................................................................... 3
Failure code [AA10NX] Air cleaner: Clogging ................................................................................................. 4
Failure code [AB00MA] Alternator: Malfunction .............................................................................................. 6
Failure code [B@BAZG] Engine oil: Lowering of oil pressure ........................................................................ 7
Failure code [B@BCNS] Coolant: Overheat ................................................................................................... 8
Failure code [B@CRNS] HST oil: Overheating............................................................................................... 9
Failure code [B@CRZG] HST oil: Lowering of oil pressure .......................................................................... 10
Failure code [CA111] Engine controller: Abnormality in controller .................................................................11
Failure code [CA115] Abnormal engine Ne and Bkup speed sensors: Abnormal speed sensor signal........ 14
Failure code [CA122] Charge pressure sensor tool high: Excessively high voltage detected ...................... 15
Failure code [CA123] Charge pressure sensor too low: Excessively low voltage detected.......................... 17
Failure code [CA131] Decelerator pedal sensor tool high: Excessively high voltage detected .................... 18
Failure code [CA132] Decelerator pedal sensor too low: Excessively low voltage detected ........................ 20
Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected ................. 22
Failure code [CA145] Coolant temperature sensor too low: Excessively low voltage detected.................... 24
Failure code [CA153] Charge air temperature sensor too high: Excessively high voltage detected ............ 26
Failure code [CA154] Charge temperature sensor too low: Excessively low voltage detected .................... 28
Failure code [CA187] Sensor power source 2 too low: Excessively low voltage detected ........................... 29
Failure code [CA221] Atmospheric pressure sensor too high: Excessively high voltage detected............... 30
Failure code [CA222] Atmospheric pressure sensor too low: Excessively low voltage detected.................. 32
Failure code [CA227] Sensor power source 2 too high: Excessively high voltage detected ........................ 34
D31/37-22 40-310 1
310 Troubleshooting by failure code (Display of code), Part 1
SEN04507-01
Failure code [CA234] Engine over speed: Excessively high speed .............................................................. 36
Failure code [CA238] Abnormal power source for Ne speed sensor: Excessively low voltage detected ..... 38
Failure code [CA271] IMV/PCV1 short circuit: Short circuit .......................................................................... 40
Failure code [CA272] IMV/PCV1 disconnection: Disconnection ................................................................... 42
40-310 2 D31/37-22
Failure code [6091NX] HST charge filter element: Clogging SEN04507-01
Failure code [6091NX] HST charge filter element: Clogging

Action code Failure code HST charge filter element: Clogging
Trouble
– 6091NX (Mechanical system)
Contents of • When the HST oil temperature reached 50? or above, the HST charge filter clogging switch was
trouble activated.
• Flashes the HST Charge Filter clogging caution lamp.
Action of
• Flashes the warning lamp and sounds the alarm buzzer.
controller
• If cause of the error disappears, the system resets itself.
Problem that
appears on • If machine is operated as it is, hydraulic components may be damaged.
machine
• Input state from the HST charge filter clogging switch (ON and OFF) can be checked with the moni-
toring mode.
Related
(Controller: HST, Code: 40910 D-IN [3])
information
• Method of reproducing failure code: Start engine and increase the HST oil temperature to 50? or
above.
Causes Standard value in normal state/Remarks on troubleshooting
Possible causes Possibly clogging of the HST charge filter has been detected at
Clogging of HST charge filter
1 present or in the past. It is, therefore, required investigate the cause
and standard (When system is normal)
and check damages and then repair or replace damaged parts.
value in normal
state Defective HST charge filter Carry out troubleshooting of HST charge filter clogging caution lamp
2 clogging caution lamp system in E-mode "Emergency warning items flash while engine is
system running."
D31/37-22 40-310 3
SEN04507-01 Failure code [AA10NX] Air cleaner: Clogging
Failure code [AA10NX] Air cleaner: Clogging 1
Action code Failure code Air cleaner: Clogging

Trouble
– AA10NX (Mechanical system)
Contents of
• Clogging of air cleaner was detected.
trouble
Action of
• Flashes the air cleaner clogging caution lamp.
controller
Problem that
appears on • If machine is operated as it is, the engine output may drop or the engine may be damaged.
machine
• Input state from the air cleaner clogging switch (ON and OFF) can be checked with the monitoring mode.
(Controller: MONITOR PANEL, Code: 40921 D-IN [6])
Related • If the air cleaner clogging monitor of the monitor panel lights up while engine stopped,
information air cleaner system may be defective. Carry out troubleshooting for Cause 2, 3 and 4 items.
• If the air cleaner clogging monitor of the monitor panel light up while engine running. Air cleaner may
be clogging. Carry out trouble shooting for Cause 1 item.

Clogging of the air cleaner a Check the air cleaner for clogging and then clean or replace it if
1
(When system is normal) clogged.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch.
Defective air cleaner
2 clogging switch CN-116 (male) Air cleaner Resistance
(Internal disconnection) Value in normal state Max. 1 z
Between (1) and (2)
Value when clogged Min. 1 Mz
Possible causes
and standard
Disconnection in wiring without turning starting switch.
value in normal
state harness Wiring harness between CN-S03 (female)
3 Resistance Max. 1 z
(Disconnection or defective (13) – CN-116 (female) (1)
contact in connector) Wiring harness between CN-116 (female) (2)
Resistance Max. 1 z
and chassis ground
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
4 Defective monitor panel CN-S03 Air cleaner Voltage
Between (13) and Value in normal state Max. 1 V
chassis ground Value when clogged Min. 7 V
40-310 4 D31/37-22
Failure code [AA10NX] Air cleaner: Clogging SEN04507-01
D31/37-22 40-310 5
SEN04507-01 Failure code [AB00MA] Alternator: Malfunction
Failure code [AB00MA] Alternator: Malfunction 1
Action code Failure code Alternator: Malfunction

Trouble
– AB00MA (Mechanical system)
Contents of
• Battery charge caution was detected while the engine is running.
trouble
• Flashes the battery charge caution lamp.
Action of
• Flashes the warning lamp.
controller
• If cause of error disappears, system resets itself.
Problem that
appears on • If machine is operated as it is, battery charging may be insufficient.
machine
• Power generation state of alternator (voltage) can be checked with the monitoring mode
Related
(Controller: MONITOR PANEL, Code: 04303 R SIGNAL).
information
• Method of reproducing failure code: Start engine.

Possible causes Possibly insufficient battery charging has been detected at present
Insufficient battery charging
and standard 1 or in the past. It is, therefore, required to investigate the cause and
(When system is normal)
value in normal check damages and then repair or replace damaged parts.
state Defective battery charge Carry out troubleshooting for E-mode "Charge level caution flashes
2
caution lamp system while engine is running."
40-310 6 D31/37-22
Failure code [B@BAZG] Engine oil: Lowering of oil pressure SEN04507-01
Failure code [B@BAZG] Engine oil: Lowering of oil pressure 1
Action code Failure code Engine oil: Lowering of oil pressure

Trouble
– B@BAZG (Mechanical system)
Contents of
• Engine oil pressure low caution was detected while engine is running.
trouble
• Flashes the engine oil pressure low caution lamp.
Action of
controller
• Limits output for travel (Limit injection rate and engine speed)
Problem that
• Engine output lowers.
appears on
• If machine is operated as it is, engine may be damaged.
machine
Related
information

Possible causes Lowering of engine oil Possibly low engine oil pressure has been detected at present or in
and standard 1 pressure the past. It is, therefore, required to investigate the cause and check
value in normal (When system is normal) damages and then repair or replace damaged parts.
state Defective engine oil pressure If cause 1 is not detected, engine oil pressure switch system may be
2
switch system defective. Carry out troubleshooting for failure code [CA435].
D31/37-22 40-310 7
SEN04507-01 Failure code [B@BCNS] Coolant: Overheat
Failure code [B@BCNS] Coolant: Overheat 1
Action code Failure code Coolant: Overheat

Trouble
– B@BCNS (Mechanical system)
Contents of
• Engine coolant overheat caution detected while the engine is running.
trouble
• Flashes the engine coolant overheat caution lamp.
Action of • Flashes the warning lamp and sounds the alarm buzzer.
controller • If cause of error disappears, system resets itself.
• Limits output and continues operation.
Problem that
• Engine output lowers.
appears on
• If machine is operated as it is, engine may be damaged.
machine
• Input state from the engine coolant temperature sensor (coolant temperature, sensor voltage) can be
Related checked with the monitoring mode.
information (Controller: ENGINE, Code: 04107 COOLANT TEMP and code: 04105 COOLANT TEMP)

Possible causes Engine coolant overheat Engine coolant may be overheating. Check it and remove cause if it
1
and standard (When system is normal) is overheating.
value in normal If cause 1 is not detected, the engine coolant sensor system may be
state Defective engine coolant
2 defective. Carry out troubleshooting for failure codes [CA144] and
temperature sensor system
[CA145].
40-310 8 D31/37-22
Failure code [B@CRNS] HST oil: Overheating SEN04507-01
Failure code [B@CRNS] HST oil: Overheating 1
Action code Failure code HST oil: Overheating

Trouble
– B@CRNS (Mechanical system)
Contents of
• The HST oil temperature caution was indicated while the engine was running.
trouble
• Flashes the HST oil temperature caution lamp.
Action of
controller
Problem that
• If machine is operated as it is, HST hydraulic equipment or hydraulic equipment on the work equip-
appears on
ment may be damaged.
machine
• Input state from the HST oil temperature sensor (oil temperature, oil temperature sensor voltage) can
Related be checked with the monitoring mode.
information (Controller: HST, Code: 04401 HST TEMP and code: 04402 HST TEMP)

Possibly overheat of HST oil has been detected at present or in the
Possible causes Overheat of HST oil (When
1 past. It is, therefore, required to investigate the cause and check
and standard system is normal)
damages and then repair or replace it.
value in normal
state Defective HST oil Carry out troubleshooting for EST oil temperature caution lamp sys-
2 temperature caution lamp tem in E-mode "Emergency warning items flash while engine is run-
system ning."
D31/37-22 40-310 9
SEN04507-01 Failure code [B@CRZG] HST oil: Lowering of oil pressure
Failure code [B@CRZG] HST oil: Lowering of oil pressure 1
Action code Failure code HST oil: Lowering of oil pressure

Trouble
– B@CRZG (Mechanical system)
Contents of • When parking brake was released while the engine was running, brake pressure (charge pressure)
trouble lowered.
• Flashes the HST charge pressure caution lamp.
Action of
controller
Problem that
• If machine is operated as it is, HST hydraulic equipment or hydraulic equipment on the work equip-
appears on
ment may be damaged.
machine
• Input state (oil pressure, voltage) from the brake pressure sensor can be checked with the monitor-
ing mode.
Related
(Controller: HST, CODE: 91902 BRAKE PRESS, CODE: 91903 BRAKE PRESS)
information
• Method of reproducing failure code: Start engine, operate parking brake lever (Free) and operate
brake pedal (release)

Possibly low HST charge pressure has been detected at present or
Possible causes HST charge pressure low
1 in the past. It is, therefore, required to investigate the cause and
and standard (When system is normal)
check damages and then repair or replace it.
value in normal
state Defective HST oil Carry out troubleshooting for HST charge pressure caution lamp
2 temperature caution lamp system in E-mode "Emergency warning items flash while engine is
system running."
40-310 10 D31/37-22
Failure code [CA111] Engine controller: Abnormality in controller SEN04507-01
Failure code [CA111] Engine controller: Abnormality in controller 1
Action code Failure code Engine controller: Abnormality in controller

Trouble
E04 CA111 (Engine controller system)
Contents of
• An abnormality occurs in internal memory or internal power supply circuit.
trouble
Action of
controller
Problem that
appears on • Engine runs normally but it may stop during operation or may not be able to start.
machine
Related
information

1 Defective fuse (F01 – 10) If fuse is broken, circuit probably has ground fault. (Refer to cause 4)
Defective power supply cut- without turning starting switch ON.
2
out relay Wiring harness between CN-CE02 (female) Resis- 185 –
(55) – (32) tance 265 z
without turning starting switch ON.
Wiring harness between CN-CE02 (female) Resis-
Max. 1 z
(55) – CN-R23 (1) tance
Max. 1 z
Possible causes (55) – CN-R24 (1) tance
and standard Wiring harness between CN-CE02 (female) Resis-
value in normal Max. 1 z
(32) – CN-R23 (2) tance
state Disconnection in wiring Wiring harness between CN-CE02 (female) Resis-
harness Max. 1 z
(32) – CN-R24 (2) tance
3 (Disconnection in wiring or
defective contact in connec- Max. 1 z
tor) (1) – CN-T-20 tance
Max. 1 z
(3) – CN-R23 (5) tance
Max. 1 z
(3) – CN-R24 (5) tance
Wiring harness between CN-R23 (female) Resis-
Max. 1 z
(3) – battery (+) tance
Wiring harness between CN-R24 (female) Resis-
Max. 1 z
(3) – battery (+) tance
D31/37-22 40-310 11
SEN04507-01 Failure code [CA111] Engine controller: Abnormality in controller

a Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch ON.
Wiring harness between CN-CE02
Resis- Min.
(female) (55) – CN-R23 (1) and chassis
tance 1 Mz
ground
Resis- Min.
tance 1 Mz
ground
Resis- Min.
tance 1 Mz
ground
Ground fault in wiring harness Wiring harness between CN-CE02
Possible causes 4 Resis- Min.
(Short circuit with GND circuit) (female) (32) – CN-R24 (2) and chassis
and standard tance 1 Mz
ground
value in normal
state Resis- Min.
tance 1 Mz
ground
Resis- Min.
tance 1 Mz
ground
Wiring harness between CN-R23 (female) Resis- Min.
(3) – battery (+) and chassis ground tance 1 Mz
Wiring harness between CN-R24 (female) Resis- Min.
(3) – battery (+) and chassis ground tance 1 Mz
a Prepare with starting switch OFF, turn starting switch ON and
carry out troubleshooting.
5 Defective engine controller
CN-CE03 Voltage
Between (3) – (1) 20 – 30 V
40-310 12 D31/37-22
Failure code [CA111] Engine controller: Abnormality in controller SEN04507-01
D31/37-22 40-310 13
SEN04507-01 Failure code [CA115] Abnormal engine Ne and Bkup speed sensors: Abnormal speed sensor signal
Failure code [CA115] Abnormal engine Ne and Bkup speed sensors:

Abnormal speed sensor signal 1
Action code Failure code Abnormal engine Ne and Bkup speed sensors: Abnormal speed
Trouble sensor signal
Contents of
• Abnormality occurred in both signals of engine Ne speed sensor and engine Bkup speed sensor.
trouble
Action of
controller
Problem that
• Engine stops (if engine has been running).
appears on
• Engine cannot be started (if engine has been stopped).
machine
Related
• Duplication of failure code: start the engine.
information

Defective Ne speed sensor
1 Carry out troubleshooting for failure code [CA689].
system
Defective Bkup speed sen-
2 Carry out troubleshooting for failure code [CA778].
sor system
Possible causes
Defective mount of Ne speed Check mount of Ne speed sensor directly for defect (defective
and standard 3
sensor installation of sensor, internal of flywheel, etc.)
value in normal
state Defective mount of Bkup Check mount of Bkup speed sensor directly for defect (defective
4
speed sensor installation of sensor, internal of supply pump, etc.)
Defective connection (Wrong Check Ne speed sensor and Bkup speed sensor directly for defec-
5
connection) tive connection (wrong connection).
If causes 1 – 5 are not detected, engine controller may be defective.
(Since trouble is in system, troubleshooting cannot be carried out.)
Reference: Bkup speed sensor = Cam speed sensor
40-310 14 D31/37-22
Failure code [CA122] Charge pressure sensor tool high: Excessively high voltage detected SEN04507-01
Failure code [CA122] Charge pressure sensor tool high: Excessively

high voltage detected 1
Action code Failure code Charge pressure sensor too high: excessively high voltage detected
Trouble
Contents of • Excessively high voltage is detected at pressure signal circuit of boost pressure and temperature
trouble sensor.
controller • Operates with a fixed charge pressure.
Problem that
• Engine output is reduced.
appears on
• Acceleration performance of engine drops.
machine
• The signal voltage of boost pressure and temperature sensor on boost pressure side can be
Related checked in monitoring mode.
information (Controller: ENGINE, Code: 36501 - CHG PRESS - A)
• Duplication of failure code: turn ON the starting switch.

Defective sensor power sup- If failure code [CA187] or [CA227] is indicated, carry out trouble-
1
ply system shooting for it first.
Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
Defective charge pressure CN-PTIM Voltage
2 sensor Between (3) – (1) Power supply 4.75 – 5.25 V
(Internal trouble)
Sensor voltage is measured with wiring harness connected. Accord-
ingly, if voltage is abnormal, check wiring harness and controller,
too, for another cause of trouble, and then judge.
Disconnection in wiring har- Wiring harness between CN-ENG1 (female) Resis-
Possible causes ness Max. 1 z
and standard (19) – CN-PTIM (female) (4) tance
value in normal Wiring harness between CN-ENG1 (female) Resis-
state tor) (36) – CN-PTIM (female) (3) tance
Wiring harness between CN-ENG1 (female) Resis-
Max. 1 z
(48) – CN-PTIM (female) (1) tance
Wiring harness between CN-ENG1 (female)
Resis- Min.
(19) – CN-PTIM (female) (4) and chassis
Ground fault in wiring har- tance 1 Mz
ground
ness
4 Wiring harness between CN-ENG1 (female)
(Short circuit with GND cir- Resis- Min.
cuit) (36) – CN-PTIM (female) (3) and chassis
tance 1 Mz
ground
Resis- Min.
tance 1 Mz
ground
D31/37-22 40-310 15
SEN04507-01 Failure code [CA122] Charge pressure sensor tool high: Excessively high voltage detected

Wiring harness between CN-ENG1
(female) (19) – CN-PTIM (female) (4) and Resis- Min.
wiring harness between CN-ENG1 tance 1 Mz
(female) (36) – CN-PTIM (female) (3)
Short circuit in wiring harness Wiring harness between CN-ENG1
Possible causes 5
(With another wiring harness) (female) (19) – CN-PTIM (female) (4) and Resis- Min.
and standard wiring harness between CN-ENG1 tance 1 Mz
value in normal (female) (48) – CN-PTIM (female) (1)
state
Chassis ground between CN-ENG1
(female) (36) – CN-PTIM (female) (3) and Resis- Min.
chassis ground between CN-ENG1 tance 1 Mz
(female) (48) – CN-PTIM (female) (1)
a Prepare with starting switch OFF, turn starting switch ON or
START and carry out troubleshooting.
CN-ENG1 Voltage
Between (36) – (48) Power supply 4.75 – 5.25 V
40-310 16 D31/37-22
Failure code [CA123] Charge pressure sensor too low: Excessively low voltage detected SEN04507-01
Failure code [CA123] Charge pressure sensor too low: Excessively low
voltage detected 1
Action code Failure code Charge pressure sensor too low: Excessively low voltage detected
Trouble
Contents of
• Excessively low voltage is detected at signal circuit of charge pressure and temperature sensor.
trouble
controller • Operates with a fixed charge pressure (101 kPa {1.02 kg/cm²}).
Problem that
appears on
• Acceleration performance of engine drops.
machine
• The signal voltage of boost pressure and temperature sensor on boost pressure side can be
information (Controller: ENGINE, Code: 36501 - CHG PRESS - A)
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out troubleshooting for failure code [CA122].
state
D31/37-22 40-310 17
SEN04507-01 Failure code [CA131] Decelerator pedal sensor tool high: Excessively high voltage detected
Failure code [CA131] Decelerator pedal sensor tool high: Excessively

Action code Failure code Decelerator pedal sensor too high: Excessively high voltage
Trouble detected
Contents of
• Excessively high voltage is detected at signal circuit of decelerator pedal.
trouble
• Flashes warning lamp and turns alarm buzzer ON.
Action of • Recognizes that decelerator pedal is at half position and continues control.
controller • Limits function partly.
• If cause of failure disappears, system resets itself.
Problem that • Engine speed cannot be controlled by decelerator pedal.
appears on • Engine speed is limited to medium (half).
machine • Once the machine is stopped and started again, its travel speed is limited to 50%.
• The signal voltage of decelerator pedal can be checked in monitoring mode.
Related
(Controller: ENGINE, Code: 31702 - DECEL PEDAL)
information

Defective decel sensor If failure code [CA2185] is displayed at the same time, carry out
1
power supply circuit troubleshooting for that first.
a Prepare with starting switch OFF, then start troubleshooting with
starting switch ON.
CN-DP1 Voltage
2 Defective decelerator pedal Between (B) – (C) Power source 4.75 – 5.25 V
Since voltage is measured with the harness connected, further diag-
nose the harness and the controller if the voltage is not normal, and
then make judgment after it is determined that there is no other
defective cause.
Hot short of harness (a con- starting switch ON.
3 tact with 5 V circuit or 24 V Between ground and wiring harness between
Possible causes circuit) CN-CE02 (female) (35) – CN-DP1 (female) Voltage Max. 1 V
and standard (A)
value in normal
state
starting switch OFF.
Harness short Wiring harness between CN-CE02 (female)
4
(Harness internal short) (35) – CN-DP1 (female) (A) and wiring har- Resis- Min.
ness between CN-CE02 (female) (27) – CN- tance 1 Mz
DP1 (female) (B)
The connections among decelerator pedal – body harness – engine
controller are suspected to be defective. Visually check it.
Defective wiring harness • Connector is loose, lock is broken, seal is broken.
5
connector • Pin is corroded, bent, broken, pushed in, expanded.
• Moisture in connector, entry of dirt or sand, etc., and insufficient
insulation.
starting switch ON.
CN-CE02 Voltage
Between (27) – (28) Power source 4.75 – 5.25 V
40-310 18 D31/37-22
Failure code [CA131] Decelerator pedal sensor tool high: Excessively high voltage detected SEN04507-01
D31/37-22 40-310 19
SEN04507-01 Failure code [CA132] Decelerator pedal sensor too low: Excessively low voltage detected
Failure code [CA132] Decelerator pedal sensor too low: Excessively low
voltage detected 1
Action code Failure code Decelerator pedal sensor too low: excessively low voltage detected
Trouble
Contents of
• Excessively low voltage is detected at signal circuit of decelerator pedal.
trouble
• Flashes warning lamp and turns alarm buzzer ON.
Action of • Recognizes that decelerator pedal is at half position and continues control.
controller • Limits function partly.
• If cause of failure disappears, system resets itself.
Problem that • Engine speed cannot be controlled by decelerator pedal.
appears on • Engine speed is limited to medium (half).
• The signal voltage of decelerator pedal can be checked in monitoring mode.
Related
(Controller: ENGINE, Code: 31702 - DECEL PEDAL)
information

Defective decel sensor If failure code [CA2186] is displayed at the same time, carry out
1
power supply circuit troubleshooting for that first.
starting switch ON.
CN-DP1 Voltage
2 Defective decelerator pedal Between (B) – (C) Power source 4.75 – 5.25 V
Since voltage is measured with the harness connected, further diag-
nose the harness and the controller if the voltage is not normal, and
then make judgment after it is determined that there is no other
defective cause.
Defective harness grounding
3
(Contact with ground circuit) Between ground and wiring harness between Resis- Min.
Possible causes CN-CE02 (female) (35) – CN-DP1 (female)
and standard tance 1 Mz
(A)
value in normal
state
Harness short Wiring harness between CN-CE02 (female)
4
(Harness internal short) (35) – CN-DP1 (female) (A) and wiring har- Resis- Min.
ness between CN-CE02 (female) (28) – CN- tance 1 Mz
DP1 (female) (C)
The connections among decelerator pedal – body harness – engine
controller are suspected to be defective. Visually check it.
5
insulation.
starting switch ON.
CN-CE02 Voltage
Between (27) – (28) Power source 4.75 – 5.25 V
40-310 20 D31/37-22
Failure code [CA132] Decelerator pedal sensor too low: Excessively low voltage detected SEN04507-01
D31/37-22 40-310 21
SEN04507-01 Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected
Failure code [CA144] Coolant temperature sensor too high: Excessively

Action code Failure code Coolant temperature sensor too high: Excessively high voltage detected
Trouble
Contents of
• Excessively high voltage is detected at signal circuit of engine coolant temperature sensor.
trouble
controller • Operates with a fixed engine coolant temperature (90?).
Problem that
• Exhaust gas color becomes white.
appears on
• Overheat prevention function does not work.
machine
• The signal voltage of engine coolant sensor can be checked in monitoring mode.
Related
(Controller: ENGINE, Code: 04105 - COOLANT TEMP)
information

CN-TWTR (male) Coolant temperature Resistance
Defective coolant tempera- 0? 30 – 37 kz

1
ture sensor (Internal trouble) 25? 9.3 – 10.7 kz
Between (B) – (A) 50? 3.2 – 3.8 kz
80? 1.0 – 1.3 kz
95? 700 – 800 z
Disconnection in wiring har- without turning starting switch ON.
ness (Disconnection in wiring Wiring harness between CN-ENG1 (female) Resis-
2 Max. 1 z
Possible causes or defective contact in con- (47) – CN-TWTR (female) (A) tance
and standard nector) Wiring harness between CN-ENG1 (female) Resis-
(49) – CN-TWTR (female) (B) tance
state
Ground fault in wiring har- without turning starting switch ON.
3 ness (Short circuit with GND Wiring harness between CN-ENG1 (female)
circuit) Resis- Min.
(49) – CN-TWTR (female) (B) and chassis
tance 1 Mz
ground
CN-ENG1 (female) Coolant temperature Resistance
0? 30 – 37 kz
25? 9.3 – 10.7 kz
Between (49) – (47) 50? 3.2 – 3.8 kz
80? 1.0 – 1.3 kz
95? 700 – 800 z
40-310 22 D31/37-22
Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected SEN04507-01
D31/37-22 40-310 23
SEN04507-01 Failure code [CA145] Coolant temperature sensor too low: Excessively low voltage detected
Failure code [CA145] Coolant temperature sensor too low: Excessively

low voltage detected 1
Action code Failure code Coolant temperature sensor too low: Excessively low voltage
Trouble detected
Contents of
• Excessively low voltage is detected at signal circuit of engine coolant temperature sensor.
trouble
controller • Operates with a fixed engine coolant temperature (90?).
Problem that
appears on
• Overheat prevention function does not work.
machine
• The signal voltage of engine coolant sensor can be checked in monitoring mode.
Related
(Controller: ENGINE, Code: 04105 - COOLANT TEMP)
information

and standard
state
40-310 24 D31/37-22
Failure code [CA145] Coolant temperature sensor too low: Excessively low voltage detected SEN04507-01
D31/37-22 40-310 25
SEN04507-01 Failure code [CA153] Charge air temperature sensor too high: Excessively high voltage detected
Failure code [CA153] Charge air temperature sensor too high:

Excessively high voltage detected 1
Action code Failure code Charge air temperature sensor too high: Excessively high voltage
Trouble detected
Contents of • Excessively high voltage is detected at temperature signal circuit of boost pressure and temperature
trouble sensor.
Action of
• Operates with a fixed charge temperature (46?).
controller
Problem that
appears on
• Engine protection function by boost temperature does not work.
machine
• The signal voltage of boost pressure and temperature sensor on boost temperature side can be
information (Controller: ENGINE, Code: 18501 - CHG TEMP)

Intake air
CN-PTIM (male) Resistance
temperature
Defective charge tempera- 0? 29 – 36 kz

1
ture sensor (Internal trouble) 25? 9 – 11 kz
Between (2) – (1)
40? 4.9 – 5.8 kz
100? 600 – 700 z
Between (2) –
All range Min. 1 Mz
chassis ground
Disconnection in wiring Wiring harness between CN-ENG1 (female) Resis-
harness Max. 1 z
(11) – CN-PTIM (female) (2) tance
Possible causes defective contact in connec- Max. 1 z
tor) (36) – CN-PTIM (3) tance
and standard
value in normal Wiring harness between CN-ENG1 (female) Resis-
Max. 1 z
state (48) – CN-PTIM (female) (1) tance
Ground fault in wiring har- Resis- Min.
3 ness (Short circuit with GND tance 1 Mz
ground
circuit)
Resis- Min.
tance 1 Mz
ground
Intake air
CN-ENG1 (female) Resistance
temperature
4 Defective engine controller 29 – 36 kz
0?
25? 9 – 11 kz
Between (11) – (48)
40? 4.9 – 5.8 kz
100? 600 – 700 z
40-310 26 D31/37-22
Failure code [CA153] Charge air temperature sensor too high: Excessively high voltage detected SEN04507-01
D31/37-22 40-310 27
SEN04507-01 Failure code [CA154] Charge temperature sensor too low: Excessively low voltage detected
Failure code [CA154] Charge temperature sensor too low: Excessively

low voltage detected 1
Action code Failure code Charge temperature sensor too low: Excessively low voltage
Trouble detected
Contents of • Excessively low voltage is detected at temperature signal circuit of boost pressure and temperature
trouble sensor.
Action of
• Operates with a fixed charge temperature (46?).
controller
Problem that
appears on
• Engine protection function by boost temperature does not work.
machine
• The signal voltage of boost pressure and temperature sensor on boost temperature side can be
information (Controller: ENGINE, Code: 18501 - CHG TEMP)

and standard
state
40-310 28 D31/37-22
Failure code [CA187] Sensor power source 2 too low: Excessively low voltage detected SEN04507-01
Failure code [CA187] Sensor power source 2 too low: Excessively low
voltage detected 1
Action code Failure code Sensor power source 2 too low: Excessively low voltage detected
Trouble
Contents of
• Excessively low voltage has been detected at sensor power source 2 circuit.
trouble
Action of • Operates with a fixed boost pressure (101 kPa {1.02 kg/cm²}).
controller • Operates with a fixed atmospheric pressure (55.44 kPa {0.53 kg/cm²}).
• Runs by limiting output.
Problem that
appears on • Engine output is reduced.
machine
Related
information

and standard
state
D31/37-22 40-310 29
SEN04507-01 Failure code [CA221] Atmospheric pressure sensor too high: Excessively high voltage detected
Failure code [CA221] Atmospheric pressure sensor too high:

Action code Failure code Atmospheric pressure sensor too high: Excessively high voltage
Trouble detected
Contents of
• Excessively high voltage is detected at signal circuit of atmospheric pressure sensor.
trouble
Problem that
• Startability gets worse.
appears on
machine
• The signal voltage of the atmospheric pressure sensor can be checked in monitoring mode.
Related
(Controller: ENGINE, Code: 37401 - AMBIENT PRESS)
information

1
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
CN-PAMB Voltage
Defective atmospheric pres-
2 sure sensor
(Internal trouble) Between (2) – (1) Signal 0.3 – 4.7 V
Possible causes Disconnection in wiring har- Wiring harness between CN-ENG1 (female) Resis-
and standard ness Max. 1 z
(36) – CN-PAMB (female) (3) tance
value in normal 3 (Disconnection in wiring or
state defective contact in connec- Max. 1 z
tor) (20) – CN-PAMB (female) (2) tance
Max. 1 z
(48) – CN-PAMB (female) (1) tance
Resis- Min.
(36) – CN-PAMB (female) (3) and chassis
ground
ness
cuit) (20) – CN-PAMB (female) (2) and chassis
tance 1 Mz
ground
Resis- Min.
(48) – CN-PAMB (female) (1) and chassis
tance 1 Mz
ground
40-310 30 D31/37-22
Failure code [CA221] Atmospheric pressure sensor too high: Excessively high voltage detected SEN04507-01

(female) (36) – CN-PAMB (female) (3) and Resis- Min.
(female) (20) – CN-PAMB (female) (2)
5
(With another wiring harness) (female) (36) – CN-PAMB (female) (3) and Resis- Min.
Possible causes
and standard wiring harness between CN-ENG1 tance 1 Mz
value in normal (female) (48) – CN-PAMB (female) (1)
state Wiring harness between CN-ENG1
(female) (20) – CN-PAMB (female) (2) and Resis- Min.
(female) (48) – CN-PAMB (female) (1)
or start engine and carry out troubleshooting.
6 Defective engine controller CN-ENG1 Voltage
Between (36) – (48) 4.75 – 5.25 V
Between (20) – (48) 0.3 – 4.7 V
D31/37-22 40-310 31
SEN04507-01 Failure code [CA222] Atmospheric pressure sensor too low: Excessively low voltage detected
Failure code [CA222] Atmospheric pressure sensor too low:

Excessively low voltage detected 1
Action code Failure code Atmospheric pressure sensor too low: Excessively low voltage
Trouble detected
Contents of
• Excessively low voltage is detected at signal circuit of atmospheric pressure sensor.
trouble
Problem that
machine
• The signal voltage of the atmospheric pressure sensor can be checked in monitoring mode.
Related
(Controller: ENGINE, Code: 37401 - AMBIENT TEMP)
information

and standard
state
40-310 32 D31/37-22
Failure code [CA222] Atmospheric pressure sensor too low: Excessively low voltage detected SEN04507-01
D31/37-22 40-310 33
SEN04507-01 Failure code [CA227] Sensor power source 2 too high: Excessively high voltage detected
Failure code [CA227] Sensor power source 2 too high: Excessively high
voltage detected 1
Action code Failure code Sensor power source 2 too high: Excessively high voltage detected
Trouble
Contents of
• Excessively high voltage has been detected in sensor power source 2 circuit.
trouble
Action of • Operates with a fixed boost pressure (101 kPa {1.02 kg/cm²}).
• Runs by limiting output.
Problem that
machine
Related
information

1 Defective related system If another failure code is indicated, carry out troubleshooting for it.
Disconnect devices at Bkup speed sensor CN-CAM connector
Defective sensor (Internal right in order. If failure Atmospheric
2 code disappears CN-PAMB connector
trouble) pressure sensor
when a device is dis-
connected, that Charge pressure
device has a defect in CN-PTIM connector
sensor
it.
ness
3 (Disconnection in wiring or Max. 1 z
(36) – each sensor (female) tance
defective contact in connec-
tor) Wiring harness between CN-ENG1 (female) Resis-
Possible causes Max. 1 z
(48) – each sensor (female) tance
and standard
value in normal
state
Ground fault in wiring har- Wiring harness between CN-ENG1 (female)
Resis- Min.
ness (36) – each sensor (female) and chassis
4 tance 1 Mz
(Short circuit with GND cir- ground
cuit) Wiring harness between CN-ENG1 (female)
Resis- Min.
(48) – each sensor (female) and chassis
tance 1 Mz
ground
Short circuit in wiring har- without turning starting switch ON.
ness Wiring harness between CN-ENG1 (female)
5
(With another wiring har- (36) – each sensor (female) and Resis- Min.
ness) Wiring harness between CN-ENG1 (female) tance 1 Mz
(48) – each sensor (female)
CN-ENG1 Voltage
Between (36) – (48) 4.75 – 5.25V
40-310 34 D31/37-22
Failure code [CA227] Sensor power source 2 too high: Excessively high voltage detected SEN04507-01
D31/37-22 40-310 35
SEN04507-01 Failure code [CA234] Engine over speed: Excessively high speed
Failure code [CA234] Engine over speed: Excessively high speed 1
Action code Failure code Engine over speed: Excessively high speed
Trouble
— CA234 (Engine controller system)
Contents of
• The engine speed exceeds upper control limit speed.
trouble
Action of
• Stops operation of injector.
controller
Problem that
appears on • Engine stops.
machine
• The engine speed can be checked in monitoring mode.
Related
(Controller: Engine, Code: 01002 - ENG SPEED)
information
• Duplication of failure code: Start engine and operate at high idle.

Possible causes 1 Defective related system If another failure code is indicated, carry out troubleshooting for it.
and standard 2 Improper way of use Way of use may be improper. Teach proper way of use to operator.
value in normal
If causes 1 and 2 are not detected, engine controller may be defec-
state
3 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
40-310 36 D31/37-22
Failure code [CA234] Engine over speed: Excessively high speed SEN04507-01
D31/37-22 40-310 37
SEN04507-01 Failure code [CA238] Abnormal power source for Ne speed sensor: Excessively low voltage detected
Failure code [CA238] Abnormal power source for Ne speed sensor:

Action code Failure code Abnormal power source for Ne speed sensor: Excessively low volt-
Trouble age detected
Contents of
• Excessively low voltage is detected at power source circuit of engine Ne speed sensor.
trouble
controller • Continues the control by engine Bkup speed sensor signal.
Problem that • Running engine stops (when Bkup speed sensor is also abnormal).
appears on • Stopped engine cannot be started (when Bkup speed sensor is also abnormal).
machine • Engine is hunting.
Related
information

Disconnect devices at
Defective Ne speed sensor right in order. If fail-
1 ure code disappears
(Internal trouble)
when a device is dis- Ne speed sensor CN-NE connector
connected, that
device has a defect in
it.
2 Max. 1 z
or defective contact in con- (26) – CN-NE (female) (3) tance
nector) Wiring harness between CN-ENG1 (female) Resis-
Max. 1 z
Possible causes (44) – CN-NE (female) (2) tance
and standard a Prepare with starting switch OFF, then carry out troubleshooting
value in normal without turning starting switch ON.
state
(26) – CN-NE (female) (3) and chassis
ground
circuit)
Resis- Min.
tance 1 Mz
ground
4 ness (with another wiring Wiring harness between CN-ENG1 (female)
harness) Resis- Min.
(26) – CN-NE (female) (3) and between CN-
tance 1 Mz
ENG1 (female) (44) – CN-NE (female) (2)
CN-ENG1 Voltage
Between (26) – (44) 4.75 – 5.25 V
40-310 38 D31/37-22
Failure code [CA238] Abnormal power source for Ne speed sensor: Excessively low voltage detected SEN04507-01
D31/37-22 40-310 39
SEN04507-01 Failure code [CA271] IMV/PCV1 short circuit: Short circuit
Failure code [CA271] IMV/PCV1 short circuit: Short circuit 1
Action code Failure code IMV/PCV1 short circuit: Short circuit

Trouble
Contents of
• Short circuit has been detected at drive circuit of supply pump actuator.
trouble
controller • Reduces quantity of fuel injection.
Problem that
machine
Related
information

Defective supply pump IMV CN-PREG (male) Resistance
1
(Internal trouble) Between (1) – (2) 2.3 – 5.3 z
Between (1), (2) – chassis
Min. 1 Mz
ground
ness Wiring harness between CN-ENG1 (female) Resis- Min.
2
(Short circuit with GND cir- (10) – CN-PREG (female) (1) tance 1 Mz
cuit) Wiring harness between CN-ENG1 (female) Resis- Min.
Possible causes
(14) – CN-PREG (female) (2) tance 1 Mz
and standard
value in normal a Prepare with starting switch OFF, then turn starting switch ON
state and carry out troubleshooting.
Hot short (Short circuit with (10) – CN-PREG (female) (1) and chassis Voltage Max. 1 V
3
24V circuit) in wiring harness ground
(14) – CN-PREG (female) (2) and chassis Voltage Max. 1 V
ground
Between (10) – (14) 2.3 – 5.3 z
Min. 1 Mz
ground
40-310 40 D31/37-22
Failure code [CA271] IMV/PCV1 short circuit: Short circuit SEN04507-01
D31/37-22 40-310 41
SEN04507-01 Failure code [CA272] IMV/PCV1 disconnection: Disconnection
Failure code [CA272] IMV/PCV1 disconnection: Disconnection 1
Action code Failure code IMV/PCV1 disconnection: Disconnection

Trouble
Contents of
• Disconnection is detected at drive circuit of supply pump actuator.
trouble
controller • Reduces quantity of fuel injection.
Problem that
machine
Related
information

1
(Internal disconnection) Between (1) – (2) 2.3 – 5.3 z
Min. 1 Mz
ground
ness
Possible causes 2 (Disconnection in wiring or Max. 1 z
(10) – CN-PREG (female) (1) tance
and standard defective contact in connec-
state (14) – CN-PREG (female) (2) tance
ness
cuit) (10) – CN-PREG (female) (1) and chassis
tance 1 Mz
ground
4 Defective engine controller CN-ENG1 (female) Resistance
Between (10) – (14) 2.3 – 5.3 z
Between (10) – chassis ground Min. 1 Mz
40-310 42 D31/37-22
Failure code [CA272] IMV/PCV1 disconnection: Disconnection SEN04507-01
D31/37-22 40-310 43
SEN04507-01
D31/37-22 Bulldozer
©2009 KOMATSU
All Rights Reserved
40-310 44
SEN04508-02
D31EX-22
D31PX-22
D37EX-22
D37PX-22
D31EX-22 60001 and up
D31PX-22 60001 and up
D37EX-22 60001 and up
D37PX-22 60001 and up

Failure code [CA322] Injector No. 1 system disconnection or short circuit: disconnection, short circuit ........ 4
Failure code [CA332] Injector No. 4 system disconnection or short circuit: disconnection, short circuit ...... 10
Failure code [CA351] Injector drive circuit abnormality: Abnormal circuit ..................................................... 12
Failure code [CA352] Sensor power source 1 too low: Excessively low voltage detected ........................... 14
Failure code [CA386] Sensor power source 1 too high: Excessively high voltage detected ........................ 16
Failure code [CA428] Water in fuel sensor too high: Excessively high voltage detected.............................. 18
Failure code [CA429] Water in fuel sensor too low: Excessively low voltage detected ................................ 20
Failure code [CA435] Abnormal engine oil pressure switch: Abnormal signal circuit ................................... 22
Failure code [CA441] Power source voltage too low: Excessively low voltage detected.............................. 23
Failure code [CA442] Power source voltage too high:
Excessively high voltage has occurred in the controller power source circuit ....................................... 24
Failure code [CA449] Common rail pressure too high (2): Excessively high pressure trouble occurred ...... 25
Failure code [CA451] Common rail pressure sensor too high: Excessively high voltage detected .............. 26
Failure code [CA452] Common rail pressure sensor too low: Excessively low voltage detected ................. 28
Failure code [CA553] Common rail pressure too high (1): Excessively high pressure detected .................. 29
Failure code [CA559] Loss of pressure feed from supply pump (1): Loss of pressure feed detected .......... 30
Failure code [CA689] Abnormal engine Ne speed sensor: Abnormal signal ................................................ 34
Failure code [CA731] Abnormal engine Bkup speed sensor phase: Abnormal phase ................................. 36
Failure code [CA757] Loss of all engine controller data: Loss of all data ..................................................... 37
D31/37-22 40-320 1
SEN04508-02
Failure code [CA778] Abnormal engine Bkup speed sensor: Abnormal Bkup signal ................................... 38
Failure code [CA1633] Abnormal KOMNET: Abnormal communication ....................................................... 40
Excessively high voltage detected ......................................................................................................... 42
Failure code [CA2186] Decelerator pedal sensor power source too low: Excessively low voltage detected .44
Failure code [CA2249] Loss of pressure feed from supply pump (2): Loss of pressure feed detected ........ 45
Failure code [CA2311] Abnormal IMV solenoid: Abnormal resistance.......................................................... 46
Failure code [CA2555] Air intake heater relay disconnection: Disconnection............................................... 48
Failure code [CA2556] Air intake heater relay short circuit: Short circuit ...................................................... 50
40-320 2 D31/37-22
SEN04508-02
D31/37-22 40-320 3
SEN04508-02 Failure code [CA322] Injector No. 1 system disconnection or short circuit: disconnection, short circuit
Failure code [CA322] Injector No. 1 system disconnection or short

circuit: disconnection, short circuit 1
Action code Failure code Injector No. 1 system disconnection or short circuit: disconnection,
Trouble short circuit
Contents of
• A disconnection or short circuit has been detected in No. 1 injector drive circuit.
trouble
Action of
controller
Problem that
• Engine rotation is unstable.
appears on
machine
Related
information

Defective injector #1 CN-CN1 (male) Resistance
1
(Internal trouble) Between (1) – (2) 0.4 – 1.1 z
Min. 1 Mz
ground
ness
(57) – CN-CN1 (female) (2) tance
Max. 1 z
Possible causes
state Ground fault in wiring har- Wiring harness between CN-ENG1 (female)
Resis- Min.
ness (57) – CN-CN1 (female) (2) and chassis
3 tance 1 Mz
Resis- Min.
(53) – CN-CN1 (female) (1) and chassis
tance 1 Mz
ground
Defective injector or wiring If another failure code for injector abnormality is displayed, carry out
4
harness of another cylinder troubleshooting for it.
Between (57) – (53) 0.4 – 1.1 z
Min. 1 Mz
ground
40-320 4 D31/37-22
Failure code [CA322] Injector No. 1 system disconnection or short circuit: disconnection, short circuit SEN04508-02
D31/37-22 40-320 5
Failure code [CA324] Injector No. 3 system disconnection or short circuit:

disconnection, short circuit 1
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Defective injector #3 (Inter- CN-CN3 (male) Resistance
1
nal trouble) Between (2) – (1) 0.4 – 1.1 z
Min. 1 Mz
ground
2 Max. 1 z
or defective contact in con- (55) – CN-CN3 (female) (2) tance
Max. 1 z
Possible causes
state Wiring harness between CN-ENG1 (female)
ground
circuit)
Resis- Min.
tance 1 Mz
ground
4
Between (55) – (59) 0.4 – 1.1 z
Min. 1 Mz
ground
40-320 6 D31/37-22
D31/37-22 40-320 7

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1
Min. 1 Mz
ground
2 Max. 1 z
Max. 1 z
Possible causes
ground
circuit)
Resis- Min.
tance 1 Mz
ground
4
Between (45) – (58) 0.4 – 1.1 z
Min. 1 Mz
ground
40-320 8 D31/37-22
D31/37-22 40-320 9

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1
Min. 1 Mz
ground
2 Max. 1 z
Max. 1 z
Possible causes
ground
circuit)
Resis- Min.
tance 1 Mz
ground
4
Between (56) – (51) 0.4 – 1.1 z
Min. 1 Mz
ground
40-320 10 D31/37-22
D31/37-22 40-320 11
SEN04508-02 Failure code [CA351] Injector drive circuit abnormality: Abnormal circuit
Failure code [CA351] Injector drive circuit abnormality: Abnormal

circuit 1
Action code Failure code

Trouble Injector drive circuit abnormality: Abnormal circuit
E03 CA351
Contents of
• Abnormality occurred in injector drive power supply circuit.
trouble
controller • Limits output and continues operation.
Problem that
appears
• Engine output drops.
on machine
Related
information
Causes Standard value in normal and remarks on troubleshooting

If another failure code is indicated, carry out troubleshooting for it
1 Defective related system
first.
2 Defective fuse No. 10 If fuse is burnt out, circuit probably has ground fault.
Defective relay for engine
3 Replace relays for engine controller power supply (R23, R24) with
controller power supply
other relays. If blinking failure code lights after reproduction opera-
Possible causes tion is conducted, that relay has a defect.
and standard
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state without turning starting switch.
Disconnection in wiring har- Wiring harness between CN-F01 (10) – CN- Resis- Max.
ness R23, CN-R24 (female) (3) tance 0.5 z
defective contact in connec- Wiring harness between CN-R23, CN-R24 Resis- Max.
tor) (female) (5) – CN-CE03 (female) (3) tance 0.5 z
Wiring harness between CN-CE03 (female) Resis- Max.
(1) – chassis ground (T20) tance 10 z
If causes 1 – 4 are not detected, engine controller may be defective.
40-320 12 D31/37-22
Failure code [CA351] Injector drive circuit abnormality: Abnormal circuit SEN04508-02
D31/37-22 40-320 13
SEN04508-02 Failure code [CA352] Sensor power source 1 too low: Excessively low voltage detected
Failure code [CA352] Sensor power source 1 too low:

Action code Failure code Sensor power source 1 too low: Excessively low voltage detected
Trouble
Contents of
• Excessively low voltage has been detected in sensor power source 1 circuit
trouble
Action of
• Operates with a fixed atmospheric pressure (55.44 kPa {0.53 kg/cm²}).
controller
• Operates with a fixed charge pressure (101 kPa {1.02 kg/cm²}).
Problem that
• Startability of engine deteriorates.
appears on
machine
Related
information
Possible causes Causes Standard value in normal state/Remarks on troubleshooting

and standard
state
40-320 14 D31/37-22
Failure code [CA352] Sensor power source 1 too low: Excessively low voltage detected SEN04508-02
D31/37-22 40-320 15
SEN04508-02 Failure code [CA386] Sensor power source 1 too high: Excessively high voltage detected
Failure code [CA386] Sensor power source 1 too high: Excessively high
voltage detected 1
Action code Failure code Sensor power source 1 too high: excessively high voltage detected
Trouble
Contents of
• Excessively high voltage has been detected in sensor power source 1 circuit
trouble
Action of
• Operates with a fixed atmospheric pressure (55.44 kPa {0.53 kg/cm²}).
controller
• Operates with a fixed charge pressure (101 kPa {1.02 kg/cm²}).
Problem that
• Startability of engine deteriorates.
appears on
machine
Related
information

Disconnect devices at
Defective sensor (Internal right in order. If failure
2 code disappears
trouble) Common rail pres-
when a device is dis- CN-PFUEL connector
sure sensor
connected, that
device has a defect in
it.
ness
(36) – CN-PFUEL (female) (3) tance
Possible causes Max. 1 z
and standard
value in normal
state
Ground fault in wiring har- Wiring harness between CN-ENG1 (female)
Resis- Min.
ness (36) – CN-PFUEL (female) (3) and chassis
4 tance 1 Mz
Resis- Min.
(48) – CN-PFUEL (female) (1) and chassis
tance 1 Mz
ground
5
(With another wiring har- (36) – CN-PFUEL (female) (3) and Resis- Min.
ness) wiring harness between CN-ENG1 (female) tance 1 Mz
(48) – CN-PFUEL (female) (1)
CN-ENG1 Voltage
Between (36) – (48) 4.75 – 5.25 V
40-320 16 D31/37-22
Failure code [CA386] Sensor power source 1 too high: Excessively high voltage detected SEN04508-02
D31/37-22 40-320 17
SEN04508-02 Failure code [CA428] Water in fuel sensor too high: Excessively high voltage detected
Failure code [CA428] Water in fuel sensor too high: Excessively high
voltage detected 1
Action code Failure code Water in fuel sensor too high: Excessively high voltage detected
Trouble
Contents of
• Excessively high voltage has occurred in the water in fuel sensor signal circuit.
trouble
Action of
• No particular action
controller
Problem that
appears on • Water separator monitor does not display normally.
machine
• The signal status of the water in fuel sensor can be checked with the monitoring mode.
Related
(Controller: ENGINE, Code: 18800 - WATER IN FULL)
information

a Prepare with starting switch OFF and diagnose with starting
Defective water in fuel sen- switch still OFF.
1
sor CN-WIF (female) Resistance
Between (1) – (2) Max. 100 kz
Disconnection in wiring har- switch still OFF.
ness Between CN-ENG1 (female) (34) – CN-WIF Resis-
2 Max. 10 z
(Disconnection or defective (male) (1) tance
contact of connectors) Between CN-ENG1 (female) (48) – CN-WIF Resis-
Max. 10 z
(male) (2) tance
Possible causes switch still OFF.
and standard Harness short
3 Between CN-ENG1 (female) (34) and each
value in normal (Harness internal short) Resis- Min.
other pin
state tance 100 kz
(All connectors in the harness disconnected)
Problem is possibly at the connections between water in fuel sensor
– engine harness – engine controller, so inspect them directly.
4 • Pin is corroded, bent, broken, pushed in, expanded.
connector
insulation.
Defect in other locations than switch still OFF.
5
engine controller CN-ENG1 (female) Resistance
Between (34) – (48) Max. 100 kz
Engine controller is possibly defective if no problem is found in
6 Defective engine controller causes 1 – 5.
(Since this is an internal defect, it cannot be diagnosed.)
40-320 18 D31/37-22
Failure code [CA428] Water in fuel sensor too high: Excessively high voltage detected SEN04508-02
Circuit diagram related to water in fuel sensor
D31/37-22 40-320 19
SEN04508-02 Failure code [CA429] Water in fuel sensor too low: Excessively low voltage detected
Failure code [CA429] Water in fuel sensor too low: Excessively low
voltage detected 1
Action code Failure code Water in fuel sensor too low: Excessively low voltage detected
Trouble
Contents of
• Excessively low voltage has occurred in the water in fuel sensor signal circuit.
trouble
Action of
controller
Problem that
appears on • Water separator monitor does not display normally.
machine
• The signal status of the water in fuel sensor can be checked with the monitoring mode.
Related
(Controller: ENGINE, Code: 18800 - WATER IN FUEL)
information

switch still OFF.
Defective water in fuel sen- CN-WIF (female) Resistance
1
sor
Between (1) – (2) Max. 10 z
Between (1) – chassis ground Min. 100 kz
Defective harness grounding switch still OFF.
2
(Contact with ground circuit) Between CN-ENG1 (female) (34) or CN-WIF Resis- Min.
(male) (1) and ground tance 100 kz
switch still OFF.
Harness short
Possible causes 3 Between CN-ENG1 (female) (34) and each
(Harness internal short) Resis- Min.
and standard other pin
value in normal tance 100 kz
(All connectors in the harness disconnected)
state
Problem is possibly at the connections between water in fuel sensor
– engine harness – engine controller, so inspect them directly.
4 • Pin is corroded, bent, broken, pushed in, expanded.
connector
insulation.
switch still OFF.
Defect in other locations than CN-ENG1 (female) Resistance
5
engine controller
Between (34) – (48) Max. 10 z
Between (34) – ground Min. 100 kz
6 Defective engine controller causes 1 – 5.
40-320 20 D31/37-22
Failure code [CA429] Water in fuel sensor too low: Excessively low voltage detected SEN04508-02
Circuit diagram related to water in fuel sensor
D31/37-22 40-320 21
SEN04508-02 Failure code [CA435] Abnormal engine oil pressure switch: Abnormal signal circuit
Failure code [CA435] Abnormal engine oil pressure switch: Abnormal

signal circuit 1
Action code Failure code Abnormal engine oil pressure switch: Abnormal signal circuit
Trouble
Contents of
• A problem has occurred in the engine oil pressure switch signal circuit
trouble
Action of
controller
Problem that
• Protection function by engine oil pressure does not operate.
appears on
• Engine oil pressure monitor does not display normally.
machine
Related
• Duplication of failure code: turn ON the starting switch or start the engine.
information

Defective engine oil pressure without turning starting switch ON.
1
switch CN-POIL (Male) Resistance
Between (1) – chassis ground Max. 1 z
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
ness without turning starting switch ON.
Possible defective contact in connec- Wiring harness between CN-ENG1 (female) Resis-
Max. 1 z
tor) (32) – CN-POIL (female) (1) tance
causes and
standard value a Troubleshoot with starting switch OFF, then carry out trouble-
in normal state shooting without turning starting switch ON.
Short circuit in wiring harness Wiring harness among all pins between CN-
3
(With another wiring harness) ENG1 (female) (32) – CN-ENG1 (female) Resis- Min.
(With all connectors of wiring harness distance 1 Mz
connected)
Between (32) – chassis ground Max. 1 z
40-320 22 D31/37-22
Failure code [CA441] Power source voltage too low: Excessively low voltage detected SEN04508-02
Failure code [CA441] Power source voltage too low: Excessively low
voltage detected 1
Action code Failure code Power source voltage too low: Excessively low voltage detected
Trouble
Contents of
• Excessively low voltage has occurred in the controller power source voltage circuit
trouble
Action of
controller
Problem that
appears on
machine
Related
information

and standard
state
D31/37-22 40-320 23
Failure code [CA442] Power source voltage too high: Excessively high voltage has occurred in the
SEN04508-02 controller power source circuit
Failure code [CA442] Power source voltage too high: Excessively high
voltage has occurred in the controller power source circuit 1
Action code Failure code Power source voltage too high: Excessively high voltage has
Trouble occurred in the controller power source circuit.
Contents of
• Excessively high voltage (36 V or more) has occurred in the controller power source voltage circuit.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

and standard
state
40-320 24 D31/37-22
Failure code [CA449] Common rail pressure too high (2): Excessively high pressure trouble occurred SEN04508-02
Failure code [CA449] Common rail pressure too high (2): Excessively high
pressure trouble occurred 1
Action code Failure code Common rail pressure too high (2): Excessively high pressure trou-
Trouble ble occurred
Contents of
• Excessively high pressure trouble (2) has occurred in the common rail circuit.
trouble
controller • Operates with limited output.
Problem that
machine
• Common rail pressure can be checked with the monitoring function.
Related
(Controller: ENGINE, Code: 36400 - RAIL PRESS)
information
• Duplication of failure code: Start the engine.

and standard
state
D31/37-22 40-320 25
SEN04508-02 Failure code [CA451] Common rail pressure sensor too high: Excessively high voltage detected
Failure code [CA451] Common rail pressure sensor too high:

Action code Failure code Common rail pressure sensor too high: Excessively high voltage
Trouble detected
Contents of
• Excessively high voltage has occurred in the common rail pressure sensor signal circuit
trouble
Problem that
machine
• The signal voltage of the common rail pressure sensor can be checked with the monitoring mode.
Related
information

1
a Prepare with starting switch OFF, then turn starting switch ON or
CN-PFUEL Voltage
Defective common rail pres-
2 sure sensor
(Internal trouble) Between (2) – (1) Signal 0.25 – 4.6 V
Possible causes Disconnection in wiring har- Wiring harness between CN-ENG1 (female) Resis-
and standard ness Max. 1 z
value in normal 3 (Disconnection in wiring or
state defective contact in connec- Max. 1 z
tor) (29) – CN-PFUEL (female) (2) tance
Max. 1 z
Resis- Min.
ground
ness
cuit) (29) – CN-PFUEL (female) (2) and chassis
tance 1 Mz
ground
Resis- Min.
tance 1 Mz
ground
40-320 26 D31/37-22
Failure code [CA451] Common rail pressure sensor too high: Excessively high voltage detected SEN04508-02

(female) (36) – CN-PFUEL (female) (3) Resis- Min.
and wiring harness between CN-ENG1 tance 1 Mz
(female) (29) – CN-PFUEL (female) (2)
5
(With another wiring harness) (female) (36) – CN-PFUEL (female) (3) Resis- Min.
Possible causes
and standard and wiring harness between CN-ENG1 tance 1 Mz
value in normal (female) (48) – CN-PFUEL (female) (1)
state Wiring harness between CN-ENG1
(female) (29) – CN-PFUEL (female) (2) Resis- Min.
and wiring harness between CN-ENG1 tance 1 Mz
(female) (48) – CN-PFUEL (female) (1)
or start engine and carry out troubleshooting.
6 Defective engine controller CN-ENG1 Voltage
Between (36) – (48) 4.75 – 5.25 V
Between (29) – (48) 0.25 – 4.6 V
D31/37-22 40-320 27
SEN04508-02 Failure code [CA452] Common rail pressure sensor too low: Excessively low voltage detected
Failure code [CA452] Common rail pressure sensor too low:

Action code Failure code Common rail pressure sensor too low: Excessively low voltage
Trouble detected
Contents of
• Excessively low voltage is detected in the common rail pressure sensor signal circuit
trouble
Problem that
machine
• The signal voltage of the common rail pressure sensor can be checked with the monitoring mode.
Related
information

and standard
state
40-320 28 D31/37-22
Failure code [CA553] Common rail pressure too high (1): Excessively high pressure detected SEN04508-02
Failure code [CA553] Common rail pressure too high (1): Excessively
high pressure detected 1
Action code Failure code Common rail pressure high trouble (1): Excessively high pressure
Trouble trouble occurred.
Contents of
• Excessively high pressure trouble (1) has occurred in the common rail circuit.
trouble
Action of
controller
Problem that
machine
• Common rail pressure can be checked with the monitoring mode.
Related
information

Check fuel used directly
2 Use of improper fuel
(for high viscosity).
Defective electrical system of Common rail pressure sensor may have electric trouble. Carry out
Possible causes 3
common rail pressure sensor troubleshooting for failure code [CA451].
and standard
value in normal Defective mechanical system
state 4 of common rail pressure sen- Check mechanical system of common rail pressure sensor directly.
sor
Check overflow valve directly for broken spring, worn seat, and
5 Defective overflow valve
stuck ball.
6 Clogging of overflow piping Check overflow piping directly for clogging.
7 Defective pressure limiter Check pressure limiter directly for mechanical defect.
D31/37-22 40-320 29
SEN04508-02 Failure code [CA559] Loss of pressure feed from supply pump (1): Loss of pressure feed detected
Failure code [CA559] Loss of pressure feed from supply pump (1): Loss
of pressure feed detected 1
Action code Failure code Loss of pressure feed from supply pump (1): Loss of pressure feed
Trouble detected
Contents of
• Loss of pressure feed (1) occurred in the common rail circuit.
trouble
Action of
controller
Problem that • Engine does not start or engine is hard to start.
appears on • Exhaust gas color becomes black.
machine • Engine output is reduced.
Related
information

2 Use of improper fuel Check fuel used directly (for high viscosity).
3 Clogging of fuel filter a If a fuel filter is clogged, replace it.
a For contents of troubleshooting, see Note 1. For check of pres-
sure in fuel low-pressure circuit, see Testing and adjusting, "Test-
Defective low-pressure cir- ing fuel pressure".
4
cuit device Pressure in fuel low-pressure
circuit –49 – 0 MPa {–0.5 – 0 kg/cm2}
(At high idle or rated (stall) load)
Defective electrical system of Supply pump EMV may have electric trouble. Carry out trouble-
5
supply pump EMV shooting for following failure codes [CA271], [CA272].
Defective common rail pres- Common rail pressure sensor may be defective. Check wiring har-
6
sure sensor ness for damage.
Possible causes a For testing of leakage from pressure limiter, see Testing and
and standard adjusting, "Testing leakage from pressure limiter and return rate
value in normal from injector".
state 7 Defective pressure limiter Leakage from pressure limiter
Max. 20 cc/min
(At stall load)
Reference: A limit value is the value mentioned above, but a stan-
dard value in normalcy is "0 cc/min. (no leak)".
a For testing of return rate (spill) from injector, see Testing and
adjusting, "Testing leakage from pressure limiter and return rate
from injector".
Speed at rated operation
Return (Spill) limit from injector
(at stall)
8 Defective injector 1,600 rpm 190 cc/min
1,700 rpm 200 cc/min
9 Defective supply pump If causes 1 – 8 are not detected, supply pump may be defective.
<How to use check sheet>

Carry out the above troubleshooting and take a record of the contents of the attached ÅgCheck sheet for no-
pressure feedÅg.
40-320 30 D31/37-22
Failure code [CA559] Loss of pressure feed from supply pump (1): Loss of pressure feed detected SEN04508-02
Note 1. If fuel low-pressure circuit parts seem to be defective, check the following items.
1) Fuel level
2) Clogging of fuel tank breather
3) Leaking or clogging of fuel low-pressure piping
4) Clogging of fuel prefilter
5) Clogging of fuel main filter
6) Replace the fuel filters when trouble doesn’t cancel it even if clogging is checked.
D31/37-22 40-320 31
SEN04508-02 Failure code [CA559] Loss of pressure feed from supply pump (1): Loss of pressure feed detected
Check sheet for no-pressure feed
Model Work No.

Machine serial No. # Date of check / /
Engine Service meter h
Engine serial No. # Worker's name
A. Visual check Good NG

1 Fuel leakage to outside
2 Clogging of fuel tank breather
B. Check with machine monitor (Fault history function, monitoring function, and reduced cylinder mode function) Good NG
3 Check of error/failure code / / / /
Check of monitoring information
Standard value
Code Displayed item Checking condition Unit Measured value Good NG
(Reference value)
Low idle rpm 975 Å} 25
*1 Engine speed High idle rpm 2,400 Å} 50
Equivalent to rating rpm 2,200
Low idle % 0
*2 Throttle opening
High idle % 100
*3 Fuel injection command Equivalent to rating mm3 – – –
Common rail pressure
4 *4 Equivalent to rating MPa 90
command
Common rail fuel
*5 Equivalent to rating MPa –
pressure
Low idle CA – – –
Fuel injection timing
*6 High idle CA – – –
command
Equivalent to rating CA – – –
*7 Boost pressure Equivalent to rating kPa – – –
Engine coolant
*8 Low idle °C – – –
temperature
*9 Fuel temperature Low idle °C – – –
Check of reduced cylinder mode operation (Engine speed)
Standard value
Function Reduced cylinder Checking condition Unit Measured value Good NG
(Reference value)
5 No. 1 cylinder Low idle rpm – – –
No. 2 cylinder Low idle rpm – – –
*10
C. Check of fuel circuit pressure Standard value
Checking condition Unit Measured value Good NG
(Reference value)
kPa –49 – 0
6 Fuel low-pressure circuit pressure High idle or rated (stall) load
{kg/cm2} {–0.5 – 0
D. Check of strainers and filters Good NG

7 Visual check of fuel filter
E.Check of leakage and return rate Standard value

Checking condition Unit Measured value Good NG
(Reference value)
8 Leakage through pressure limiter Equivalent to rating cc/min Max. 20 (*)
Equivalent to rating 1,600 rpm cc/min 190
Equivalent to rating 1,700 rpm cc/min 200 Speed:
9 Return rate from injector Equivalent to rating 1,800 rpm cc/min 210
Equivalent to rating 1,900 rpm cc/min 220 Return rate:
Equivalent to rating 2,000 rpm cc/min 230
*1 – *10: Refer to monitoring code table of "Special function of monitor panel" in Testing and adjusting sec-
tion.
*11: A limit value is "Max. 20 cc/min.", but a standard value in normalcy is "0 cc/min. (no leak)".
40-320 32 D31/37-22
D31/37-22 40-320 33
SEN04508-02 Failure code [CA689] Abnormal engine Ne speed sensor: Abnormal signal
Failure code [CA689] Abnormal engine Ne speed sensor: Abnormal signal 1
Action code Failure code Abnormal engine Ne speed sensor: Abnormal signal
Trouble
Contents of
• Abnormal signal of the engine Ne speed sensor has been detected.
trouble
controller • Continues the control by engine Bkup speed sensor signal.
Problem that • Running engine stops (when Bkup speed sensor is also abnormal).
appears on • Stopped engine cannot be started (when Bkup speed sensor is also abnormal).
machine • Engine is hunting.
Related
information

Defective sensor power sup- If failure code [CA238] is indicated, carry out troubleshooting for it
1
ply system first.
ness Max. 1 z
(26) – CN-NE (female) (3) tance
tor) (44) – CN-NE (female) (2) tance
Max. 1 z
(42) – CN-NE (female) (1) tance
Resis- Min.
ground
ness
Possible causes cuit) (44) – CN-NE (female) (2) and chassis
tance 1 Mz
and standard ground
value in normal Wiring harness between CN-ENG1 (female)
state Resis- Min.
tance 1 Mz
ground
(26) – CN-NE (female) (3) and Resis- Min.
wiring harness between CN-ENG1 (female) tance 1 Mz
Short circuit in wiring har- (44) – CN-NE (female) (2)
4
(With another wiring har- (26) – CN-NE (female) (3) and Resis- Min.
ness) wiring harness between CN-ENG1 (female) tance 1 Mz
(42) – CN-NE (female) (1)
(44) – CN-NE (female) (2) and Resis- Min.
wiring harness between CN-ENG1 (female) tance 1 Mz
(42) – CN-NE (female) (1)
Defective mount of sensor or Check Ne speed sensor directly for defective mount (defective
5 defective rotation sensing clearance) or check rotation sensing part (crankshaft pulley) directly
part for defect.
40-320 34 D31/37-22
Failure code [CA689] Abnormal engine Ne speed sensor: Abnormal signal SEN04508-02

Possible causes If causes 1 – 5 are not detected, engine Ne speed sensor may be
Defective engine Ne speed
and standard 6 defective. (Since trouble is in system, troubleshooting cannot be
sensor
value in normal carried out.)
state If causes 1 – 6 are not detected, engine controller may be defective.
D31/37-22 40-320 35
SEN04508-02 Failure code [CA731] Abnormal engine Bkup speed sensor phase: Abnormal phase
Failure code [CA731] Abnormal engine Bkup speed sensor phase:

Abnormal phase 1
Action code Failure code Abnormal engine Bkup speed sensor phase: Abnormal phase
Trouble
Contents of • Abnormal phase is detected from the signals of engine Ne speed sensor and engine Bkup speed
trouble sensor.
Action of
• Continues the control using engine Ne speed sensor signal.
controller
Problem that
• Running engine stops (when Ne speed sensor is also abnormal).
appears on
• Stopped engine cannot be started (when Ne speed sensor is also abnormal).
machine
Related
information

Possible causes
Defective engine Ne speed Engine Ne speed sensor may be defective. Carry out troubleshoot-
and standard 1
sensor system ing for [CA698].
value in normal
state Defective engine Bkup Engine Bkup speed sensor may be defective. Carry out trouble-
2
speed sensor system shooting for [CA778].
40-320 36 D31/37-22
Failure code [CA757] Loss of all engine controller data: Loss of all data SEN04508-02
Failure code [CA757] Loss of all engine controller data: Loss of all data 1
Action code Failure code Loss of all engine controller data: Loss of all data
Trouble
Contents of
• Loss of all data in engine controller has been detected.
trouble
Action of
controller
Problem that
• Engine continues operation normally, but it may stop during operation or may not be able to start.
appears on
• Monitoring function of monitor panel (engine controller system) may not operate normally.
machine
Related
information

and standard
state
D31/37-22 40-320 37
SEN04508-02 Failure code [CA778] Abnormal engine Bkup speed sensor: Abnormal Bkup signal
Failure code [CA778] Abnormal engine Bkup speed sensor: Abnormal

Bkup signal 1
Action code Failure code Abnormal engine Bkup speed sensor: Abnormal Bkup signal
Trouble
Contents of
• Abnormal engine Bkup speed sensor signal has been detected.
trouble
controller • Continue the control using engine Ne speed sensor signal.
Problem that
• Running engine stops (when Ne speed sensor is also abnormal).
appears on
• Stopped engine cannot be started (when Ne speed sensor is also abnormal).
machine
Related
information

1
ness Max. 1 z
(36) – CN-CAM (female) (3) tance
tor) (48) – CN-CAM (female) (2) tance
Max. 1 z
(37) – CN-CAM (female) (1) tance
Resis- Min.
(36) – CN-CAM (female) (3) and chassis
ground
ness
Possible causes cuit) (48) – CN-CAM (female) (2) and chassis
tance 1 Mz
and standard ground
value in normal Wiring harness between CN-ENG1 (female)
state Resis- Min.
(37) – CN-CAM (female) (1) and chassis
tance 1 Mz
ground
(36) – CN-CAM (female) (3) and between Resis- Min.
CN-ENG1 (female) (48) – CN-CAM (female) tance 1 Mz
Short circuit in wiring har- (2)
4
(With another wiring har- (36) – CN-CAM (female) (3) and between Resis- Min.
ness) CN-ENG1 (female) (37) – CN-CAM (female) tance 1 Mz
(1)
(48) – CN-CAM (female) (2) and between Resis- Min.
CN-ENG1 (female) (37) – CN-CAM (female) tance 1 Mz
(1)
Defective mount of sensor or Check Bkup speed sensor directly for defective mount (defective
5 defective rotation sensing clearance) or check rotation sensing part (in supply pump) directly
part for defect.
40-320 38 D31/37-22
Failure code [CA778] Abnormal engine Bkup speed sensor: Abnormal Bkup signal SEN04508-02

Possible causes If causes 1 – 5 are not detected, engine Bkup speed sensor may be
Defective engine Bkup
and standard 6 defective. (Since trouble is in system, troubleshooting cannot be
speed sensor
value in normal carried out.)
state If causes 1 – 6 are not detected, engine controller may be defective.
D31/37-22 40-320 39
SEN04508-02 Failure code [CA1633] Abnormal KOMNET: Abnormal communication
Failure code [CA1633] Abnormal KOMNET: Abnormal communication 1
Action code Failure code Abnormal KOMNET: Abnormal communication

Trouble
Contents of • Engine controller detected an abnormal communication in the KOMNET communication circuit
trouble between HST controller.
Action of
• Operate in a default mode.
controller
• When the cause of the failure has been eliminated, it returns to normal.
Problem that • Machine may not operate normally because the informations which are exchanged through KOM-
appears on NET communication are not transmitted properly.
machine (A symptom of failure depends on the location where it occurs.)
• The engine controller outputs this code.
Related
Since CAN communication between the engine controller and HST controller is defective, however,
information
this code is not displayed or recorded on the monitor panel and KOMTRAX terminal.
When the system resets itself, this code is displayed for only a moment.

switch still OFF.
Disconnection in wiring har- Wiring harnesses between CN-S04 (female)
Resis-
ness (1), (6) – CN-CE02 (female) (1), CN-ST2 Max. 1 z
1 tance
(Disconnection or defective (female) (32), CN-119 (female) (A)
contact of connectors) Wiring harnesses between CN-S04 (female)
Resis-
(3), (4) – CN-CE02 (female) (21), CN-ST2 Max. 1 z
tance
(female) (22), CN-119 (female) (B)
switch still OFF.
Between ground and wiring harnesses
between CN-S04 (female) (1), (2) – CN- Resis-
Min. 1 Mz
Defective harness grounding CE02 (female) (1), CN-ST2 (female) (32), tance
2
(Contact with ground circuit) CN-119 (female) (A) – CN-DT12 (male) (3)
Possible causes between CN-S04 (female) (3), (4) – CN- Resis-
Min. 1 Mz
and standard CE02 (female) (21), CN-ST2 (female) (22), tance
value in normal CN-119 (female) (B) – CN-DT12 (male) (10)
state a Prepare with starting switch OFF and diagnose with starting
switch ON.
between CN-S04 (female) (1), (6) – CN- Max.
Voltage
Hot short of wiring harness CE02 (female) (1), CN-ST2 (female) (32), 5.5 V
3
(a contact with 24 V circuit) CN-119 (female) (A) – CN-DT12 (male) (3)
between CN-S04 (female) (3) – CN-CE02 Max.
Voltage
(female) (21), CN-ST2 (female) (22), CN-119 5.5 V
(female) (B) – CN-DT12 (male) (10)
Defective terminal resis- a Prepare with starting switch OFF and diagnose with starting
tance in CAN switch still OFF.
4
(Internal short circuit and dis- CN-119 (male) Resistance
connection) Between (A) – (B) 120 ± 12 z
HST controller or engine controller is possibly defective if no prob-
Defective HST controller or
5 lem is found in causes 1 – 4. (Since this is an internal defect, it can-
engine controller
not be diagnosed.)
40-320 40 D31/37-22
Failure code [CA1633] Abnormal KOMNET: Abnormal communication SEN04508-02
D31/37-22 40-320 41
Failure code [CA2185] Decelerator pedal sensor power source too high: Excessively high voltage
SEN04508-02 detected
Action code Failure code Decelerator pedal sensor power source too high: Excessively high
Trouble voltage detected
Contents of • Excessively high voltage (Min. 5.25 V) is detected in the circuit of decelerator pedal sensor power
trouble source.
Action of • Flashes warning lamp and turns alarm buzzer ON.
controller • Recognizes that decelerator pedal is at half position and continues control.
Problem that
appears on • Engine speed cannot be controlled by decelerator pedal.
machine
Related
information

switch still OFF.
Between CN-CE02 (female) (27) – all pins of
Resis- Min.
CN-CE02 (female)
Harness short tance 1 Mz
1 (with CN-DP1 disconnected)
(Harness internal short)
Wiring harness between CN-CE02 (female)
(27) – CN-DP1 (female) (B) and wiring har- Resis- Min.
Possible causes ness between CN-CE02 (female) (35) – CN- tance 1 Mz
and standard DP1 (female) (A)
value in normal
Since the connections among decelerator pedal – body harness –
state
engine controller are suspected to be defective, visually check
them.
Defective wiring harness
2 • Connector is loose, lock is broken, seal is broken.
connector
• Pin is corroded, bent, broken, pushed in, expanded.
insulation.
3 Defective engine controller causes 1 – 2. (Since this is an internal defect, it cannot be diag-
nosed.)
40-320 42 D31/37-22
Failure code [CA2185] Decelerator pedal sensor power source too high: Excessively high voltage
detected SEN04508-02
D31/37-22 40-320 43
Failure code [CA2186] Decelerator pedal sensor power source too low: Excessively low voltage
SEN04508-02 detected
Failure code [CA2186] Decelerator pedal sensor power source too low:
Action code Failure code Decelerator pedal sensor power source too low: Excessively low
Trouble voltage detected
Contents of
• Excessively low voltage is detected at decelerator pedal sensor power source circuit.
trouble
Action of • Flashes warning lamp and turns alarm buzzer ON.
controller • Recognizes that decelerator pedal is at half position and continues control.
Problem that
appears on • Engine speed cannot be controlled by decelerator pedal.
machine
Related
information

and standard
state
40-320 44 D31/37-22
Failure code [CA2249] Loss of pressure feed from supply pump (2):
Loss of pressure feed detected 1
Action code Failure code Loss of pressure feed from supply pump (2): Loss of pressure feed
Trouble detected
Contents of
• Loss of pressure feed (2) occurred in the common rail circuit.
trouble
Problem that
appears on • Engine output decreases.
machine
Related
information

and standard
value in normal 1 Carry out troubleshooting of [CA559].
state
D31/37-22 40-320 45
SEN04508-02 Failure code [CA2311] Abnormal IMV solenoid: Abnormal resistance
Failure code [CA2311] Abnormal IMV solenoid: Abnormal resistance 1
Action code Failure code Abnormal IMV solenoid: Abnormal resistance

Trouble
Contents of
• Resistance value of supply pump actuator circuit is abnormally high or low.
trouble
Action of
controller
Problem that
appears on • Engine output decreases.
machine
Related
information

2
solenoid
Between (1) – (2) 2.3 – 5.3 z
ness
Possible Wiring harness between CN-ENG1 (female) Resis-
causes and (10) – CN-PREG (female) (1) tance
standard value Wiring harness between CN-ENG1 (female) Resis-
tor) Max. 1 z
in normal state (14) – CN-PREG (female) (2) tance
Ground fault in wiring harness without turning starting switch ON.
4
(Short circuit with GND circuit) Wiring harness between CN-ENG1 (female) Resis- Min.
(10) – CN-PREG (female) (1) tance 1 Mz
5 Defective engine controller CN-ENG1 (female) Resistance
Between (10) – (14) 2.3 – 5.3 z
40-320 46 D31/37-22
Failure code [CA2311] Abnormal IMV solenoid: Abnormal resistance SEN04508-02
D31/37-22 40-320 47
SEN04508-02 Failure code [CA2555] Air intake heater relay disconnection: Disconnection
Failure code [CA2555] Air intake heater relay disconnection:

Disconnection 1
Action code Failure code Air intake heater relay disconnection: Disconnection
Trouble
Contents of
• Disconnection is detected in the drive circuit of air intake heater relay.
trouble
Action of
controller
Problem that
• Air intake heater does not operate (Startability deteriorates in a low temperature and white smoke is
appears on
exhausted.)
machine
Related
• Duplication of failure code: Turn the starting switch ON with coolant temperature below -4°C.
information

and standard
value in normal Carry out troubleshooting failure code [CA2556].
state
40-320 48 D31/37-22
Failure code [CA2555] Air intake heater relay disconnection: Disconnection SEN04508-02
D31/37-22 40-320 49
SEN04508-02 Failure code [CA2556] Air intake heater relay short circuit: Short circuit
Failure code [CA2556] Air intake heater relay short circuit: Short circuit1
Action code Failure code Air intake heater relay short circuit: Short circuit
Trouble
Contents of
• Short circuit is detected in the drive circuit of air intake heater relay.
trouble
Action of
controller
Problem that
• Air intake heater does not operate (Startability deteriorates in a low temperature and white smoke is
appears on
exhausted.)
machine
Related
• Duplication of failure code: Turn the starting switch ON with coolant temperature below –4°C.
information

switch still OFF (diagnose by itself).
CN-RHR (male) Resistance
Between (1) – (2) 290 z ±10%
Defective preheat relay
1 a Prepare with starting switch OFF and diagnose with starting
(internal disconnection)
switch ON (diagnose by replacing with other relay)
Replace preheat relay (RHR) with other relay and carry out the pro-
cedure to duplicate the failure code. If failure code changes from
flashing to steady ON, the relay is defective.
switch still OFF.
Defective harness grounding
2
(Contact with ground circuit) Between ground and wiring harness between Resis- Min.
CN-CE02 (female) (44) – CN-RHR (female)
tance 100 kz
(1) and chassis ground
Possible causes
switch still OFF.
and standard Harness short
value in normal 3 Between CN-CE02 (female) (44) – all pins of
(Harness internal short) Resis- Min.
state CN-CE02 (female)
tance 100 kz
(with CN-RHR also disconnected)
The connections among preheat relay – body harness – engine
controller are suspected to be defective. Visually check them.
4
insulation.
Defect in other locations than switch still OFF.
5
engine controller CN-CE02 (female) Resistance
Between (44) – (54) 290 z ±10%
CN-CE02 Heater relay Voltage
Under operating
Max. 1 V
6 Defective engine controller condition
Between (44) – (54)
Under stopping
20 – 30 V
condition
40-320 50 D31/37-22
Failure code [CA2556] Air intake heater relay short circuit: Short circuit SEN04508-02
D31/37-22 40-320 51
SEN04508-02
D31/37-22 Bulldozer
©2014 KOMATSU
All Rights Reserved
40-320 52
SEN04509-00
D31EX-22
D31PX-22
D37EX-22
D37PX-22
D31EX-22 60001 and up
D31PX-22 60001 and up
D37EX-22 60001 and up
D37PX-22 60001 and up

Failure code [D130KA] Neutral safety relay: Disconnection ........................................................................... 4
Failure code [D130KB] Neutral safety relay: Short circuit............................................................................... 6
Failure code [DAFRKR] CAN communication (Monitor panel – HST controller):
Defective communication (Abnormality in objective component system) ................................................ 8
Failure code [DAFRMC] CAN communication (Monitor panel – ENGINE controller):
Defective communication (Abnormality in objective component system) ...............................................11
Failure code [DAJ000] HST controller: Memory error ................................................................................... 14
Failure code [DAJ0KK] HST controller: Lowing of source voltage ................................................................ 16
Failure code [DAJ0KQ] HST controller: Machine code error ........................................................................ 18
Failure code [DAJ0KT] HST controller: Memory error .................................................................................. 19
Failure code [DAJRKR] CAN communication (HST controller – Monitor panel):
Defective communication (Abnormality in objective component system) .............................................. 24
Failure code [DB2RKR] CAN communication (HST controller – Engine controller):
Defective communication (Abnormality in objective component system) .............................................. 27
Failure code [DD12KA] Shift up switch: Disconnection ................................................................................ 30
Failure code [DD12KB] Shift up switch: Short circuit .................................................................................... 32
Failure code [DD13KA] Shift down switch: Disconnection ............................................................................ 34
Failure code [DD13KB] Shift down switch: Short circuit ............................................................................... 36
Failure code [DD14KB] Travel lock limit switch 1: Short circuit..................................................................... 38
D31/37-22 40-330 1
SEN04509-00
Failure code [DD1NL4] Fan rotation selector switch: Disagreement of ON, OFF Signals ............................ 40
Failure code [DDDCKB] Reverse travel speed switch: Short circuit ............................................................. 42
Failure code [DDP6KA] Brake oil pressure sensor: Disconnection............................................................... 44
Failure code [DDP6KB] Brake oil pressure sensor: Short circuit .................................................................. 46
Failure code [DDP6MA] Brake oil pressure sensor: Malfunction .................................................................. 48
Failure code [DDQ2KA] Travel lock limit switch 1: Disconnection ................................................................ 50
Failure code [DDT0L4] Shift mode switch: Disagreement of ON/ OFF Signals ............................................ 52
Failure code [DDU1FS] Travel lock limit switches 1 and 2: Fixing ................................................................ 54
Failure code [DDU1KA] Travel lock limit switch 2: Disconnection................................................................. 56
Failure code [DDU1KY] Travel lock limit switch 2: Short circuit with power supply line ................................ 58
Failure code [DGS1KA] HST oil temperature sensor: Disconnection ........................................................... 60
Failure code [DGS1KX] HST oil temperature sensor: Out of Input signal range .......................................... 62
40-330 2 D31/37-22
SEN04509-00
D31/37-22 40-330 3
SEN04509-00 Failure code [D130KA] Neutral safety relay: Disconnection
Failure code [D130KA] Neutral safety relay: Disconnection 1
Action code Failure code Neutral safety relay: Disconnection

Trouble
E02 D130KA (HST controller system)
Contents of
• When the ground circuit of the neutral safety relay is disconnected, 24V is not generated.
trouble
controller • Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• When the engine is stopped, it can not be restarted (Disconnection).
appears on
• Engine can be started regardless of the parking lever switch position (Ground fault).
machine
• Output state to the neutral safety switch (ON and OFF, voltage) can be checked with the monitoring
mode.
(Controller: HST, code: 40918 D-OUT [3], code: 50901 N-SAFETY)
Related
• Method of reproducing failure code: Turn the starting switch ON and operate parking brake lever
information
(Free).
• This failure code is generated when the primary (coil side) of neutral safety relay has failed. A failure
of the secondary cannot be detected with this code.

a Prepare with starting switch OFF and carry out troubleshooting
without and with turning starting switch.
Defective starting switch Starting switch Starting switch Resistance
1
(Internal disconnection)
Between T250 (B) OFF Min. 1 Mz
and T270 (ACC) ON Max. 1 z
Defective neutral safety relay without turning starting switch.
2
(Internal disconnection) CN-11 (Male) Resistance
Between (1) and (2) 200 – 400 z
Disconnection of wiring without turning starting switch.
Possible causes harness Wiring harness between CN-ST2 (female)
and standard 3 Resistance Max. 1 z
(Disconnection or defective (8) – CN-11 (female) (2)
value in normal contact of connector) Wiring harness between CN-11 (female) (1)
state Resistance Max. 1 z
– starting switch CN-T270 (ACC)
Grounding fault in wiring Wiring harness between CN-ST2 (female)
Resistance Min. 1 Mz
4 harness (Short circuit with (8) – CN-11 (female) (2) and chassis ground
ground circuit) Wiring harness between CN-11 (female) (1)
– starting switch CN-Y270 (ACC), – F01 Resistance Min. 1 Mz
(20F) inlet and chassis ground
5 Defective HST controller CN-ST2 Parking brake lever Voltage
Between (8) and Free 20 – 30 V
chassis ground Locked Max. 1 V
40-330 4 D31/37-22
Failure code [D130KA] Neutral safety relay: Disconnection SEN04509-00
D31/37-22 40-330 5
SEN04509-00 Failure code [D130KB] Neutral safety relay: Short circuit
Failure code [D130KB] Neutral safety relay: Short circuit 1
Action code Failure code Neutral safety relay: Short circuit

Trouble
E02 D130KB (HST controller system)
Contents of
• Abnormal current flowed at the GND output to the neutral safety relay.
trouble
Problem that
appears on • When the engine is stopped, it can not be restarted.
machine
• Output state to the neutral safety switch (ON, OFF, and voltage) can be checked with the monitoring
mode.
(Controller: HST, code: 40918 D-OUT [3], code: 50901 N-SAFETY)
Related
information
(Lock).
• This failure code is generated when the primary (coil side) of neutral safety relay has failed. A failure
of the secondary cannot be detected with this code.

Defective neutral safety relay without turning starting switch.
1
(Internal short circuit) CN-11 (Male) Resistance
Between (1) and (2) 200 – 400 z
Possible causes a Prepare with starting switch OFF, then turn starting switch ON
Short circuit with power supply and carry out troubleshooting.
and standard
2 line circuit wiring harness
value in normal Wiring harness between CN-ST2 (female)
(Contact with 24 V) Voltage Max. 1 V
state (8) – CN-11 (female) (2) and chassis ground
3 Defective HST controller CN-ST2 Parking brake lever Voltage
Between (8) and Free 20 – 30 V
chassis ground Locked Max. 1 V
40-330 6 D31/37-22
Failure code [D130KB] Neutral safety relay: Short circuit SEN04509-00
D31/37-22 40-330 7
Failure code [DAFRKR] CAN communication (Monitor panel – HST controller): Defective
SEN04509-00 communication (Abnormality in objective component system)
Failure code [DAFRKR] CAN communication (Monitor panel – HST

controller): Defective communication (Abnormality in objective component
system) 1
Action code Failure code CAN communication (Monitor panel – HST controller): Defective
Trouble communication (Abnormality in objective component system)
E03 DAFRKR (Monitor panel system)
Contents of
• The monitor panel cannot recognize the HST controller in the CAN communication circuit.
trouble
Action of
• Limit the functions partly.
controller
• The system may not work properly.
Problem that
• Once the machine is stopped, Engine speed is limited to 50% of the value.
appears on
• Once the machine is stopped and started again, its travel speed is limited to 50%.
machine
• The monitor panel does not display information.
• Method of reproducing failure code: Turn the starting switch ON
• Indicate failure code [DAFRMC], when the monitor panel cannot recognize the engine controller.
Related
• Indicate failure code [DB2RKR], when HST controller cannot recognize the engine controller.
information
• Indicate failure code [DAJRKR], when HST controller cannot recognize the monitor panel.
• Indicate failure code [CA1633], when engine controller cannot recognize the HST controller.

Short circuit in wiring without turning starting switch.
1
harness CN-DT12 (male) Resistance
Between (3) and (10) 50 – 70 z
Wiring harness between CN-S04 (female) (1),
Disconnection in wiring (6) – CN-CE02 (female) (1), – CN-ST2
Resistance Max. 1 z
harness (female) (32), – CN-G01 (female) (8), – CN-
2
(Disconnection or defective 119 (female) (A), CN-DT12 (male) (3)
Possible causes contact in connector) Wiring harness between CN-S04 (female)
and standard (3) – CN-CE02 (female) (21), – CN-ST2
Resistance Max. 1 z
value in normal (female) (22), – CN-G01 (female) (7), – CN-
state 119 (female) (B), CN-DT12 (male) (10)
Wiring harness between CN-S04
(female)(1), (6) – CN-CE02 (female) (1), –
Grounding fault in wiring CN-ST2 (female) (32), – CN-G01 (female) Resistance Min. 1 Mz
harness (8), – CN-119 (female) (A), CN-DT12 (male)
3
(Short circuit with ground (3) and chassis ground
circuit) Wiring harness between CN-S04 (female)
(3) – CN-CE02 (female) (21), – CN-ST2
(female) (22), – CN-G01 (female) (7), – CN- Resistance Min. 1 Mz
119 (female) (B), CN-DT12 (male) (10) and
chassis ground
40-330 8 D31/37-22
communication (Abnormality in objective component system) SEN04509-00

a Prepare with starting switch OFF, then turning starting switch ON
Short circuit with power CN-ST2 (female) (32), – CN-G01 (female) Voltage Max. 1 V
supply line circuit in wiring (8), – CN-119 (female) (A), CN-DT12 (male)
4
harness (3) and chassis ground
(Contact with 24V circuit) Wiring harness between CN-S04 (female)
(3) – CN-CE02 (female) (21), – CN-ST2
(female) (22), – CN-G01 (female) (7), – CN- Voltage Max. 1 V
Possible causes 119 (female) (B), CN-DT12 (male) (10) and
and standard chassis ground
value in normal
state a Prepare with starting switch OFF, then carry out troubleshooting
Defective CAN end point without turning starting switch.
5
resistance CN-119 (female) Resistance
Between (A) and (B) 100 – 140 z
6 resistance
CN-S04 (male) Resistance
(Internal of monitor)
Between (3) and (6) 100 – 140 z
If causes 1 – 6 are not detected, monitor panel or HST controller
Defective monitor panel or
7 may be defective.
HST controller
D31/37-22 40-330 9
40-330 10 D31/37-22
Failure code [DAFRMC] CAN communication (Monitor panel – ENGINE controller): Defective
Failure code [DAFRMC] CAN communication (Monitor panel – ENGINE

controller): Defective communication (Abnormality in objective
component system) 1
Action code Failure code CAN communication (Monitor panel – ENGINE controller):
Trouble Defective communication (Abnormality in objective component system)
E03 DAFRMC (Monitor panel system)
Contents of
• The monitor panel cannot recognize the ENGINE controller in the CAN communication circuit.
trouble
Action of
• Limits the functions partly.
controller
Problem that
• Once the machine is stopped, its engine speed is limited to medium (half) speed.
appears on
machine
• Method of reproducing failure code: Starting switch ON.
• Indicate failure code [DAFRKR], when the monitor panel cannot recognize the HST controller.
Related
• Indicate failure code [DB2RKR], when HST controller cannot recognize the engine controller.
information
• Indicate failure code [DAJRKR], when HST controller cannot recognize the monitor panel.
• Indicate failure code [CA1633], when engine controller cannot recognize the HST controller.

1
Between (3) – (10) 50 – 70 z
Wiring harness between CN-S04 (female)
Disconnection in wiring (1), (6) – CN-CE02 (female) (1), – CN-ST2
Resistance Max. 1 z
2
Resistance Max. 1 z
(1), (6) – CN-CE02 (female) (1), – CN-ST2
Grounding fault in wiring (female) (32), – CN-G01 (female) (8), – CN- Resistance Min. 1 Mz
harness 119 (female) (A), CN-DT12 (male) (3) and
3
(Short circuit with ground cir- chassis ground
cuit) Wiring harness between CN-S04 (female)
(3) – CN-CE02 (female) (21), – CN-ST2
chassis ground
D31/37-22 40-330 11

(1), (6) – CN-CE02 (female) (1), – CN-ST2
Short circuit with power (female) (32), – CN-G01 (female) (8), – CN- Voltage Max. 1 V
supply line circuit in wiring 119 (female) (A), CN-DT12 (male) (3) and
4
harness chassis ground
(3) – CN-CE02 (female) (21), – CN-ST2
value in normal
5
6 resistance
Between (3) and (6) 100 – 140 z
If causes 1 – 6 are not detected, monitor panel or engine controller
7 may be defective.
engine controller
40-330 12 D31/37-22
D31/37-22 40-330 13
SEN04509-00 Failure code [DAJ000] HST controller: Memory error
Failure code [DAJ000] HST controller: Memory error 1
Action code Failure code HST controller: Memory error

Trouble
– DAJ000 (HST controller system)
Contents of
• The information in the HST controller ROM (non-volatile memory) is abnormal.
trouble
Action of
• Use normal data only in the main area and in the backup area.
controller
Problem that
appears on
machine
Related
information

Possible causes Since trouble is in system, troubleshooting cannot be carried out. (If
and standard 1 Defective HST controller no visible error appears on the machine, the controller can be con-
value in normal tinuously used as it is.)
state Disconnection or grounding The HST controller source power (VB) might have dropped when
2
fault in wiring harness writing to memory. Carry out troubleshooting for [DAJ0KK].
40-330 14 D31/37-22
Failure code [DAJ000] HST controller: Memory error SEN04509-00
D31/37-22 40-330 15
SEN04509-00 Failure code [DAJ0KK] HST controller: Lowing of source voltage
Failure code [DAJ0KK] HST controller: Lowing of source voltage 1
Action code Failure code HST controller: Lowing of source voltage

Trouble
E04 DAJ0KK (HST controller system)
Contents of
• HST controller source voltage goes to 18 V or lower.
trouble
Action of
• Limits the function partly.
controller
• If cause of the error disappears, the system resets itself.
Problem that • Once the machine is stopped, it cannot be restarted.
appears on • Monitor panel may not display data normally.
machine • The relays and solenoids may become inoperable, disabling the normal operation of the system.
• Power supply state of the HST controller can be checked with the monitoring code.
Related
(Controller: HST, Code: 03207 PWR IN BATT, Code: 03202 PWR IN BRY)
information
• Method of reproducing failure code: Turn the starting switch ON.

1 Battery voltage drop Battery voltage 20 – 30 V
If the fuse is burn, the circuit probably has a grounding fault, etc.
2 Defective fuse (F01-5 or 15)
(See cause 4.)
Wiring harness between CN-ST3 (female)
Resistance Max. 1 z
(1), (11) – F01 (15) outlet
Disconnection in wiring
harness Wiring harness between CN-ST3 (female)
(Disconnection or defective (2), (12), (22) – F01 (5) outlet
contact in connector) Wiring harness between F01 (15E) – CN-T7 Resistance Max. 1 z
Wiring harness between F01 (5B) – CN-T8 Resistance Max. 1 z
Resistance Max. 1 z
(21), (31), (32), (33) – chassis ground
Possible causes
value in normal without turning starting switch.
state Wiring harness between CN-ST3 (female)
(1), (11) – F01 (15) outlet and chassis Resistance Min. 1 Mz
Grounding fault in wiring ground
4
(Short circuit with ground (2), (12), (22) – F01 (5) outlet and chassis Resistance Min. 1 Mz
circuit) ground
Wiring harness between F01 (15E) – CN-T7
and chassis ground
Wiring harness between F01 (5B) – CN-T8
and chassis ground
5 Defective HST controller ST3 Voltage
Between (1), (11), (2), (12), (22)
20 – 30 V
and (21), (31), (32), (33)
40-330 16 D31/37-22
Failure code [DAJ0KK] HST controller: Lowing of source voltage SEN04509-00
D31/37-22 40-330 17
SEN04509-00 Failure code [DAJ0KQ] HST controller: Machine code error
Failure code [DAJ0KQ] HST controller: Machine code error 1
Action code Failure code HST controller: Machine code error

Trouble
E03 DAJ0KQ (HST controller system)
• There is a disagreement between the selected machine model being saved on the HST controller
Contents of
and that on the machine.
trouble
• Do not select machine select mode.
Action of
• Limits the function partly.
controller
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that • The system may not work properly.
appears on • Once the machine is stopped, its engine speed is limited to medium (half) speed.
• Machine model codes being recognized by the controller can be checked with the monitoring mode.
Related
(Controller: HST, Code: 00204 MACHINE CODE)
information
(Controller: MONITOR PANEL, Code: 00205 MACHINE CODE)
Possible causes • Confirm and record the machine model that the monitor panel
and standard and the HST controller recognize in the real monitoring mode.
value in normal Defective machine model • Make appropriate setting for the machine model in the machine
1
state selection model selection mode.
• When setting for different machine model from the one that the
HST controller recognizes was made, carry out all initial setting.
40-330 18 D31/37-22
Failure code [DAJ0KT] HST controller: Memory error SEN04509-00
Failure code [DAJ0KT] HST controller: Memory error 1
Action code Failure code HST controller: Memory error

Trouble
E03 DAJ0KT (HST controller system)
Contents of • The information in the HST controller PROM (non-volatile memory) is abnormal.
trouble (Both the main area memory and backup area memory are abnormal)
Action of • Limits the functions partly.
controller • Clear all the memory and use default values.
Problem that
appears on
machine
• The setting of machine model is also cleared, and [DAJ0KQ] appears.
Related
information

Since trouble is in system, troubleshooting cannot be carried out.
Possible causes
(If no visible error appears on the machine after the machine model
and standard 1 Defective HST controller
is reset and the initial adjustment is made again, the controller can
value in normal
be continuously used as it is.)
state
Disconnection or grounding The HST controller source power (VB) might have dropped when
2
fault in wiring harness writing to memory. Carry out troubleshooting for [DAJ0KK].
D31/37-22 40-330 19
SEN04509-00 Failure code [DAJ5KK] HST controller sensor 5 V power supply No.1: Lowing of source voltage/Input
Failure code [DAJ5KK] HST controller sensor 5 V power supply No.1:

Lowing of source voltage/Input 1
Action code Failure code HST controller sensor 5 V power supply No.1: Lowing of source
Trouble voltage/Input
Contents of • Voltage of 5 V power output No.1 circuit of the HST controller went to 4.5 V or lower or 5.5 V or higher.
trouble • Abnormal current flowed in HST controller sensor 5 V power supply No. 1
Action of • Stops output of 5 V power (No.1) circuit.
controller • Limits the functions partly
Problem that
• Once the machine is stopped, it cannot be restarted.
appears on
machine
• If this failure occurs, individual failure codes of the target components of power supply such as the
Related
pressure sensor and potentiometer are displayed and recorded at the same time.
information

Defective travel potentiometer a Disconnect connector with starting switch OFF, then turn starting
switch ON and carry out troubleshooting.
Defective fuel dial potentiometer Travel potentiometer CN-EL connector
Defective brake potentiometer When sequentially Fuel dial potentiometer CN-FP connector
disconnect the devices Brake potentiometer CN-BPI connector
1 Defective left HST pump suggested on the right
and if failure code is Left HST pump
pressure sensor CN-LP connector
not lit and displayed pressure sensor
Defective right HST (reset display), internal Right HST pump
component may be CN-RP connector
pump pressure sensor pressure sensor
defective.
Brake pressure sensor CN-BS connector
Defective brake pressure sensor
Grounding fault in wiring
Possible causes harness Wiring harness between CN-ST2 (female)
2
and standard (Short circuit with ground cir- (22) – CN-EL (female) (4), (5), – CN-BP
value in normal cuit) (female) (3), – CN-RP (female) (3), – CN-LP Resistance Min. 1 Mz
state (female) (3), – CN-BP1 (female) (C), CN-FP
(female) (A) and chassis ground
(22) – CN-EL (female) (4), (5), – CN-BP
Short circuit with power supply
(female) (3), – CN-RP (female) (3), – CN-LP Voltage Max. 1 V
(female) (3), – CN-BP1 (female) (C), CN-FP
(Contact with 24 V)
If the wiring harness is short circuit with power supply line circuit in wir-
ing harness circuited, the controller and each sensor may be defective,
too. Check them after repairing wiring harness.
4 Defective HST controller
CN-ST1 (female) Voltage
Between (22) and (21) 4.5 – 5.5 V
40-330 20 D31/37-22
Failure code [DAJ5KK] HST controller sensor 5 V power supply No.1: Lowing of source voltage/Input SEN04509-00
D31/37-22 40-330 21
SEN04509-00 Failure code [DAJ6KK] HST controller sensor 5 V power supply No.2: Lowing of source voltage/Input
Failure code [DAJ6KK] HST controller sensor 5 V power supply No.2:

Lowing of source voltage/Input 1
Action code Failure code HST controller sensor 5 V power supply No.2: Lowing of source
Trouble voltage/Input
Contents of • Voltage of 5 V power output No.2 circuit of the HST controller went to 4.5 V or lower or 5.5 V or higher.
trouble • Abnormal current flowed in HST controller sensor 5 V power supply No. 2
• Stops output of 5 V power No.2 circuit.
Action of
• Stops use of the HST motor speed sensor.
controller
• If this error occurs, individual failure codes of the target devices of power supply such as the HST
Related
motor speed sensor are displayed and recorded at the same time.
information

When sequentially
Defective left HST motor disconnect the Left HST
speed sensor devices suggested on motor speed sensor CN-LRS2 connector
1 the right and if failure
Defective right HST motor code is not lit and dis-
speed sensor played (reset dis-
play), internal Right HST
CN-RRS2 connector
component may be motor speed sensor
defective.
Grounding fault in wiring without turning starting switch.
Possible causes
harness
and standard 2
(Short circuit with ground cir- Wiring harness between CN-ST3 (female)
value in normal (34) – CN-LRS2 (female) (A), – CN-RRS2 Resistance Min. 1 Mz
cuit)
state (female) (A) and chassis ground
(34) – CN-LRS2 (female) (A), – CN-RRS2 Voltage Max. 1 V
(Contact with 24 V)
If the wiring harness is short circuit with power supply line circuit wiring
harness circuited, the controller and each HST motor revolution sensor
may be defective, too. Check them after repairing wiring harness.
CN-ST3 Voltage
Between (34) and (39) 4.5 – 5.5 V
40-330 22 D31/37-22
Failure code [DAJ6KK] HST controller sensor 5 V power supply No.2: Lowing of source voltage/Input SEN04509-00
D31/37-22 40-330 23
Failure code [DAJRKR] CAN communication (HST controller – Monitor panel): Defective
Failure code [DAJRKR] CAN communication (HST controller – Monitor

panel): Defective communication (Abnormality in objective component
system) 1
Action code Failure code CAN communication (HST controller – Monitor panel):
E03 DAJRKR (HST controller system)
Contents of • The HST controller detected a communication error, but communication with the monitor panel is not
trouble available.
Action of
controller
Problem that
appears on
machine
• Though the HST controller outputs this code, the CAN communication is defective between the HST
controllers and this code is neither displayed on the monitor nor recorded.
KOMTRAX outputs it depending on the failed portion.
Related
• [DAFRKR] is output when the monitor panel cannot recognize the HST controller.
information
• [DAFRMC] is output when the monitor panel cannot recognize the engine controller.
• [DB2RKR] is output when the HST controller cannot recognize the engine controller.
• [CA1633] is output when the engine controller cannot recognize the HST controller

1
Between (3) and (10) 50 – 70 z
Disconnection in wiring (1), (6) – CN-CE02 (female) (1), – CN-ST2
Resistance Max. 1 z
2
Resistance Max. 1 z
Grounding fault in wiring CN-ST2 (female) (32), – CN-G01 (female) Resistance Min. 1 Mz
harness (8), – CN-119 (female) (A), CN-DT12 (male)
3
(Short circuit with ground (3) and chassis ground
(3) – CN-CE02 (female) (21), – CN-ST2
chassis ground
40-330 24 D31/37-22

a Prepare with starting switch OFF, then turning starting switch ON
(1), (6) – CN-CE02 (female) (1), – CN-ST2
4
(3) – CN-CE02 (female) (21), – CN-ST2
value in normal
5
Defective CAN and point without turning starting switch.
6 resistance
Between (3) and (6) 100 – 140 z
7 may be defective.
HST controller
D31/37-22 40-330 25
40-330 26 D31/37-22
Failure code [DB2RKR] CAN communication (HST controller – Engine controller): Defective
Failure code [DB2RKR] CAN communication (HST controller – Engine

controller): Defective communication (Abnormality in objective
component system) 1
Action code Failure code CAN communication (HST controller – Engine controller):
E03 DB2RKR (HST controller system)
Contents of
• Abnormality was detected in the communication between the HST controller and engine controller.
trouble
Action of
controller
appears on • Engine speed is limited to medium (half) speed by modulated rate.
Method of reproducing failure code: Turn the starting switch ON
[DAFRKR] is output when the monitor panel cannot recognize the HST controller.
Related
[DAFRMC] is output when the monitor panel cannot recognize the engine controller.
information
[DAJRKR] is output when the HST controller cannot recognize the monitor panel.
[CA1633] is output when the engine controller cannot recognize the HST controller.

1
harness CN-PT12 (male) Resistance
Between (3) and (10) 50 – 70 z
Wiring harness between CN-S04 (female) (1),
Disconnection in wiring (6) – CN-CE02 (female) (1), – CN-ST2 (female)
Resistance Max. 1 z
harness (32), – CN-G01 (female) (8), – CN-119 (female)
2
(Disconnection or defective (A), CN-DT12 (male) (3)
Possible causes contact in connector) Wiring harness between CN-S04 (female) (3) –
and standard CN-CE02 (female) (21), – CN-ST2 (female)
Resistance Max. 1 z
value in normal (22), – CN-G01 (female) (7), – CN-119 (female)
state (B), CN-DT12 (male) (10)
(1), (6) – CN-CE02 (female) (1), – CN-ST2
Grounding fault in wiring (female) (32), – CN-G01 (female) (8), – CN- Resistance Min. 1 Mz
harness 119 (female) (A), CN-DT12 (male) (3) and
3
(Short circuit with ground chassis ground
(3) – CN-CE02 (female) (21), – CN-ST2
chassis ground
D31/37-22 40-330 27

(1), (6) – CN-CE02 (female) (1), – CN-ST2
4
(3) – CN-CE02 (female) (21), – CN-ST2
value in normal
5
6 resistance
Between (3) and (6) 100 – 140 z
4 may be defective.
HST controller
40-330 28 D31/37-22
D31/37-22 40-330 29
SEN04509-00 Failure code [DD12KA] Shift up switch: Disconnection
Failure code [DD12KA] Shift up switch: Disconnection 1
Action code Failure code Shift up switch: Disconnection

Trouble
E02 DD12KA (HST controller system)
Contents of
• 2 systems in the shift up switch circuit were turned off (set to OPEN) at the same time.
trouble
Action of
• Recognizes that the shift up switch is not pressed.
controller
• Resets itself 3 seconds after if the detection conditions are unsuitable.
Problem that
appears on • Pressing the button does not operate the shift up.
machine
• Among the signals of 2 systems of the switch circuit, NO is used to detect the operation and NC is
used to detect errors.
Related
• Input state (ON/OFF) from the shift up switch can be checked with the monitoring function.
information
(Controller: HST, Code: 40910 D-IN [0]: NO, [6]: NC)
• Method of reproducing failure code: Turning on the starting switch and operating the shift up switch

Defective shift up switch Shift up switch

1 CN-38 (Male)
(Internal disconnection) OFF (Release) ON (Press)
Between (2) and (3) Max. 1 z Min. 1 Mz
Between (2) and (1) Min. 1 Mz Max. 1 z
Disconnection in wiring Wiring harness between CN-ST1 (female)
Resistance Max. 1 z
harness (12) – CN-38 (female) (3)
2
(Disconnection or defective Wiring harness between CN-ST1 (female)
contact of connector) Resistance Max. 1 z
(23) – CN-38 (female) (1)
Possible causes
and standard Resistance Max. 1 z
value in normal (4) – CN-38 (female) (2)
state a Prepare with starting switch OFF, then turn starting switch ON
(12) – CN-38 (female) (3) and chassis Voltage Max. 1 V
ground
(Contact with 24 V)
ground
Shift up switch
4 Defective HST controller CN-ST1
OFF (Release) ON (Press)
Between (12) and (4) Max. 1 V 5 –11 V
Between (23) and (4) 5 – 11 V Max. 1 V
40-330 30 D31/37-22
Failure code [DD12KA] Shift up switch: Disconnection SEN04509-00
D31/37-22 40-330 31
SEN04509-00 Failure code [DD12KB] Shift up switch: Short circuit
Failure code [DD12KB] Shift up switch: Short circuit 1
Action code Failure code Shift up switch: Short circuit

Trouble
E02 DD12KB (HST controller system)
Contents of
• 2 systems in the shift up switch circuit were turned ON (set to CLOSE) at the same time.
trouble
Action of
• Recognizes that the shift up switch is not pressed.
controller
Problem that
appears on • Pressing the button does not operate the shift up.
machine
Related
• Input state (ON/OFF) from the shift up switch can be checked with the monitoring function.
information
(Controller: HST, Code: 40910 D-IN [0]: NO, [6]: NC)
• Method of reproducing failure code: Turning on the starting switch and operating the shift up switch

Defective shift up switch Shift up switch

1 CN-38 (Male)
(Internal short) OFF (Release) ON (Press)
Possible causes
and standard Grounding fault in wiring Wiring harness between CN-ST1 (female)
value in normal harness (12) – CN-38 (female) (3) and chassis Resistance Min. 1 Mz
2
state (Short circuit with ground ground
circuit) Wiring harness between CN-ST1 (female)
(23) – CN-38 (female) (1) and chassis Resistance Min. 1 Mz
ground
Shift up switch
Between (12) and (4) Max. 1 V 5 –11 V
40-330 32 D31/37-22
Failure code [DD12KB] Shift up switch: Short circuit SEN04509-00
D31/37-22 40-330 33
SEN04509-00 Failure code [DD13KA] Shift down switch: Disconnection
Failure code [DD13KA] Shift down switch: Disconnection 1
Action code Failure code Shift down switch: disconnection

Trouble
E02 DD13KA (HST controller system)
Contents of
• 2 systems in the shift down switch circuit were turned OFF (set to OPEN) at the same time.
trouble
controller • Recognizes that the shift up switch is not pressed.
Problem that
appears on • Pressing the button does not operate the shift down.
machine
Related • Input state (ON/OFF) from the shift down switch can be checked with the monitoring function.
information (Controller: HST, code: 40910 D-IN [4]: NC, [5]: NO)
• Method of reproducing failure code: Turning on the starting switch and operating the shift down
switch.

Defective shift down switch Shift down switch

1 CN-39 (female)
(Internal disconnection) OFF (Release) ON (Press)
Resistance Max. 1 z
harness (24) – CN-39 (male) (3)
2
Possible causes contact of connector) Resistance Max. 1 z
(18) – CN-39 (male) (1)
and standard
value in normal Resistance Max. 1 z
state (4) – CN-39 (male) (2)
3 line circuit wiring harness Voltage Max. 1 V
(24) – CN-39 (male) (3) and chassis ground
(Contact with 24 V)
Voltage Max. 1 V
Shift down switch
Between (24) and (4) Max. 1 V 5 – 11 V
40-330 34 D31/37-22
Failure code [DD13KA] Shift down switch: Disconnection SEN04509-00
D31/37-22 40-330 35
SEN04509-00 Failure code [DD13KB] Shift down switch: Short circuit
Failure code [DD13KB] Shift down switch: Short circuit 1
Action code Failure code Shift down switch: Short circuit

Trouble
Contents of
• 2 systems in the shift down switch circuit were turned ON (set to CLOSE) at the same time.
trouble
Action of
• Recognizes that the shift down switch is not pressed.
controller
Problem that
appears on • Pressing the button does not operate the shift down.
machine
Related • Input state (ON/OFF) from the shift down switch can be checked with the monitoring function.
information (Controller: HST, Code: 40910 D-IN [4]: NC, [5]: NO)
• Method of reproducing failure code: Turning on the starting switch and operating the shift down
switch

Defective shift down switch Shift down switch

1 CN-39 (female)
(Internal short) OFF (Release) ON (Press)
Possible causes without turning starting switch.
and standard Grounding fault in wiring
value in normal harness Wiring harness between CN-ST1 (female)
2 Resistance Min. 1 Mz
state (Short circuit with ground (24) – CN-39 (male) (3) and chassis ground
Shift down switch
Between (24) and (4) Max. 1 V 5 – 11 V
40-330 36 D31/37-22
Failure code [DD13KB] Shift down switch: Short circuit SEN04509-00
D31/37-22 40-330 37
SEN04509-00 Failure code [DD14KB] Travel lock limit switch 1: Short circuit
Failure code [DD14KB] Travel lock limit switch 1: Short circuit 1
Action code Failure code Travel lock limit switch 1: Short circuit
Trouble
Contents of
• 2 systems in the travel lock limit switch 1 circuit were turned ON (set to CLOSE) at the same time.
trouble
Action of • Recognizes that the travel lock lever is set to the Free position.
controller • Limits its functions partly.
Problem that • Once the machine is stopped, its engine speed is limited to medium (half) speed.
appears on • Once the machine is stopped and started again, its travel speed is limited to 50%.
machine • The engine does not start.
Related
• Input state (ON/OFF) from the travel lock limit switch 1 can be checked with the monitoring mode.
information
(Controller: HST, code: 40912 D-IN [18]: NO, [19]: NC)
• Method of reproducing failure code: Turn the starting switch ON and operate travel lock lever.

Defective travel lock limit Parking brake lever
1 switch 1 CN-26 (Male)
Free (Top) Lock (Bottom)
(Internal short circuit)
Between (A) and (B) Max. 1 z Min. 1 Mz
Between (A) and (C) Min. 1 Mz Max. 1 z
Possible causes
and standard harness Wiring harness between CN-ST2 (female)
2 Resistance Min. 1 Mz
value in normal (Short circuit with ground (5) – CN-26 (female) (B) and chassis ground
state circuit) Wiring harness between CN-ST2 (female)
(15) – CN-26 (female) (C) and chassis ground
Parking brake lever
CN-ST1 and CN-ST2
Free (Top) Locked (Bottom)
Between CN-ST2 (5)
Max. 1 V 5 – 11 V
and CN-ST1 (10)
Between CN-ST2
5 – 11 V Max. 1 V
(15) and CN-ST1 (10)
40-330 38 D31/37-22
Failure code [DD14KB] Travel lock limit switch 1: Short circuit SEN04509-00
D31/37-22 40-330 39
SEN04509-00 Failure code [DD1NL4] Fan rotation selector switch: Disagreement of ON, OFF Signals
Failure code [DD1NL4] Fan rotation selector switch: Disagreement of

ON, OFF Signals 1
Action code Failure code Fan rotation selector switch: Disagreement of ON / OFF Signals
Trouble
E01 DD1NL4 (HST controller system)
Contents of
• 2 systems in fan rotation selector switch circuit were turned ON (set to CLOSE) at the same time.
trouble
Action of • Recognizes that the fan rotation selector switch is not pressed.
Problem that
appears on • Fan rotation does not change, even if the fan rotation selector switch is pressed.
machine
Related • Input state (ON/OFF) from the fan rotation selector switch can be checked with the monitoring mode.
information (Controller: HST, code: 40913 D-IN [26]: Reverse rotation (Right side), [27]: Normal rotation (Left side))

Fan rotation
CN-FAN (male) Resistance
selector switch
Center, reverse
Defective fan rotation Min. 1 Mz
rotation (Right)
1 selector switch Between (4) and (5)
Normal rotation
(Internal short circuit) Max. 1 z
(Left)
Center, normal
Min. 1 Mz
rotation (Left)
Between (5) and (6)
Reverse
Max. 1 z
rotation (Right)
Possible causes
and standard Grounding fault in wiring Wiring harness between CN-ST2 (female)
value in normal harness (7) – CN-FAN (female) (4) and chassis Resistance Min. 1 Mz
2
state (Short circuit with ground ground
(17) – CN-FAN (female) (6) and chassis Resistance Min. 1 Mz
ground
Fan rotation
CN-ST1 and ST2 Voltage
selector switch
Center reverse
5 – 11 V
Between CN-ST2 (7) rotation (right)
and CN-ST1 (10) Normal rotation
Max. 1 V
(Left)
Center normal
5 – 11 V
Between CN-ST2 rotation (Left)
(17) and CN-ST1 (10) Reverse rotation
Max. 1 V
(Right side)
40-330 40 D31/37-22
Failure code [DD1NL4] Fan rotation selector switch: Disagreement of ON, OFF Signals SEN04509-00
D31/37-22 40-330 41
SEN04509-00 Failure code [DDDCKB] Reverse travel speed switch: Short circuit
Failure code [DDDCKB] Reverse travel speed switch: Short circuit 1
Action code Failure code Reverse travel speed switch: short circuit
Trouble
E01 DDDCKB (HST controller system)
Contents of
• 2 systems in the reverse speed switch circuit were turned ON (set to CLOSE) at the same time.
trouble
Action of • Recognizes that the reverse travel speed switch is not pressed.
Problem that
• Problem that appears on machine
appears on
• Setting for reverse travel speed does not change, even if the reverse travel speed switch is pressed.
machine
• Input state (ON/OFF) from the reverse travel speed switch can be checked with the monitoring mode.
Related (Controller: HST, code: 40912 D-IN [16] deceleration (Left hand), [17]: acceleration (Right hand))
information • Method of reproducing failure code: Turn the starting switch ON and operate the reverse travel
speed switch

Reverse travel
CN-REV (male) Resistance
speed switch
Defective reverse speed Center, acceleration
Min. 1 Mz
1 setup switch (Right)
Between (4) and (5)
(Internal short circuit) Deceleration
Max. 1 z
(Left)
Center, deceleration
Min. 1 Mz
Between (5) and (6) (Left)
Acceleration (Right) Max. 1 z
Possible causes Wiring harness between CN-ST2 (female)
and standard Grounding fault in wiring har-
(35) – CN-REV (female) (4) and chassis Resistance Min. 1 Mz
value in normal 2 ness (Short circuit with
ground
state ground circuit)
(25) – CN-REV (female) (6) and chassis Resistance Min. 1 Mz
ground
Reverse travel
CN-ST1 and ST2 Voltage
speed switch
Center, acceleration
5 – 11 V
Between CN-ST2 (Right)
(35) and CN-ST1 (10) Deceleration
Max. 1 V
(Left)
Center, deceleration
5 – 11 V
Between CN-ST2 (left hand)
(25) and CN-ST1 (10) Acceleration
Max. 1 V
(Right)
40-330 42 D31/37-22
Failure code [DDDCKB] Reverse travel speed switch: Short circuit SEN04509-00
D31/37-22 40-330 43
SEN04509-00 Failure code [DDP6KA] Brake oil pressure sensor: Disconnection
Failure code [DDP6KA] Brake oil pressure sensor: Disconnection 1
Action code Failure code Brake oil pressure sensor: Disconnection

Trouble
E02 DDP6KA (HST controller system)
Contents of
• Input signal voltage from the brake oil pressure sensor dropped under 0.3 V.
trouble
Action of
• Recognizes the brake pressure as 2 MPa {20 kg/cm2} when the machine stopped.
controller
Problem that
appears on • Even when the brake oil pressure lowers, the charge pressure caution lamp does not light up.
machine
• If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken.
Related • Input state from the brake oil pressure sensor (brake oil pressure and brake sensor voltage) can be
information checked with the monitoring mode.
(Controller: HST, code: 91902 BRAKE PRESS, Code: 91903 BRAKE PRESS)

Defective sensor power sup- If failure code [DAJ5KK] is also displayed, carry out troubleshooting
1
ply system for it first.
a Prepare with starting switch OFF, then turn starting switch ON or
CN-BS Voltage
Defective brake oil pressure
Between (3) and (1) Power supply 4.5 – 5.5 V
2 sensor
(Internal defect) Between (2) and (1) Signal 0.4 – 0.6 V
Voltage is measured with wiring harness connected. Accordingly, if
voltage is abnormal, check wiring harness and controller, too, for
another cause of trouble, and then judge.
Possible causes
harness (22) – CN-BS (female) (3)
value in normal 3
state (Disconnection or defective Wiring harness between CN-ST1 (female)
contact of connector) Resistance Max. 1 z
(21) – CN-BS (female) (1)
Resistance Max. 1 z
(8) – CN-BS (female) (2)
Grounding fault in wiring a Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch.
4
(Short circuit with ground Wiring harness between CN-ST1 (female)
circuit) Resistance Min. 1 Mz
(8) – CN-BS (female) (2) and chassis ground
CN-ST1 Voltage
Power
Between (22) and (21) 4.5 – 5.5 V
source
Between (8) and (21) Signal 0.4 – 0.6 V
40-330 44 D31/37-22
Failure code [DDP6KA] Brake oil pressure sensor: Disconnection SEN04509-00
D31/37-22 40-330 45
SEN04509-00 Failure code [DDP6KB] Brake oil pressure sensor: Short circuit
Failure code [DDP6KB] Brake oil pressure sensor: Short circuit 1
Action code Failure code Brake oil pressure sensor: Short circuit
Trouble
E02 DDP6KB (HST controller system)
Contents of
• Input signal voltage from the brake oil pressure sensor dropped under 4.42 V.
trouble
Action of
• Recognizes the brake pressure as 2 MPa {20 kg/cm2} when the machine stopped.
controller
Problem that
machine
• If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken.
Related • Input state from the brake oil pressure sensor (brake oil pressure and brake sensor voltage) can be
information checked with the monitoring mode.
(Controller: HST, code: 91902 BRAKE PRESS, Code: 91903 BRAKE PRESS)

Defective sensor power sup- If failure code [DAJ5KK] is also displayed, carry out troubleshooting
1
ply system for it first.
CN-BS Voltage
Brake oil pressure sensor Between (3) and (1) Power supply 4.5 – 5.5 V
2
(Internal defect) Between (2) and (1) Signal 0.4 – 0.6 V
Possible causes another cause of trouble, and then judge.
and standard
value in normal a Prepare with starting switch OFF, then turn starting switch ON
state
(Contact with 24 V) Wiring harness between CN-ST1 (female)
Voltage Max. 1 V
(8) – CN-BS (female) (2) and chassis ground
CN-ST1 Voltage
Power
Between (22) and (21) 4.5 – 5.5 V
supply
Brake pressure may be 4.9 MPa {50 kg/cm } or higher. Check
2
5 Hydraulic defect
charge pressure and brake pressure. (See “Testing and adjusting”.)
40-330 46 D31/37-22
Failure code [DDP6KB] Brake oil pressure sensor: Short circuit SEN04509-00
D31/37-22 40-330 47
SEN04509-00 Failure code [DDP6MA] Brake oil pressure sensor: Malfunction
Failure code [DDP6MA] Brake oil pressure sensor: Malfunction 1
Action code Failure code Brake oil pressure sensor: Malfunction

Trouble
E02 DDP6MA (HST controller system)
Contents of
• The Input signal voltage from the brake oil pressure sensor detected abnormal state (sensor failure).
trouble
Problem that
machine
• Input state from the brake pressure sensor (brake pressure and brake sensor voltage) can be
Related checked with the monitoring mode.
information (Controller: HST, code: 91902 BRAKE PRESS, Code: 91903 BRAKE PRESS)

Defective brake pressure CN-BP (male) Voltage

sensor Between (3) and (1) Power supply 4.5 – 5.5 V
1
(Internal disconnection or Between (2) and (1) Signal 0.4 – 0.6 V
Possible causes
short circuit)
and standard Voltage is measured with wiring harness connected. Accordingly, if
value in normal voltage is abnormal, check wiring harness and controller, too, for
state another cause of trouble, and then judge.
2 Defective HST controller CN-ST1 Voltage
Between (22) and (21) 4.5 – 5.5 V
Between (8) and (21) 0.4 – 0.6 V
40-330 48 D31/37-22
Failure code [DDP6MA] Brake oil pressure sensor: Malfunction SEN04509-00
D31/37-22 40-330 49
SEN04509-00 Failure code [DDQ2KA] Travel lock limit switch 1: Disconnection
Failure code [DDQ2KA] Travel lock limit switch 1: Disconnection 1
Action code Failure code Travel lock limit switch 1: Disconnection

Trouble
E03 DDQ2KA (HST controller system)
Contents of
• 2 systems in the travel lock limit switch 1 circuit were turned OFF (set to OPEN) at the same time.
trouble
• Flashes the centralized warning lamp and sounds the alarm buzzer.
Action of • Recognizes that the travel lock lever is set to the Free position.
controller • Limits the functions portly.
Problem that • Travel speed is reduced to 50% of the value being set from the button. Likewise, the throttle opening
appears on is reduced to 50% of the set value.
machine • The engine does not start.
Related • Input state (ON/OFF) from the travel lock limit switch 1 can be checked with the monitoring mode.
information (Controller: HST, code: 40912 D-IN [18]: NO, [19]: NC)
• Method of reproducing failure code:
Turn the starting switch ON and operate travel lock lever.

1 switch 1 CN-26 (male)
Free (Top) Locked (Bottom)
Installation of travel lock limit Installation of travel lock limit switch 1 may be defective.
2
switch 1 may be defective. Check them directly referencing the "Testing and adjusting".
Resistance Max. 1 z
harness (5) – CN-26 (female) (B)
3
Possible causes contact of connector) Resistance Max. 1 z
(15) – CN-26 (female) (C)
and standard
value in normal Wiring harness between CN-ST1 (female)
Resistance Max. 1 z
state (10) – CN-26 (female) (A)
(5) – CN-26 (female) (B) and chassis ground
(Contact with 24 V)
Voltage Max. 1 V
(15) – CN-26 (female) (C) and chassis ground
Parking brake lever
CN-ST1 and ST2
Between CN-ST2 (5)
Max. 1 V 5 – 11 V
and CN-ST1 (10)
Between CN-ST2
5 – 11 V Max. 1 V
(15) and CN-ST1 (10)
40-330 50 D31/37-22
Failure code [DDQ2KA] Travel lock limit switch 1: Disconnection SEN04509-00
D31/37-22 40-330 51
SEN04509-00 Failure code [DDT0L4] Shift mode switch: Disagreement of ON/ OFF Signals
Failure code [DDT0L4] Shift mode switch: Disagreement of ON/ OFF

Signals 1
Action code Failure code Shift mode switch: Disagreement of ON/ OFF Signals
Trouble
E01 DDT0L4 (HST controller system)
Contents of
• 2 systems in the shift mode switch circuit were turned ON (set to CLOSE) at the same time.
trouble
Action of • Recognizes that the shift mode switch is not pressed.
Problem that
appears on • Shift mode does not change, even if the shift mode switch is pressed.
machine
• Input state (ON/OFF) from the shift mode switch can be checked with the monitoring mode.
Related
(Controller: HST, code: 40913 D-IN [24]: Quick shift mode (right side), [25]: variable shift mode (Left side)
information
• Method of reproducing failure code: Turn the starting switch ON and operate shift mode switch.

CN-MTS (male) Shift mode switch Resistance
Center and quick
Min. 1 Mz
Defective shift mode switch shift (right side)
1 Between (4) and (5)
(Internal short circuit) Variable shift
Max. 1 z
(left side)
Center and Variable
Min. 1 Mz
Between (6) and (5) shift (left side)
Quick shift (right side) Max. 1 z
value in normal harness
2 (27) – CN-MTS (female) (4) and chassis Resistance Min. 1 Mz
state (Short circuit with ground
ground
circuit)
Wiring harness between ST2 (female) (37) –
CN-MTS (female) (6) and chassis ground
CN-ST2, ST1 Shift mode switch Voltage
Center and quick
5 – 11 V
Between CN-ST2 shift (right side)
(27) and CN-ST1 (10) Variable shift
Max. 1 V
(left side)
Center and variable
Between CN-ST2 5 – 11 V
shift (left side)
(37) and CN-ST2 (10)
Quick shift (right side) Max. 1 V
40-330 52 D31/37-22
Failure code [DDT0L4] Shift mode switch: Disagreement of ON/ OFF Signals SEN04509-00
D31/37-22 40-330 53
SEN04509-00 Failure code [DDU1FS] Travel lock limit switches 1 and 2: Fixing
Failure code [DDU1FS] Travel lock limit switches 1 and 2: Fixing 1
Action code Failure code Travel lock limit switches 1 and 2: Fixing
Trouble
E03 DDU1FS (HST controller system)
Contents of • Though the signal of travel lock limit switch 1 is set to LOCK, The output circuit to the brake solenoid
trouble valve is operating normally.
Action of
controller
Problem that
appears on
machine
• Input state (ON/OFF) from the travel lock limit switch 1 and 2 can be checked with the monitoring
mode.
Related
(Controller: HST, code: 40911 D-IN [12]: Switch 2 (NO), code: 40912 D-IN [18]: Switch 1 (NO), [19]:
information
Switch 1(nc))

1 switch 1 CN-26 (male)
(Internal defect)
Possible causes Between (A) and (C) Min. 1 Mz Max. 1 z
state
2 CN-26B (male)
switch 2 (Internal defect) Free (Top) Lock (Bottom)
Defective installation of
Installation of travel lock limit switches 1 and 2 may be defective.
3 travel lock limit switches 1
Check them directly referencing the "Testing and adjusting."
and 2
40-330 54 D31/37-22
Failure code [DDU1FS] Travel lock limit switches 1 and 2: Fixing SEN04509-00
D31/37-22 40-330 55
SEN04509-00 Failure code [DDU1KA] Travel lock limit switch 2: Disconnection
Failure code [DDU1KA] Travel lock limit switch 2: Disconnection 1
Action code Failure code Travel lock limit switch 2: Disconnection

Trouble
E03 DDU1KA (HST controller system)
• Though the signal of travel lock limit switch 1 is set to Lock position and no current flows to output cir-
Contents of
cuit of the slow brake solenoid valve, the signal of travel lock limit switch 2 (NO) was turned OFF (set
trouble
to OPEN).
Action of
• Limits its function partly.
controller
Problem that
appears on
machine
mode.
Related (Controller: HST, code: 40911 D-IN [12] switch 2 (NO), code: 40912 D-IN [18] switch 1 (NO), [19]
information switch 1 (NC))
• If [DW7EKA] is also output, carry out troubleshooting for it first.

1 switch 2 CN-26B (male)
(Internal failure)
Possible causes Between (A) and (C) Min. 1 Mz Max. 1 z
and standard
Defective installation of
value in normal Installation of travel lock limit switches 1 and 2 may be defective.
2 travel lock limit switches 1
state Check them directly referencing the Testing and adjusting.
and 2
Disconnection in wiring har- without turning starting switch.
ness Wiring harness between CN-ST3 (female)
(Disconnection or defective (9) – CN-26B (female) (C)
contact in connector) Wiring harness between CN-ST3 (female)
Resistance Max. 1 z
(37) – CN-26B (female) (A)
40-330 56 D31/37-22
Failure code [DDU1KA] Travel lock limit switch 2: Disconnection SEN04509-00
D31/37-22 40-330 57
SEN04509-00 Failure code [DDU1KY] Travel lock limit switch 2: Short circuit with power supply line
Failure code [DDU1KY] Travel lock limit switch 2: Short circuit with
power supply line 1
Action code Failure code Travel lock limit switch 2: Short circuit with power supply line
Trouble
E03 DDU1KY (HST controller system)
• Though the signal of travel lock limit switch 1 is set to Free position and the output circuit of the slow
Contents of
brake solenoid valve outputs normally, the signal of travel lock limit switch 2 (NO) was turned ON (set
trouble
to CLOSE).
• When the travel lock limit switch is set to the lock position, disconnection in the slow brake solenoid
Action of
may be detected.
controller
Problem that
appears on
machine
mode.
Related (Controller: HST, code: 40911 D-IN [12]: switch 2 (NO), code: 40912 D-IN [18]: switch 1 (NO), [19]:
information switch 1 (NC))
(FREE)

1 switch 2 CN-26B (male)
Possible causes Free (Top) Locked (Bottom)
(Internal failure)
and standard Between (A) and (B) Max. 1 z Min. 1 Mz
value in normal
state
2 line circuit wiring harness Wiring harness between CN-ST3 (female)
(Contact with 24 V) (9) – CN-26B (female) (C) and chassis Voltage Max. 1 V
ground
40-330 58 D31/37-22
Failure code [DDU1KY] Travel lock limit switch 2: Short circuit with power supply line SEN04509-00
D31/37-22 40-330 59
SEN04509-00 Failure code [DGS1KA] HST oil temperature sensor: Disconnection
Failure code [DGS1KA] HST oil temperature sensor: Disconnection 1
Action code Failure code HST oil temperature sensor: Disconnection

Trouble
E01 DGS1KA (HST controller system)
Contents of • The signal of HST oil temperature sensor remains unchanged at low temperature even when the
trouble engine coolant temperature rises.
Action of • Recognizes the HST oil temperature as 85 °C.
Problem that
• Monitor panel HST oil temperature is not displayed normally.
appears on
• The fan speed is set to over 70%.
machine
• Input state from the HST oil temperature sensor (HST oil temperature and HST oil temperature sen-
sor voltage) can be checked with the monitoring mode.
Related
(Controller: HST, code: 04401 HST TEMP, and Code: 04402 HST TEMP)
information
• Method of reproducing failure code: Keep the engine coolant temperature at 76°C or higher for 10
minutes.

Defective HST oil tempera- CN-12 (male) HST oil temperature Resistance
1 ture sensor
(Internal disconnection) Between (1) and (2) 3.5 – 90 kz
Between (1)(2) and 10 – 100°C
Min. 1 Mz
chassis ground
Possible causes (Disconnection or defective (9) – CN-12 (female) (1)
and standard contact of wiring harness) Wiring harness between CN-ST1 (female)
(21) – CN-12 (female) (2)
state
Short circuit with power supply Wiring harness between CN-ST1 (female)
Voltage Max. 1 V
3 line circuit wiring harness (9) – CN-12 (female) (1) and chassis ground
ground
CN-ST1 HST oil temperature Voltage
Between (9) and (21) 10 – 100°C 2.0 – 4.6 V
40-330 60 D31/37-22
Failure code [DGS1KA] HST oil temperature sensor: Disconnection SEN04509-00
D31/37-22 40-330 61
SEN04509-00 Failure code [DGS1KX] HST oil temperature sensor: Out of Input signal range
Failure code [DGS1KX] HST oil temperature sensor: Out of Input signal
range 1
Action code Failure code HST oil temperature sensor: Out of Input signal range
Trouble
E01 DGS1KX (HST controller system)
Contents of
• Input signal voltage from the HST oil temperature sensor dropped under 0.3 V.
trouble
Action of • Recognizes the HST oil temperature as 85°C.
Problem that
• Monitor panel HST oil temperature is not displayed normally.
appears on
• The fan speed is set to over 70%.
machine
• Input state from the HST oil temperature sensor (HST oil temperature in HST oil temperature sensor
Related voltage) can be checked with the monitoring mode.
information (Controller: HST, code: 04401HST TEMP, and Code: 04402 HST TEMP)

Defective HST oil CN-12 (male) HST oil temperature Resistance
1 temperature sensor (Internal
short circuit) Between (1) – (2) 3.5 – 90 kz
Between (1)(2) and 10 – 100°C
Possible causes Min. 1 Mz
chassis ground
and standard
state 2 harness (Contact with
ground circuit) Wiring harness between CN-ST1 (female)
(9) – CN-12 (female) (1) and chassis ground
CN-ST1 HST oil temperature Voltage
Between (9) – (21) 10 – 100°C 2.0 – 4.6 V.
Circuit diagram related to HST oil temperature sensor
40-330 62 D31/37-22
Failure code [DGS1KX] HST oil temperature sensor: Out of Input signal range SEN04509-00
D31/37-22 40-330 63
SEN04509-00
D31/37-22 Bulldozer
©2008 KOMATSU
All Rights Reserved
40-330 64
SEN04510-00
D31EX-22
D31PX-22
D37EX-22
D37PX-22
D31EX-22 60001 and up
D31PX-22 60001 and up
D37EX-22 60001 and up
D37PX-22 60001 and up

Failure code [DHH5KA] Left HST pump pressure sensor: Disconnection ...................................................... 4
Failure code [DHH5KB] Left HST pump pressure sensor: Short circuit.......................................................... 6
Failure code [DHH6KA] Right HST pump pressure sensor: Disconnection.................................................... 8
Failure code [DHH6KB] Right HST pump pressure sensor: Short circuit ..................................................... 10
Failure code [DK10KA] Fuel dial sensor: Disconnection .............................................................................. 12
Failure code [DK10KB] Fuel dial sensor: Short circuit .................................................................................. 14
Failure code [DK30KX] Steering angle sensor: Out of input signal range .................................................... 20
Failure code [DK30KZ] Steering angle sensor: Disconnection or short circuit.............................................. 21
Failure code [DK30L8] Steering angle sensor: Disagreement of analog signals .......................................... 22
Failure code [DK40KA] Brake pedal sensor: Disconnection ......................................................................... 28
Failure code [DK40KB] Brake pedal sensor: Short circuit ............................................................................ 30
Failure code [DK55KX] Directional potentiometer: Out of input signal range ............................................... 32
Failure code [DK55KZ] Directional potentiometer: Disconnection or short circuit ........................................ 33
Failure code [DK55L8] Directional potentiometer: Disagreement of analog signals ..................................... 34
Failure code [DK56KB] Directional potentiometer 1: Short circuit ................................................................ 38
D31/37-22 40-340 1
SEN04510-00

Failure code [DLM0KX] HST motor speed sensors: Out of input signal range ............................................. 44
Failure code [DLM1KA] Left HST motor speed sensor: Disconnection ........................................................ 46
Failure code [DLM1KB] Left HST motor speed sensor: Short circuit ............................................................ 48
Failure code [DLM1MA] Left HST motor speed sensor: Malfunction ............................................................ 50
Failure code [DLM2KA] Right HST motor speed sensor: Disconnection ...................................................... 52
Failure code [DLM2KB] Right HST motor speed sensor: Short circuit.......................................................... 54
Failure code [DLM2MA] Right HST motor speed sensor: Malfunction.......................................................... 56
Failure code [DLM3KA] Fan speed sensor: Disconnection........................................................................... 58
Failure code [DLM3KB] Fan speed sensor: Short circuit .............................................................................. 60
40-340 2 D31/37-22
SEN04510-00
D31/37-22 40-340 3
SEN04510-00 Failure code [DHH5KA] Left HST pump pressure sensor: Disconnection
Failure code [DHH5KA] Left HST pump pressure sensor: Disconnection1
Action code Failure code Left HST pump pressure sensor: Disconnection
Trouble
E02 DHH5KA (HST controller system)
Contents of
• Input signal voltage from the Left HST pump pressure dropped under 0.3 V.
trouble
• Until the machine stops, the controller maintains the control using the pressure signal being received
Action of immediately prior to the failure.
controller • Once the machine stops, the controller maintains the control assuming that the pump pressure is 9.8
MPa{100 kg/cm2}.
Problem that
appears on • The Left HST pump oil pressure may not be monitored in the monitoring mode.
machine
a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
Related • Input state from the Left HST pump pressure sensor (pressure and voltage) can be checked with the
information monitoring mode.
(Controller: HST, code: 52502 HST L PRESS and code: 52503 HST L PRESS)
• Method of reproducing failure code: Turn the starting switch ON or start the engine.

Defective sensor power If failure code [DAJ5KK] is displayed, carry out the troubleshooting
1
supply system first as stated.
CN-LP Voltage
Defective Left HST pump
2 pressure sensor (Internal
failure) Between (2) – (1) Signal 0.4 – 0.6 V
Possible causes another cause of trouble, and then judge.
state
Resistance Max. 1 z
harness (Disconnection in (22) – CN-LP (female) (3)
3
wiring or defective contact in Wiring harness between CN-ST1 (female)
connector) Resistance Max. 1 z
(21) – CN-LP (female) (1)
Resistance Max. 1 z
(14) – CN-LP (female) (2)
4 harness (Contact with Wiring harness between CN-ST1 (female)
ground circuit) (14) – CN-LP (female) (2) and chassis Resistance Min. 1 Mz
ground
40-340 4 D31/37-22
Failure code [DHH5KA] Left HST pump pressure sensor: Disconnection SEN04510-00

Possible causes and carry out troubleshooting.
and standard CN-ST1 Voltage
value in normal 5 Defective HST controller Between (22) and
state Power supply 4.5 – 5.5 V
(21)
Between (14) and
Signal 0.4 – 0.6 V
(21)
D31/37-22 40-340 5
SEN04510-00 Failure code [DHH5KB] Left HST pump pressure sensor: Short circuit
Failure code [DHH5KB] Left HST pump pressure sensor: Short circuit 1
Action code Failure code Left HST pump pressure sensor: Short circuit
Trouble
E02 DHH5KB (HST controller system)
Contents of
• Input signal voltage from the Left pump pressure is 4.42 V and above.
trouble
MPa{100kg/cm2}.
Problem that
appears on • The Left HST pump pressure may not be monitored in the monitoring mode.
machine
Related • Input state from the Left HST pump pressure sensor (pressure and voltage) can be checked with the
information monitoring mode.
(Controller: HST, code: 52502 HST L PRESS and code: 52503 HST L PRESS)

1
supply system for it first as stated.
CN-LP Voltage
Defective Left HST pump
failure) Between (2) and (1) Signal 0.4 – 0.6 V
Possible causes
and standard a Prepare with starting switch OFF, then turn starting switch ON
value in normal Short circuit with power supply and carry out troubleshooting.
state 3 line circuit wiring harness Wiring harness between CN-ST1 (female)
(Contact with 24 V) (14) – CN-LP (female) (2) and chassis Voltage Max. 1 V
ground
CN-ST1 Voltage
4 Defective HST controller Between (22) and
Power supply 4.5 – 5.5 V
(21)
Between (14) and
Signal 0.4 – 0.6 V
(21)
HST pump pressure may be 49 MPa {500 kg/cm2} or higher. Check
5 Hydraulic defect
HST main circuit pressure. (See “Testing and adjusting”.)
40-340 6 D31/37-22
Failure code [DHH5KB] Left HST pump pressure sensor: Short circuit SEN04510-00
D31/37-22 40-340 7
SEN04510-00 Failure code [DHH6KA] Right HST pump pressure sensor: Disconnection
Failure code [DHH6KA] Right HST pump pressure sensor:

Disconnection 1
Action code Failure code Right HST pump pressure sensor: Disconnection
Trouble
E02 DHH6KA (HST controller system)
Contents of
• Input signal voltage from the Right HST pump pressure sensor dropped under 0.3 V.
trouble
MPa{100kg/cm2}.
Problem that
appears on • The Right HST pump pressure may not be monitored in the monitoring mode.
machine
Related • Input state from the Right HST pump pressure sensor (pressure and voltage) can be checked with
information the monitoring mode.
(Controller: HST, code: 52500 HST R PRESS and code: 52501 HST R PRESS)

1
CN-RP Voltage
Defective Right HST pump
Possible causes Disconnection in wiring Wiring harness between CN-ST1 (female)
Resistance Max. 1 z
and standard harness (Disconnection in (22) – CN-RP (female) (3)
value in normal 3
state connector) Resistance Max. 1 z
(21) – CN-RP (female) (1)
Resistance Max. 1 z
(20) – CN-RP (female) (2)
4 harness (Contact with
(20) – CN-RP (male) (2) and chassis ground
CN-ST1 Voltage
(21)
Between (20) and
Signal 0.4 – 0.6 V
(21)
40-340 8 D31/37-22
Failure code [DHH6KA] Right HST pump pressure sensor: Disconnection SEN04510-00
D31/37-22 40-340 9
SEN04510-00 Failure code [DHH6KB] Right HST pump pressure sensor: Short circuit
Failure code [DHH6KB] Right HST pump pressure sensor: Short circuit 1
Action code Failure code Right HST pump pressure sensor: Short circuit
Trouble
E02 DHH6KB (HST controller system)
Contents of
• Input signal voltage from the Right HST pump pressure sensor is above 4.42 V.
trouble
MPa{100 kg/cm2}.
Problem that
appears on • The Right HST pump pressure may not be monitored in the monitoring mode.
machine
Related • Input state from the Right HST pump pressure sensor (pressure and voltage) can be checked with
information the monitoring mode.
(Controller: HST, code: 52500 HST R PRESS and code: 52501 HST R PRESS)

1
CN-RP Voltage
Defective Right HST pump
Possible causes
and standard a Prepare with starting switch OFF, then turn starting switch ON
value in normal Short circuit with power supply and carry out troubleshooting.
state 3 line circuit wiring harness Wiring harness between CN-ST1 (female)
(Contact with 24 V) (20) – CN-RP (female) (2) and chassis Voltage Max. 1 V
ground
CN-ST1 Voltage
(21)
Between (20) and
Signal 0.4 – 0.6 V
(21)
HST pump pressure may be 49 MPa {500 kg/cm2} or higher. Check
5 Hydraulic defect
HST main circuit pressure. (See “Testing and adjusting”.)
40-340 10 D31/37-22
Failure code [DHH6KB] Right HST pump pressure sensor: Short circuit SEN04510-00
D31/37-22 40-340 11
SEN04510-00 Failure code [DK10KA] Fuel dial sensor: Disconnection
Failure code [DK10KA] Fuel dial sensor: Disconnection 1
Action code Failure code Fuel dial sensor: Disconnection

Trouble
E03 DK10KA (HST controller system)
Contents of
• Input signal voltage from the fuel dial sensor dropped under 0.3 V.
trouble
• Until the machine stops, the controller maintains the control using the position signal being received
immediately prior to the failure.
Action of
• Once the machine is stopped, the controller maintains the control assuming that the fuel dial is half
controller
position.
Problem that • The fuel dial operation does not work.
• Input state (voltage and command of rotation) from the fuel dial sensor can be checked with the mon-
Related itoring mode.
information (Controller: HST, code: 03002 FUEL DIAL and code: 03003 FUEL DIAL)
• Method of reproducing failure code: Turn the starting switch ON and operate fuel control dial.

1
Defective installation of fuel Check if the fuel dial sensor (the black resin portion) is installed all
2
dial sensor the way in.
CN-FP (male) Resistance
Defective fuel dial
Between (A) and (C) 4.0 – 6.0 kz
3 sensor (Internal
failure) 0.5 – 4.5 kz
Between (B) and (A)
(Lo – Hi)
4.5 – 0.5 kz
Between (B) and (C)
(Lo – Hi)
Possible causes
and standard
value in normal
state harness (Disconnection in Wiring harness between CN-ST1 (female)
wiring or defective contact in (22) – CN-FP (female) (A)
connector) Wiring harness between CN-ST1 (female)
Resistance Max. 1 z
(2) – CN-FP (female) (B)
(2) – CN-FP (female) (B) and chassis ground
CN-ST1 Voltage
Between (22) and
(21)
40-340 12 D31/37-22
Failure code [DK10KA] Fuel dial sensor: Disconnection SEN04510-00
D31/37-22 40-340 13
SEN04510-00 Failure code [DK10KB] Fuel dial sensor: Short circuit
Failure code [DK10KB] Fuel dial sensor: Short circuit 1
Action code Failure code Fuel dial sensor: Short circuit

Trouble
E03 DK10KB (HST controller system)
Contents of
• Input signal voltage from the fuel dial sensor is above 4.5 V.
trouble
Action of
• Once the machine is stopped, the controller maintains the control assuming that the fuel dial is half
controller
position.
Problem that • The fuel dial operation does not work.
• Input state (voltage and command of rotation) from the fuel dial sensor can be checked with the mon-
Related itoring mode.
information (Controller: HST, code: 03002 FUEL DIAL and code: 03003 FUEL DIAL)
• Method of reproducing failure code: Turn the starting switch ON and operate fuel control dial.

1
Defective installation of fuel Check if the fuel dial sensor (the black resin portion) is installed all
2
dial sensor the way in.
CN-FP (male) Resistance
Defective fuel dial
Between (A) and (C) 4.0 – 6.0 kz
3 sensor (Internal
failure) 0.5 – 4.5 kz
Between (B) and (A)
(Lo – Hi)
4.5 – 0.5 kz
Possible causes Between (B) and (C)
(Lo – Hi)
and standard
state Disconnection in wiring har- without turning starting switch.
4
ness Wiring harness between CN-ST1 (female) Resis-
Max. 1 z
(21) – CN-FP (female) (C) tance
Voltage Max. 1 V
(2) – CN-FP (female) (B)
CN-ST1 Voltage
Between (22) and
(21)
40-340 14 D31/37-22
Failure code [DK10KB] Fuel dial sensor: Short circuit SEN04510-00
D31/37-22 40-340 15
SEN04510-00 Failure code [DK30KA] Steering angle sensor 1: Disconnection
Failure code [DK30KA] Steering angle sensor 1: Disconnection 1
Action code Failure code Steering angle sensor 1: Disconnection

Trouble
Contents of
• Input voltage from the steering angle sensor 1 is above 4.5 V.
trouble
Action of • Limits the functions partly and maintains the control using the signal from the steering angle sensor
controller 2.
Problem that
appears on
machine
• Input state (voltage) from the steering angle sensor 1 can be checked with the monitoring mode.
Related (Controller: HST, Code: 50300 S/T LEVER 1)
information • Method of reproducing failure code: Turn the starting switch ON and operate the PCCS lever (in the
steering direction)

1
Defective steering CN-EL (male) PCCS lever Resistance
2 angle sensor 1 (Internal
Between (5) and (8) 3.2 kz ± 20%
failure)
Between (7) and (5) Neutral 2.4 kz ± 20%
Between (7) and (8) 2.4 kz ± 20%
harness (Disconnection in Wiring harness between CN-ST1 (female)
Possible causes 3 Resistance Max. 1 z
and standard wiring or defective contact in (21) – CN-EL (female) (8)
value in normal connector) Wiring harness between CN-ST1 (female)
Resistance Max. 1 z
state (19) – CN-EL (female) (7)
(Contact with 24 V) (19) – CN-EL (female) (7) and chassis Voltage Max. 1 V
ground
CN-ST1 Voltage
(21)
Between (19) and
Signal 0.3 – 4.5 V
(21)
40-340 16 D31/37-22
Failure code [DK30KA] Steering angle sensor 1: Disconnection SEN04510-00
D31/37-22 40-340 17
SEN04510-00 Failure code [DK30KB] Steering angle sensor 1: Short circuit
Failure code [DK30KB] Steering angle sensor 1: Short circuit 1
Action code Failure code Steering angle sensor 1: Short circuit

Trouble
Contents of
• Input signal voltage from the steering angle sensor dropped under 0.3 V.
trouble
controller 2.
Problem that
appears on
machine
Related (Controller: HST, Code: 50300 S/T LEVER 1)
steering direction)

1
Between (5) and (8) 3.2 kz ± 20%
failure)
Between (7) and (8) 2.4 kz ± 20%
Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting
harness (Disconnection in without turning starting switch.
Possible causes 3
and standard wiring or defective contact in Wiring harness between CN-ST1 (female)
value in normal (22) – CN-EL (female) (5)
ground circuit) (19) – CN-EL (female) (7) and chassis Resistance Min. 1 Mz
ground
CN-ST1 Voltage
(21)
Between (19) and
Signal 0.3 – 4.5 V
(21)
40-340 18 D31/37-22
Failure code [DK30KB] Steering angle sensor 1: Short circuit SEN04510-00
D31/37-22 40-340 19
SEN04510-00 Failure code [DK30KX] Steering angle sensor: Out of input signal range
Failure code [DK30KX] Steering angle sensor: Out of input signal range1
Action code Failure code Steering angle sensor: Out of input signal range
Trouble
E04 DK30KX (HST controller system)
Contents of • In the systems 1 and 2 of the steering angle sensor, either of the failure codes [DK30KA] or
trouble [DK30KB], and [DK31KA] or [DK31KB] occurred at the same time.
• Limits its functions partly.
Action of
controller
Problem that
appears on
• Once the machine is stopped, it cannot be started again.
machine
• Input state (voltage) from the steering angle sensor 1 and 2 can be checked with the monitoring
mode.
Related
(Controller: HST, code: 50300 S/T LEVER 1 and Code: 50301 S/T LEVER 2)
information
• Method of reproducing failure code: Turn the starting switch ON and operate the PCCS lever (in the
steering direction)

and standard
value in normal Carry out the troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA] and [DK31KB].
state
40-340 20 D31/37-22
Failure code [DK30KZ] Steering angle sensor: Disconnection or short circuit SEN04510-00
Failure code [DK30KZ] Steering angle sensor: Disconnection or short

circuit 1
Action code Failure code Steering angle sensor: Disconnection or short circuit
Trouble
E04 DK30KZ (HST controller system)
• When the starting switch was turned ON, either of System 1 or System 2 of the steering angle sensor
was defective, but, later, a trouble occurred to the other that was normal at that time.
Contents of When the starting switch was turned ON, steering angle sensor 2 was only defective, but, later,
trouble [DK30KA] or [DK30KB] appeared.
Or, when the starting switch was turned ON, steering angle sensor 1 was only defective, but,
[DK31KA] or [DK31KB] appeared.
• Limits its functions partly.
Action of
controller
Problem that
appears on
machine
mode.
Related
information
steering direction)

and standard
value in normal Carry out the troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA] and [DK31KB].
state
D31/37-22 40-340 21
SEN04510-00 Failure code [DK30L8] Steering angle sensor: Disagreement of analog signals
Failure code [DK30L8] Steering angle sensor: Disagreement of analog

signals 1
Action code Failure code Steering angle sensor: Disagreement of analog signals
Trouble
E03 DK30L8 (HST controller system)
Contents of
• Total voltage of the systems 1 and 2 of the steering angle sensor is below 4.41 V or above 5.59 V.
trouble
controller • Maintains the control using the potentiometer that outputs normal signal.
Problem that
appears on
machine
mode.
Related
information
steering direction)

and standard
value in normal Carry out troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA] and [DK31KB].
state
40-340 22 D31/37-22
Failure code [DK30L8] Steering angle sensor: Disagreement of analog signals SEN04510-00
D31/37-22 40-340 23
SEN04510-00 Failure code [DK31KA] Steering angle sensor 2: Disconnection
Failure code [DK31KA] Steering angle sensor 2: Disconnection 1
Action code Failure code Steering angle sensor 2: Disconnection

Trouble
Contents of
• Input signal voltage from the steering angle sensor dropped under 0.3 V.
trouble
controller 1.
Problem that
appears on
machine
Related (Controller: HST, code: 50301 S/T LEVER 2)
steering direction)

1
Between (5) and (8) 3.2 kz ± 20%
failure)
Between (6) and (8) 2.4 kz ± 20%
Possible causes
value in normal wiring or defective contact in (22) – CN-EL (female) (5)
state connector) Wiring harness between CN-ST1 (female)
Resistance Max. 1 z
(7) – CN-EL (female) (8)
(7) – CN-EL (female) (6) and chassis ground
CN-ST1 Voltage
Between (22) and
(21)
40-340 24 D31/37-22
Failure code [DK31KA] Steering angle sensor 2: Disconnection SEN04510-00
D31/37-22 40-340 25
SEN04510-00 Failure code [DK31KB] Steering angle sensor 2: Short circuit
Failure code [DK31KB] Steering angle sensor 2: Short circuit 1
Action code Failure code Steering angle sensor 2: Short circuit

Trouble
Contents of
• Input signal voltage from the steering angle sensor 2 is above 4.5 V.
trouble
controller 1.
Problem that
appears on
machine
Related (Controller: HST, code: 50301 S/T LEVER 2)
steering direction)

1
Between (5) and (8) 3.2 kz ± 20%
failure) Neutral
Between (6) and (5) 2.4 kz ± 20%
Between (6) and (8) 2.4 kz ± 20%
Possible causes Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
ness (Disconnection in wiring without turning starting switch.
and standard 3
value in normal or defective contact in con- Wiring harness between CN-ST1 (female) Resis-
nector) Max. 1 z
state (21) – CN-EL (female) (8) tance
Voltage Max. 1 V
CN-ST1 Voltage
Between (22) and
(21)
40-340 26 D31/37-22
Failure code [DK31KB] Steering angle sensor 2: Short circuit SEN04510-00
D31/37-22 40-340 27
SEN04510-00 Failure code [DK40KA] Brake pedal sensor: Disconnection
Failure code [DK40KA] Brake pedal sensor: Disconnection 1
Action code Failure code Brake pedal sensor: Disconnection

Trouble
Contents of
• Input signal voltage from the brake pedal sensor dropped under 0.3 V.
trouble
controller • Once the machine stops, the controller maintains the control assuming that the brake pedal is at
stroke 0 position.
Problem that
appears on
machine
• Input state (stroke and voltage) from the brake pedal sensor can be checked with the monitoring
Related mode.
information (Controller: HST, code: 50400 BRAKE PEDAL and code: 50401 BRAKE PEDAL)
• Method of reproducing failure code: Turn the starting switch ON and operate the brake pedal

1
CN-BP1 (male) Resistance
Defective brake pedal sensor Between (B) and (C) 1.6 – 2.4 kz
2
(Internal failure) 0.2 – 1.8 kz
Between (A) and (B)
(Release – stroke end)
1.8 – 0.2 kz
Between (A) and (C)
Possible causes Disconnection in wiring without turning starting switch.
and standard harness (Disconnection in Wiring harness between CN-ST1 (female)
value in normal 3 Resistance Max. 1 z
wiring or defective contact in (22) – CN-BP1 (female) (C)
Resistance Max. 1 z
(3) – CN-BP1 (female) (A)
ground circuit) (3) – CN-BP1 (female) (A) and chassis Resistance Min. 1 Mz
ground
CN-ST1 Voltage
Between (22) and
(21)
40-340 28 D31/37-22
Failure code [DK40KA] Brake pedal sensor: Disconnection SEN04510-00
D31/37-22 40-340 29
SEN04510-00 Failure code [DK40KB] Brake pedal sensor: Short circuit
Failure code [DK40KB] Brake pedal sensor: Short circuit 1
Action code Failure code Brake pedal sensor: Short circuit

Trouble
Contents of
• Input signal voltage from the brake pedal sensor is above 4.5 V.
trouble
controller • Once the machine stops, the controller maintains the control assuming that the brake pedal is at
stroke 0 position.
Problem that
appears on
machine
• Input state (stroke and voltage) from the brake pedal sensor can be checked with the monitoring
Related mode.
information (Controller: HST, code: 50400 BRAKE PEDAL and code: 50401 BRAKE PEDAL)
• Method of reproducing failure code: Turn the starting switch ON and operate the brake pedal

1
a Prepare by turning the starting switch off and carry out trouble-
shooting without turning starting switch.
CN-BP1 (male) Resistance
Defective brake pedal sensor Between (B) and (C) 1.6 – 2.4 kz
2
(Internal failure) 0.2 – 1.8 kz
Between (A) and (B)
1.8 – 0.2 kz
Between (A) and (C)
Possible causes Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting
and standard harness (Disconnection in without turning starting switch.
value in normal 3
state connector) Resistance Max. 1 z
(21) – CN-BP1 (female) (B)
(Contact with 24 V) (3) – CN-BP1 (female) (A) and chassis Voltage Max. 1 V
ground
CN-ST1 Voltage
Between (22) and
(21)
40-340 30 D31/37-22
Failure code [DK40KB] Brake pedal sensor: Short circuit SEN04510-00
D31/37-22 40-340 31
SEN04510-00 Failure code [DK55KX] Directional potentiometer: Out of input signal range
Failure code [DK55KX] Directional potentiometer: Out of input signal

range 1
Action code Failure code Directional potentiometer: Out of input signal range
Trouble
E04 DK55KX (HST controller system)
Contents of • In the systems 1 and 2 of the directional potentiometer, either of the failure codes [DK56KA] or
trouble [DK56KB], and [DK57KA] or [DK57KB] occurred at the same.
Action of • Until the machine stops, the controller maintains the control using the position signal being received
controller immediately prior to the failure.
Problem that
appears on
machine
• Input state (voltage) from the directional potentiometers 1 and 2 can be checked with the monitoring
mode.
Related
(Controller: HST, code: 50202 FR LEVER 1 and code: 50203 FR LEVER 2)
information
• Method of reproducing failure code: Turn the starting switch ON and operate the PCCS lever (direc-
tional operation)

and standard
value in normal Carry out troubleshooting for the failure codes [DK56KA], [DK56KB], [DK57KA], and [DK57KB].
state
40-340 32 D31/37-22
Failure code [DK55KZ] Directional potentiometer: Disconnection or short circuit SEN04510-00
Failure code [DK55KZ] Directional potentiometer: Disconnection or

short circuit 1
Action code Failure code Directional potentiometer: Disconnection or short circuit

Trouble
E04 DK55KZ (HST controller system)
• When the starting switch was turned ON, either of System 1 or System 2 of the directional potentiom-
eter was defective, but, later, a trouble occurred to the other that was normal at that time.
Contents of When the starting switch was turned ON, directional potentiometer 2 was only defective, but, later,
trouble [DK56KA] or [DK56KB] appeared.
Or, when the starting switch was turned ON, directional potentiometer 1 was only defective, but,
later, [DK57KA] or [DK57KB] appeared.
Action of • Until the machine stops, the controller maintains the control using the position signal being received
controller immediately prior to the failure.
Problem that
• Once the machine is stopped, Engine speed is limited to 50% of the value.
appears on
machine
mode.
Related
information
tional operation)

and standard
state
D31/37-22 40-340 33
SEN04510-00 Failure code [DK55L8] Directional potentiometer: Disagreement of analog signals
Failure code [DK55L8] Directional potentiometer: Disagreement of

analog signals 1
Action code Failure code Directional potentiometer: Disagreement of analog signals

Trouble
E03 DK55L8 (HST controller system)
Contents of
• Total voltage of the systems 1 and 2 of the directional potentiometer is under 4.41 V or above 5.59 V.
trouble
Action of • Restricts part of the functions.
controller • Maintains the control using the potentiometer that outputs normal signal.
Problem that
appears on
machine
mode.
Related
information
tional operation)

and standard
state
40-340 34 D31/37-22
Failure code [DK55L8] Directional potentiometer: Disagreement of analog signals SEN04510-00
D31/37-22 40-340 35
SEN04510-00 Failure code [DK56KA] Directional potentiometer 1: Disconnection
Failure code [DK56KA] Directional potentiometer 1: Disconnection 1
Action code Failure code Directional potentiometer 1: Disconnection

Trouble
Contents of
• Input signal voltage from directional potentiometer 1 dropped under 0.3 V.
trouble
Action of • Restricts part of the functions and maintains the control using the signal from the directional potenti-
controller ometer 2.
Problem that
appears on
machine
• Input state (voltage) from the directional potentiometer 1 can be checked with the monitoring mode.
Related (Controller: HST, code: 50202 FR LEVER 1)
information • Method of reproducing failure code: Turn the starting switch ON and operate the PCCS lever (direc-
tional operation)

1
Defective directional CN-EL (male) PCCS lever Resistance
2 potentiometer 1 (Internal fail-
Between (4) and (1) 3.2 kz ± 20%
ure)
Between (3) and (1) 2.4 kz ± 20%
Possible causes 3 Resistance Max. 1 z
and standard wiring or defective contact in (22) – CN-EL (female) (4)
value in normal connector) Wiring harness between CN-ST1 (female)
Resistance Max. 1 z
state (13) – CN-EL (female) (3)
ground circuit) (13) – CN-EL (female) (3) and chassis Resistance Min. 1 Mz
ground
CN-ST1 Voltage
(21)
Between (13) and
Signal 0.3 – 4.5 V
(21)
40-340 36 D31/37-22
Failure code [DK56KA] Directional potentiometer 1: Disconnection SEN04510-00
D31/37-22 40-340 37
SEN04510-00 Failure code [DK56KB] Directional potentiometer 1: Short circuit
Failure code [DK56KB] Directional potentiometer 1: Short circuit 1
Action code Failure code Directional potentiometer 1: Short circuit

Trouble
Contents of
• Input signal voltage from directional potentiometer sensor 1 is above 4.5 V.
trouble
Action of • Limits the functions partly and maintains the control using the signal from the directional potentiome-
controller ter 2.
Problem that
appears on
machine
tional operation)

1
Between (4) and (1) 3.2 kz ± 20%
ure)
Between (3) and (1) 2.4 kz ± 20%
Possible causes 3
and standard or defective contact in con- Wiring harness between CN-ST1 (female)
nector) Resistance Max. 1 z
value in normal (21) – CN-EL (female) (1)
(Contact with 24 V) (13) – CN-EL (female) (3) and chassis Voltage Max. 1 V
ground
CN-ST1 Voltage
(21)
Between (13) and
Signal 0.3 – 4.5 V
(21)
40-340 38 D31/37-22
Failure code [DK56KB] Directional potentiometer 1: Short circuit SEN04510-00
D31/37-22 40-340 39
SEN04510-00 Failure code [DK57KA] Directional potentiometer 2: Disconnection
Failure code [DK57KA] Directional potentiometer 2: Disconnection 1
Action code Failure code Directional potentiometer 2: Disconnection

Trouble
Contents of
• Input signal voltage from directional potentiometer 2 dropped under 0.3 V.
trouble
controller ter 1.
Problem that
appears on
machine
tional operation)

1
Between (4) and (1) 3.2 kz ± 20%
ure)
Between (2) and (1) 2.4 kz ± 20%
Possible causes
value in normal wiring or defective contact in (22) – CN-EL (female) (4)
Resistance Max. 1 z
CN-ST1 Voltage
Between (22) and
(21)
40-340 40 D31/37-22
Failure code [DK57KA] Directional potentiometer 2: Disconnection SEN04510-00
D31/37-22 40-340 41
SEN04510-00 Failure code [DK57KB] Directional potentiometer 2: Short circuit
Failure code [DK57KB] Directional potentiometer 2: Short circuit 1
Action code Failure code Directional potentiometer 2: short circuit

Trouble
Contents of
• Input signal voltage from directional potentiometer 2 is above 4.5 V.
trouble
controller ter 1.
Problem that
appears on
machine
tional operation)

1
Between (4) and (1) 3.2 kz ± 20%
ure)
Between (2) and (1) 2.4 kz ± 20%
3
Possible causes or defective contact in con- Wiring harness between CN-ST1 (female)
and standard nector) Resistance Max. 1 z
value in normal
a Prepare with starting switch OFF and then turn starting switch ON
state
Short circuit with power supply Wiring harness between CN-ST1 (female)
4 line circuit wiring harness (22) – CN-EL (female) (4) and chassis Voltage Max. 1 V
(Contact with 24 V) ground
Voltage Max. 1 V
CN-ST1 Voltage
Between (22) and
(21)
40-340 42 D31/37-22
Failure code [DK57KB] Directional potentiometer 2: Short circuit SEN04510-00
D31/37-22 40-340 43
SEN04510-00 Failure code [DLM0KX] HST motor speed sensors: Out of input signal range
Failure code [DLM0KX] HST motor speed sensors: Out of input signal
range 1
Action code Failure code HST motor speed sensors: Out of input signal range
Trouble
E03 DLM0KX (HST controller system)
Contents of • In the Left HST motor speed sensor system and Right HST motor speed sensor system, either of the
trouble failure codes [DLM1KA] or [DLM1KB], and [DLM2KA] or [DLM2KB] occurred at the same time.
Action of
controller
Problem that • Once the machine is stopped, its engine speed is limited to medium (half) speed.
appears on • Once the machine is stopped and started again, its travel speed is limited to 50%.
machine • Travel deviation occurs.
• Input state from the Left HST motor speed sensor and Right HST motor speed sensor (speed in fre-
quency) can be checked with the monitoring mode.
Related (Controller: HST, code: 40002 R SPEED, code: 40003 L SPEED, code: 40963 R SPEED, and code:
information 40964 L SPEED)
• Method of reproducing failure code: Turn the starting switch ON and operate the PCCS lever (for-
ward or reverse travel)

and standard
value in normal Carry out troubleshooting for the failure codes [DLM1KA], [DLM1KB], [DLM2KA], and [DLM2KB].
state
40-340 44 D31/37-22
Failure code [DLM0KX] HST motor speed sensors: Out of input signal range SEN04510-00
D31/37-22 40-340 45
SEN04510-00 Failure code [DLM1KA] Left HST motor speed sensor: Disconnection
Failure code [DLM1KA] Left HST motor speed sensor: Disconnection 1
Action code Failure code Left HST motor speed sensor: Disconnection
Trouble
E01 DLM1KA (HST controller system)
Contents of
• Disconnection was detected in Left HST motor speed sensor.
trouble
Action of • Stops the straight travel correction control.
Problem that
appears on • Travel deviation occurs.
machine
• Input state from the Left HST motor speed sensor (speed and frequency) can be checked with the
monitoring mode.
Related
(Controller: HST, code: 40003 L SPEED and code: 40964 L SPEED)
information

1
a Prepare with starting switch OFF, then start engine, travel and
CN-LRS2 Voltage
Power supply
Between (A) and (B) (When travel is 4.5 – 5.5 V
Defective Left HST motor
stopped)
2 speed sensor (Internal fail-
ure) Signal
0 V io 4.5 – 5.0 V
Between (C) and (B) (When traveling at
(At a constant cycle)
constant speed)
Left HST motor speed sensor voltage is measured with the wiring har-
ness connected. Accordingly, if voltage is abnormal, check the wiring
harness and controller for another cause of trouble before judgment.
Possible causes
harness (Disconnection in (34) – CN-LRS2 (female) (A)
value in normal 3
state wiring or defective contact in Wiring harness between CN-ST2 (female)
(39) – CN-LRS2 (female) (B)
Resistance Max. 1 z
(20) – CN-LRS2 (female) (C)
Short circuit with power sup- and carry out troubleshooting.
ply line circuit in wiring har-
4 Wiring harness between CN-ST2 (female)
ness (Contact with 24V
circuit) (20) – CN-LRS2 (female) (C) and chassis Voltage Max. 1 V
ground
CN-ST2 and CN-ST3 Voltage
Power supply
5 Defective HST controller Between CN-ST3
(When travel is 4.5 – 5.5 V
(34) and CN-ST2 (39)
stopped)
Signal
Between CN-ST2 0 V io 4.5 – 5.0 V
(When traveling at
(20) and CN-ST2 (39) (At a constant cycle)
constant speed)
40-340 46 D31/37-22
Failure code [DLM1KA] Left HST motor speed sensor: Disconnection SEN04510-00
D31/37-22 40-340 47
SEN04510-00 Failure code [DLM1KB] Left HST motor speed sensor: Short circuit
Failure code [DLM1KB] Left HST motor speed sensor: Short circuit 1
Action code Failure code Left HST motor speed sensor: Short circuit
Trouble
– DLM1KB (HST controller system)
Contents of
• Signal from Left HST motor speed sensor is not input despite the travel command.
trouble
Problem that
machine
• Input state from the Left HST motor speed sensor (speed in frequency) can be checked with the
monitoring mode.
Related • Method of reproducing failure code: Turn the starting switch ON and operate the PCCS lever (for-
information ward or reverse travel)
• If the failure code is not reproduced, improper air bleeding immediately after the assembling or mod-
ification, or false detection of the signal being transmitted at low temperature can be suspected
rather than the error of the sensor. Replacement is not necessary.

1
CN-LRS2 Voltage
Voltage
Defective Left HST motor stopped)
2 speed sensor (Internal fail- Signal
ure) 0 V io 4.5 – 5.0 V
constant speed)
Possible causes Left HST motor speed sensor voltage is measured with the wiring
and standard harness connected. Accordingly, if voltage is abnormal, check the
value in normal wiring harness and controller for another cause of trouble before
state judgment.
ground circuit) (20) – CN-LRS2 (female) (C) and chassis Resistance Min. 1 Mz
ground
(34) – CN-LRS (female) (A) and chassis Voltage Max. 1 V
ground
(Contact with 24 V)
(20) – CN-LRS2 (female) (C) and chassis Voltage Max. 1 V
ground
40-340 48 D31/37-22
Failure code [DLM1KB] Left HST motor speed sensor: Short circuit SEN04510-00

Possible causes Power supply
and standard 5 Defective HST controller Between CN-ST3
value in normal (34) and CN-ST2 (39)
stopped)
state
Signal
(When traveling at
constant speed)
When the HST motor is not running practically, carry out trouble-
6 HST-related failure
shooting in the H mode.
D31/37-22 40-340 49
SEN04510-00 Failure code [DLM1MA] Left HST motor speed sensor: Malfunction
Failure code [DLM1MA] Left HST motor speed sensor: Malfunction 1
Action code Failure code Left HST motor speed sensor: Malfunction
Trouble
– DLM1MA (HST controller system)
Contents of • Signal from Left HST motor speed sensor is entered but substantial portion of the pulses are lost dur-
trouble ing transmission.
Problem that
machine
• Input state from the Left HST motor speed sensor (speed and frequency) can be checked with the
monitoring mode.

CN-LRS2 Voltage
Defective Left HST motor Power supply
Possible causes
1 speed sensor (Internal fail- Between (A) and (B) (When travel is 4.5 – 5.5 V
and standard
ure) stopped)
value in normal
state Signal
0 V io 4.5 – 5.0 V
constant speed)
Left HST motor speed sensor may be defective internally (damages
on the speed detector). Check it directly.
ure)
40-340 50 D31/37-22
Failure code [DLM1MA] Left HST motor speed sensor: Malfunction SEN04510-00
D31/37-22 40-340 51
SEN04510-00 Failure code [DLM2KA] Right HST motor speed sensor: Disconnection
Failure code [DLM2KA] Right HST motor speed sensor: Disconnection 1
Action code Failure code Right HST motor speed sensor: Disconnection
Trouble
Contents of
• Disconnection was detected in Right HST motor speed sensor.
trouble
Problem that
machine
• Input state from the Right HST motor speed sensor (speed and frequency) can be checked with the
monitoring mode.
Related
(Controller: HST, code: 40002 R SPEED and code: 40963 R SPEED)
information

1
CN-RRS2 Voltage
Power supply
Defective Right HST motor
stopped)
ure) Signal
0 V io 4.5 – 5.0 V
constant speed)
Right HST motor speed sensor voltage is measured with the wiring har-
ness connected. Accordingly, if voltage is abnormal, check the wiring
harness and controller for another cause of trouble before judgment.
Possible causes
harness (Disconnection in (34) – CN-RRS2 (female) (A)
value in normal 3
state wiring or defective contact in Wiring harness between CN-ST2 (female)
(39) – CN-RRS2 (female) (B)
Resistance Max. 1 z
(30) – CN-RRS2 (female) (C)
circuit) (30) – CN-RRS2 (female) (C) and chassis Voltage Max. 1 V
ground
Power supply
5 Defective HST controller Between CN-ST3
(34) and CN-ST2 (39)
stopped)
Signal
(When traveling at
constant speed)
40-340 52 D31/37-22
Failure code [DLM2KA] Right HST motor speed sensor: Disconnection SEN04510-00
D31/37-22 40-340 53
SEN04510-00 Failure code [DLM2KB] Right HST motor speed sensor: Short circuit
Failure code [DLM2KB] Right HST motor speed sensor: Short circuit 1
Action code Failure code Right HST motor speed sensor: Short circuit
Trouble
– DLM2KB (HST controller system)
Contents of
• Signal from Right HST motor speed sensor is not input despite the travel command.
trouble
Action of • The straight travel correction control is stopped.
Problem that
machine
• Input state from the Right HST motor speed sensor (speed in frequency) is identifiable with the mon-
itoring mode.

1
CN-RRS2 Voltage
Power supply
Defective Right HST motor stopped)
2 speed sensor (Internal fail- Signal
ure) 0 V io 4.5 – 5.0 V
Possible causes constant speed)
and standard Right HST motor speed sensor voltage is measured with the wiring
value in normal harness connected. Accordingly, if voltage is abnormal, check the
state wiring harness and controller for another cause of trouble before
judgment.
(34) – CN-RRS2 (female) (A)
(Contact with 24 V)
Voltage Max. 1 V
40-340 54 D31/37-22
Failure code [DLM2KB] Right HST motor speed sensor: Short circuit SEN04510-00

Possible causes Power supply
and standard 5 Defective HST controller Between CN-ST3
value in normal (34) and CN-ST2 (39)
stopped)
state
Signal
(When traveling at
constant speed)
When the HST motor is not running practically, carry out trouble-
6 HST-related error
shooting in the H mode.
D31/37-22 40-340 55
SEN04510-00 Failure code [DLM2MA] Right HST motor speed sensor: Malfunction
Failure code [DLM2MA] Right HST motor speed sensor: Malfunction 1
Action code Failure code Right HST motor speed sensor: Malfunction
Trouble
– DLM2MA (HST controller system)
Contents of • Signal from Right HST motor speed sensor is entered but substantial portion of the pulses are lost
trouble during transmission.
Action of • The straight travel correction control is stopped.
Problem that
machine
• Input state from the Right HST motor speed sensor (speed and frequency) can be checked with the
monitoring mode.

CN-RRS2 Voltage
Possible causes Defective Right HST motor Power supply
and standard 1 speed sensor (Internal fail- Between (A) and (B) (When travel is 4.5 – 5.5 V
value in normal ure) stopped)
state
Signal
0 V io 4.5 – 5.0 V
constant speed)
Defective Right HST motor Right HST motor speed sensor may be defective internally (dam-
2
sensor (Internal failure) ages on the speed detector). Check it directly.
40-340 56 D31/37-22
Failure code [DLM2MA] Right HST motor speed sensor: Malfunction SEN04510-00
D31/37-22 40-340 57
SEN04510-00 Failure code [DLM3KA] Fan speed sensor: Disconnection
Failure code [DLM3KA] Fan speed sensor: Disconnection 1
Action code Failure code Fan speed sensor: Disconnection

Trouble
Contents of
• Disconnection was detected in fan speed sensor.
trouble
Action of • Stop the fan control (feedback control).
Problem that
appears on • The fan speed fails to accurately meet the specified speed.
machine
• Input state from the fan speed sensor (speed and frequency) can be checked with the monitoring
Related
mode.
information
(Controller: HST, code: 10007 FAN SPEED and code: 40965 FAN SPEED)

Defective fan speed CN-FRS (male) Resistance
1
sensor (Internal failure) Between (1) and (2) 400 – 1000 z
Between (1) (2) and chassis
Min. 1 Mz
ground
Possible causes wiring or defective contact in (10) – CN-FRS (female) (1)
and standard connector) Wiring harness between CN-ST2 (female)
(39) – CN-FRS (female) (2)
state
circuit) (10) – CN-FRS (female) (1) and chassis Voltage Max. 1 V
ground
CN-ST2 (female) Resistance
Between (10) and (39) 400 – 1000 z
Between (10) and chassis
Min. 1 Mz
ground
40-340 58 D31/37-22
Failure code [DLM3KA] Fan speed sensor: Disconnection SEN04510-00
D31/37-22 40-340 59
SEN04510-00 Failure code [DLM3KB] Fan speed sensor: Short circuit
Failure code [DLM3KB] Fan speed sensor: Short circuit 1
Action code Failure code Fan speed sensor: Short circuit

Trouble
E02 DLM3KB (HST controller system)
Contents of
• While the engine is running, no signal is input from the fan speed sensor.
trouble
Action of
• Stop the fan control (feedback control).
controller
Problem that
appears on • The fan speed fails to accurately meet the specified speed.
machine
• Input state from the fan speed sensor (speed and frequency) can be checked with the monitoring
Related
mode.
information
(Controller: HST, code: 10007 FAN SPEED and code: 40965 FAN SPEED)

Defective fan speed sensor CN-FRS (male) Resistance
1
(Internal short circuit) Between (1) and (2) 400 – 1000 z
Between (1)(2) and chassis
Min. 1 Mz
ground
Defective fan speed Adjustment of the fan speed sensor may be defective. Check it
2
sensor adjustment directly (see "Testing and adjusting").
Possible causes ground circuit) (10) – CN-FRS (female) (1) and chassis Resistance Min. 1 Mz
and standard
ground
value in normal
(Contact with 24 V) (10) – CN-FRS (female) (1) and chassis Voltage Max. 1 V
ground
Between (10) and (29) 400 – 1000 z
Min. 1 Mz
ground
When the fan is rotating practically, carry out troubleshooting in the
6 Defective hydraulic system
H mode.
40-340 60 D31/37-22
Failure code [DLM3KB] Fan speed sensor: Short circuit SEN04510-00
D31/37-22 40-340 61
SEN04510-00
D31/37-22 Bulldozer
©2008 KOMATSU
All Rights Reserved
40-340 62
SEN04511-00
D31EX-22
D31PX-22
D37EX-22
D37PX-22
D31EX-22 60001 and up
D31PX-22 60001 and up
D37EX-22 60001 and up
D37PX-22 60001 and up

Failure code [DN21FS] Brake pedal and proximity switch: Fixing .................................................................. 4
Failure code [DV00KB] Caution buzzer: Short circuit ..................................................................................... 6
Failure code [DV20KB] Back alarm buzzer: Short circuit................................................................................ 7
Failure code [DW4BKA] Parking brake solenoid valve: Disconnection .......................................................... 8
Failure code [DW4BKB] Parking brake solenoid valve: Short circuit ............................................................ 10
Failure code [DW4BKY] Parking brake solenoid valve: Short circuit with power supply line ........................ 12
Failure code [DW7BKA] Fan reverse solenoid valve: Disconnection ........................................................... 14
Failure code [DW7BKB] Fan reverse solenoid valve: Short circuit ............................................................... 16
Failure code [DW7BKY] Fan reverse solenoid valve: Short circuit with power supply line ........................... 17
Failure code [DW7EKA] Slow brake solenoid valve: Disconnection ............................................................. 18
Failure code [DW7EKB] Slow brake solenoid valve: Short circuit ................................................................ 22
Failure code [DW7EKY] Slow brake solenoid valve: Short circuit with power supply line ............................ 24
Failure code [DWN5KA] Fan EPC solenoid valve: Disconnection ................................................................ 26
Failure code [DWN5KB] Fan EPC solenoid valve: Short circuit ................................................................... 28
Failure code [DWN5KY] Fan EPC solenoid valve: Short circuit with power supply line ............................... 30
Failure code [DXA4KA] LF HST pump EPC solenoid valve: Disconnection ................................................. 32
Failure code [DXA4KB] LF HST pump EPC solenoid valve: Short circuit .................................................... 34
Failure code [DXA4KY] LF HST pump EPC solenoid valve: Short circuit with power supply line ................ 36
Failure code [DXA5KA] LR HST pump EPC solenoid valve: Disconnection ................................................ 38
Failure code [DXA5KB] LR HST pump EPC solenoid valve: Short circuit .................................................... 40
Failure code [DXA5KY] LR HST pump EPC solenoid valve: Short circuit with power supply line ................ 42
D31/37-22 40-350 1
SEN04511-00
Failure code [DXA6KA] RF HST pump EPC solenoid valve: Disconnection ................................................ 44
Failure code [DXA6KB] RF HST pump EPC solenoid valve: Short circuit .................................................... 46
Failure code [DXA6KY] RF HST pump EPC solenoid valve: Short circuit with power supply line ................ 47
Failure code [DXA7KA] RR HST pump EPC solenoid valve: Disconnection ................................................ 48
Failure code [DXA7KB] RR HST pump EPC solenoid valve: Short circuit.................................................... 50
Failure code [DXA7KY] RR HST pump EPC solenoid valve: Short circuit with power supply line ............... 52
Failure code [DXK1KA] Left HST motor EPC solenoid valve: Disconnection ............................................... 53
Failure code [DXK1KB] Left HST motor EPC solenoid valve: Short circuit................................................... 54
Failure code [DXK1KY] Left HST motor EPC solenoid valve: Short circuit with power supply line .............. 55
Failure code [DXK2KA] Right HST motor EPC solenoid valve: Disconnection............................................. 56
Failure code [DXK2KB] Right HST motor EPC solenoid valve: Short circuit ................................................ 57
Failure code [DXK2KY] Right HST motor EPC solenoid valve: Short circuit with power supply line ............ 58
40-350 2 D31/37-22
SEN04511-00
D31/37-22 40-350 3
SEN04511-00 Failure code [DN21FS] Brake pedal and proximity switch: Fixing
Failure code [DN21FS] Brake pedal and proximity switch: Fixing 1
Action code Failure code Brake pedal and proximity switch: Fixing
Trouble
E03 DN21FS (HST controller system)
• The signal of travel lock limit switch 1 is set to Free position and the signal of travel lock limit switch 2
Contents of
(NO) is set to OFF (OPEN), and the proximity switch recognized that the brake pedal was pressed
trouble
up to the full position, but the output circuit to the slow brake solenoid valve is operating normally.
Action of
controller
Problem that
appears on
machine
• Input state from the travel lock limit switch 1 and 2 (ON and OFF) can be checked with the monitoring
mode.
(Controller: HST, code: 40911 D-IN [12]: switch 2 (NO), code: 40912 D-IN [18]: switch 1 (NO), [19]:
switch 2 (NC))
Related
• Input state from the brake pedal sensor (stroke and voltage) can be checked with the monitoring
information
mode.
(Controller: HST, code: 50400 BRAKE PEDAL, code: 50401 BRAKE PEDAL)
• Method of reproducing failure code: Start the engine, operate the parking brake lever (Free), and
operate the brake pedal (press to the full position)

Brake pedal
Defective center brake prox- CN-PB (male)
Possible causes 1 Fully-depressed
imity switch (Internal failure) Release position
and standard position
value in normal Between (A) and (B) Max. 1 z Min. 1 Mz
state
Defective center brake Installation of the center brake proximity switch may be defective.
2
proximity switch Check it directly (see "Testing and adjusting").
Defective brake Installation of the brake potentiometer may be defective. Check it
3
potentiometer installation directly (see "Testing and adjusting").
40-350 4 D31/37-22
Failure code [DN21FS] Brake pedal and proximity switch: Fixing SEN04511-00
D31/37-22 40-350 5
SEN04511-00 Failure code [DV00KB] Caution buzzer: Short circuit
Failure code [DV00KB] Caution buzzer: Short circuit 1
Action code Failure code Caution buzzer: Short circuit

Trouble
E01 DV00KB (Monitor panel system)
Contents of
• Abnormal current flowed at the GND output to the caution buzzer circuit.
trouble
Action of • Stops GND output from the caution buzzer circuit.
Problem that
• The caution buzzer dose not sound when the starting switch is turned ON, emergency warning items
appears on
becomes abnormal, or action code [E02], [E03] or [E04] is displayed.
machine
Related
information

Defective caution buzzer • Remove the buzzer, then connect +24V to CN-CB (male) (1) and
1 GND to CN-CB (male) (2).
Alarm buzzer sounds Alarm buzzer is normal
Alarm buzzer does not sound Defective alarm buzzer
and standard Short circuit with power supply and carry out troubleshooting.
value in normal 2 line circuit in wiring harness Wiring harness between CN-S03 (female)
state (Contact with 24 V) (18) – CN-CB (female) (2) and chassis Voltage Max. 1 V
ground
CN-S03 Caution buzzer Voltage
3 Defective monitor panel
When stopped 20 – 30 V
Between (18) and
chassis ground When operated
Max. 1 V
(sounded)
40-350 6 D31/37-22
Failure code [DV20KB] Back alarm buzzer: Short circuit SEN04511-00
Failure code [DV20KB] Back alarm buzzer: Short circuit 1
Action code Failure code Back alarm buzzer: Short circuit

Trouble
E01 DV20KB (HST controller system)
Contents of
• Abnormal current flowed at the output to the back alarm buzzer circuit.
trouble
Action of • Stops output to the back alarm buzzer circuit.
Problem that
appears on • Back alarm buzzer does not sound in the reverse travel.
machine
• Output state from the back alarm buzzer (ON, OFF and voltage) can be checked with the monitoring
mode.
Related
(Controller: HST, code: 40918 D-OUT [S], and code: 70401 BACK ALARM)
information
• Method of reproducing failure code: Turn the starting switch ON and operate the PCCS lever
(reverse travel)

ground circuit) (18) – CN-TBA3 (female) (1) and chassis Resistance Min. 1 Mz
ground
and standard and carry out troubleshooting.
value in normal
state CN-ST3 PCCS lever Voltage
When neutral Max. 1 V
Between (18) and
chassis ground When operated to
20 – 30 V
reverse travel
Since trouble is in system, troubleshooting cannot be carried out. (If
Defective back alarm buzzer
3 causes 1 – 2 above are not detected, travel alarm may be defec-
(Internal failure)
tive.)
D31/37-22 40-350 7
SEN04511-00 Failure code [DW4BKA] Parking brake solenoid valve: Disconnection
Failure code [DW4BKA] Parking brake solenoid valve: Disconnection 1
Action code Failure code Parking brake solenoid valve: Disconnection

Trouble
E04 DW4BKA (HST controller system)
Contents of
• No current flows at output to the parking brake solenoid valve circuit.
trouble
Action of • Stops output of the signal to the parking brake solenoid valve circuit.
controller • Limits the functions partly.
Problem that • The machine is stopped as long as traveling is continued.
appears on • The machine cannot be started as long as traveling is stopped.
machine • Once the machine is stopped and started again, engine speed is limited to medium (half) speed.
• Output state to the parking brake solenoid valve (ON, and OFF) can be checked with the monitoring
mode.
Related
(Controller: HST, code: 40914 D-OUT [10])
information
(Free).

Short circuit with power sup-
ply line circuit in wiring har- a If the failure code [DW4BKY] is displayed, carry out troubleshoot-
1
ness ing for it first as stated.
(Contact with 24V circuit)
Defective parking brake without turning starting switch.
2 solenoid valve (Internal
failure)
Possible causes Between (1) and (2) 40 – 60 z
and standard
value in normal
state
wiring or defective contact in (27) – CN-S4 (female) (1)
Resistance Max. 1 z
(3) – CN-S4 (female) (2)
Between (27) and (3) 40 – 60 z
40-350 8 D31/37-22
Failure code [DW4BKA] Parking brake solenoid valve: Disconnection SEN04511-00
D31/37-22 40-350 9
SEN04511-00 Failure code [DW4BKB] Parking brake solenoid valve: Short circuit
Failure code [DW4BKB] Parking brake solenoid valve: Short circuit 1
Action code Failure code Parking brake solenoid valve: Short circuit
Trouble
E04 DW4BKB (HST controller system)
Contents of
• Abnormal current flowed at output to the parking brake solenoid valve circuit.
trouble
Action of • Stops output of the signal to the parking brake solenoid valve circuit.
appears on • The machine cannot be started as long as traveling is stopped.
machine • Once the machine is stopped and started again, its engine speed is limited to medium (half) speed.
mode.
Related
information
(Free).

Defective parking brake sole-
1 noid valve CN-S4 (male) Resistance
Between (1) and chassis ground Min. 1 Mz
Defective assembled-type without turning starting switch.
2 diode
Possible causes CN-D4 (male) Resistance (Continuity)
and standard Between (4) and (8) Min. 1 Mz (No continuity)
value in normal
state Grounding fault in wiring without turning starting switch.
(27) – CN-S4 (female) (1) and chassis ground
Between (27) and (3) 40 – 60 z
Min. 1 Mz
ground
40-350 10 D31/37-22
Failure code [DW4BKB] Parking brake solenoid valve: Short circuit SEN04511-00
D31/37-22 40-350 11
SEN04511-00 Failure code [DW4BKY] Parking brake solenoid valve: Short circuit with power supply line
Failure code [DW4BKY] Parking brake solenoid valve: Short circuit with
power supply line 1
Action code Failure code Parking brake solenoid valve: Short circuit with power supply line
Trouble
E03 DW4BKY (HST controller system)
Contents of
• Abnormal current constantly flows to the parking brake solenoid valve circuit.
trouble
Action of
controller
Problem that
appears on
machine
mode.
Related
information
(Lock).

value in normal 1 line circuit wiring harness Wiring harness between CN-ST3 (female)
state (Contact with 24 V) (27) – CN-S4 (female) (1) and chassis Voltage Max. 1 V
ground
40-350 12 D31/37-22
Failure code [DW4BKY] Parking brake solenoid valve: Short circuit with power supply line SEN04511-00
D31/37-22 40-350 13
SEN04511-00 Failure code [DW7BKA] Fan reverse solenoid valve: Disconnection
Failure code [DW7BKA] Fan reverse solenoid valve: Disconnection 1
Action code Failure code Fan reverse solenoid valve: Disconnection

Trouble
E01 DW7BKA (HST controller system)
Contents of
• No current flows at output to the fan reverse solenoid valve circuit.
trouble
Action of • Stops output of the signal to the fan reverse solenoid valve circuit.
Problem that
appears on • The fan does not rotate in reverse.
machine
• Output state to the fan reverse solenoid valve (ON, and OFF) can be checked with the monitoring
mode.
Related
information
• Method of reproducing failure code: Turn the starting switch ON and operate the fan rotation selector
switch (CLN).

ply line circuit in wiring har- If the failure code [DW7BKY] is displayed, carry out troubleshooting
1
ness (Contact with 24V for it first as stated.
circuit)
Defective fan reverse without turning starting switch.
Possible causes 2 solenoid valve (Internal
CN-FAR (male) Resistance
and standard disconnection)
Between (1) and (2) 40 – 60 z
value in normal
wiring or defective contact in (7) – CN-FAR (female) (1)
Resistance Max. 1 z
(13) – CN-FAR (female) (2)
If causes 1 – 3 are not detected, HST controller may be defective.
40-350 14 D31/37-22
Failure code [DW7BKA] Fan reverse solenoid valve: Disconnection SEN04511-00
D31/37-22 40-350 15
SEN04511-00 Failure code [DW7BKB] Fan reverse solenoid valve: Short circuit
Failure code [DW7BKB] Fan reverse solenoid valve: Short circuit 1
Action code Failure code Fan reverse solenoid valve: Short circuit
Trouble
E01 DW7BKB (HST controller system)
Contents of
• Abnormal current flowed at output to the fan reverse solenoid valve circuit.
trouble
Action of • Stops output of the signal to the fan reverse solenoid valve circuit.
Problem that
appears on • The fan does not rotate in reverse.
machine
mode.
Related
information
• Method of reproducing failure code: Turn the starting switch ON and operate the fan rotation selector
switch (CLN).

Defective fan reverse
1 solenoid valve (Internal short CN-FAR (male) Resistance
circuit) Between (1) and (2) 40 – 60 z
Possible causes
and standard Between (1) and chassis ground Min. 1 Mz
state Grounding fault in wiring without turning starting switch.
ground circuit) (7) – CN-FAR (female) (1) and chassis Resistance Min. 1 Mz
ground)
40-350 16 D31/37-22
Failure code [DW7BKY] Fan reverse solenoid valve: Short circuit with power supply line SEN04511-00
Failure code [DW7BKY] Fan reverse solenoid valve: Short circuit with
power supply line 1
Action code Failure code Fan reverse solenoid valve: Short circuit with power supply line
Trouble
E03 DW7BKY (HST controller system)
Contents of
• Abnormal current constantly flows to the fan reverse solenoid valve circuit.
trouble
Action of
controller
Problem that • The fan dose not rotate in forward.
mode.
Related
information
• Method of reproducing failure code: Turn the starting switch ON and start the cleaning operation and
operate the fan rotation selector switch (NOR)

state (Contact with 24 V) (7) – CN-FAR (female) (1) and chassis Voltage Max. 1 V
ground
D31/37-22 40-350 17
SEN04511-00 Failure code [DW7EKA] Slow brake solenoid valve: Disconnection
Failure code [DW7EKA] Slow brake solenoid valve: Disconnection 1
Action code Failure code Slow brake solenoid valve: Disconnection

Trouble
E04 DW7EKA (HST controller system)
Contents of • Through the signal of travel lock limit switch 1 is set to Free position and the brake pedal stroke is
trouble less than 60%, no current flows to the circuit of the slow brake solenoid valve.
Action of • Stops output of the signal to the slow brake solenoid valve circuit.
appears on • The machine is stopped, and it cannot be started again.
machine • The machine is stopped, and its engine speed is limited to medium (half) speed.
• Input state from the travel lock limit switch (ON, and OFF) can be checked with the monitoring mode.
(Controller: HST, code: 40911 D-IN [12]: switch 2 (NO), and code: 40912 D-IN [18]: switch 1 (NO),
[19]: switch 2 (NC))
Related
• Input state from the brake pedal (stroke and voltage) can be checked with the monitoring mode.
information
(Controller: HST, code: 50400 BRAKE PEDAL, and code: 50401 BRAKE PEDAL)
• Method of reproducing failure code: Turn on the starting switch, operate the parking brake lever
(Free) and operate the brake pedal (Release)

ply line circuit in wiring har- If the failure code [DW7EKY] is displayed, carry out troubleshooting
1
circuit)
Defective slow brake without turning starting switch.
2 solenoid valve
Between (1) and (2) 40 – 60 z
Defective travel lock limit without turning starting switch.
Possible causes 3 switch 2
CN-26B (male) Travel lock lever Resistance
and standard (Internal disconnection)
value in normal Between (A) and (B) Free (Top) Max. 1 z
state Defective installation of travel Installation of travel lock limit switch 1 and 2 may be defective.
4
lock limit switch 1 and 2 Check it directly (see "Testing and adjusting")
Brake pedal
Wiring harness between CN-26B (female) Stroke
Release
Defective center brake relay (B) – CN-S3 (female) (1) end
5
(Internal disconnection) Max. 1 z Min. 1 Mz
Resistance is measured with wiring harness connected. Accord-
ingly, if resistance is abnormal, check cause 6 center brake relay
primary (coil side) and cause 12 wiring harness disconnection, too,
for another cause of trouble, and then judge.
40-350 18 D31/37-22
Failure code [DW7EKA] Slow brake solenoid valve: Disconnection SEN04511-00

Brake pedal
CN-11B (female) Stroke
Release
end
Defective center brave relay Between (1) and chassis ground 20 – 30 V 20 – 30 V
6
(coil side) Between (2) and chassis ground Max. 1 V 20 – 30 V
If voltage is abnormal, check cause 7, 8, 9, 10, and 11 and then
judge.
If the fuse is burn, the circuit probably has a grounding fault, etc.
7 Defective fuse
(See cause 11)
Brake pedal
CN-PB Stroke
Release
Defective center brake prox- end
8
imity switch (Internal error) Between (A) and (C) 20 – 30 V 20 – 30 V
Between (B) and (C) Max. 1 V 20 – 30 V
voltage is abnormal, check cause 9, 10 and 11, too, for another
cause of trouble, and then judge.
Possible causes Defective installation of Installation of brake potentiometer or brake proximity switches may
and standard 9 brake potentiometer or brake be defective. Check them directly referencing the "Testing and
value in normal proximity switches adjusting".
Wiring harness between CN-11B (female) (1) Resis-
Max. 1 z
– F01 (6) outlet tance
Disconnection in wiring
Wiring harness between CN-PB (female) (A) Resis-
10 harness Max. 1 z
– F01 (6) outlet tance
(primary side of relay)
Max. 1 z
– CN-PB (female) (B) tance
Wiring harness between CN-PB (female) (C) Resis-
Max. 1 z
– CN-T36 tance
Wiring harness between CN-11B (female) (1)
Grounding fault in wiring har- Resis- Min.
11 – CN-PB (female) (A), – F01 (6) outlet and
ness (relay primary) tance 1Mz
chassis ground
Wiring harness between CN-11B (female) (2) Resis- Min.
– CN-PB (female) (B) and chassis ground tance 1Mz
Wiring harness between CN-ST3 (female) Resis-
Max. 1 z
Disconnection in wiring (37) – CN-26B (female) (A) tance
12
harness Wiring harness between CN-26B (female) Resis-
Max. 1 z
(B) – CN-11B (female) (3) tance
Max. 1 z
– CN-S3 (female) (1) tance
D31/37-22 40-350 19
SEN04511-00 Failure code [DW7EKA] Slow brake solenoid valve: Disconnection
40-350 20 D31/37-22
Failure code [DW7EKA] Slow brake solenoid valve: Disconnection SEN04511-00
D31/37-22 40-350 21
SEN04511-00 Failure code [DW7EKB] Slow brake solenoid valve: Short circuit
Failure code [DW7EKB] Slow brake solenoid valve: Short circuit 1
Action code Failure code Slow brake solenoid valve: Short circuit
Trouble
E04 DW7EKB (HST controller system)
Contents of
• Abnormal current flowed at output to the slow brake solenoid valve circuit.
trouble
Action of • Stops output of the signal to the slow brake solenoid valve circuit.
appears on • The machine is stopped, and it cannot be started again.
machine • The machine is stopped, and engine speed is limited to medium (half) speed.
• Input state from the travel lock limit switch 1 and 2 (ON, and OFF) can be checked with the monitor-
ing mode.
(Controller: HST, code: 40911 D-IN [12]: switch 2 (NO), and code: 40912 D-IN [18]: switch 1 (NO),
Related [19]: switch 2 (NC))
information • Input state from the brake pedal (stroke and voltage) can be checked with the monitoring mode.
(Controller: HST, code: 50400 BRAKE PEDAL, and code: 50401 BRAKE PEDAL)
• Method of reproducing failure code: Turn on the starting switch, operate the parking brake lever
(Free) and operate the brake pedal (Release)

Defective slow brake
1 solenoid valve CN-S3 (male) Resistance
Defective assembled-type without turning starting switch.
2
diode (Internal short circuit) CN-D4 (male) Resistance (Continuity)
Between (3) and (7) Min. 1 Mz (No Continuity)
Defective travel lock limit without turning starting switch.
3 switch 2
CN-26B (male) Resistance
Possible causes Between (A) (B) (C) and chassis ground Min. 1 Mz
and standard
state Defective center brake without turning starting switch.
4 solenoid relay CN-11B (male) Resistance
(Internal short circuit) Between (3) (5) (6) and chassis
Min. 1 Mz
ground
Grounding fault in wiring har- (37) – CN-26B (female) (A) and chassis Resistance Min. 1 Mz
5 ness (Short circuit with ground
ground circuit) Wiring harness between CN-26B (female)
(B) – CN-11B (3) and chassis ground
– CN-S3 (female) (1) and chassis ground
40-350 22 D31/37-22
Failure code [DW7EKB] Slow brake solenoid valve: Short circuit SEN04511-00
D31/37-22 40-350 23
SEN04511-00 Failure code [DW7EKY] Slow brake solenoid valve: Short circuit with power supply line
Failure code [DW7EKY] Slow brake solenoid valve: Short circuit with
power supply line 1
Action code Failure code Slow brake solenoid valve: Short circuit with power supply line
Trouble
E03 DW7EKY (HST controller system)
Contents of
• Abnormal current constantly flows to the slow brake solenoid valve circuit.
trouble
Action of
controller
Problem that
appears on
machine
Related • Method of reproducing failure code: Turn on the starting switch, operate the parking brake lever
information (Free) and operate the brake pedal (Release)

Possible causes
(37) – CN-26B (female) (A) and chassis Voltage Max. 1 V
and standard Short circuit with power supply ground
value in normal 1 line circuit wiring harness
state (Contact with 24 V) Wiring harness between CN-26B (female)
(B) – CN-11B (female) (3) and chassis Voltage Max. 1 V
ground
Voltage Max. 1 V
– CN-S3 (female) (1) and chassis ground
40-350 24 D31/37-22
Failure code [DW7EKY] Slow brake solenoid valve: Short circuit with power supply line SEN04511-00
D31/37-22 40-350 25
SEN04511-00 Failure code [DWN5KA] Fan EPC solenoid valve: Disconnection
Failure code [DWN5KA] Fan EPC solenoid valve: Disconnection 1
Action code Failure code Fan EPC solenoid valve: Disconnection

Trouble
E01 DWN5KA (HST controller system)
Contents of
• No current flows at output to the fan EPC solenoid valve circuit.
trouble
Action of • Stops output of the signal to the fan EPC solenoid valve circuit.
Problem that
appears on • The fan speed is set to the maximum.
machine
• The output state (command current, sensed current) to the fan EPC solenoid valve can be checked
Related with the monitoring mode.
information (Controller: HST, code: 31623 FAN EPC, and code: 31624 FAN EPC FB)

ply line circuit in wiring har- If the failure code [DWN5KY] is displayed, carry out troubleshooting
1
circuit)
Defective fan EPC solenoid without turning starting switch.
2 valve
CN-FAC (male) Resistance
and standard
value in normal
state
wiring or defective contact in (25) – CN-FAC (female) (1)
Resistance Max. 1 z
(23) – CN-FAC (female) (2)
Between (25) and (23) 5 – 15 z
40-350 26 D31/37-22
Failure code [DWN5KA] Fan EPC solenoid valve: Disconnection SEN04511-00
D31/37-22 40-350 27
SEN04511-00 Failure code [DWN5KB] Fan EPC solenoid valve: Short circuit
Failure code [DWN5KB] Fan EPC solenoid valve: Short circuit 1
Action code Failure code Fan EPC solenoid valve: Short circuit
Trouble
E01 DWN5KB (HST controller system)
Contents of
• Abnormal current flowed at output to the fan EPC solenoid valve circuit.
trouble
Action of • Stops output of the signal to the fan EPC solenoid valve circuit.
Problem that
appears on • The fan speed is set to the maximum.
machine

Defective fan EPC solenoid CN-FAC (male) Resistance
1
valve (Internal short circuit)
Between (1) and (2) 5 – 15 z
value in normal 2 harness (Contact with Resistance Min. 1 Mz
state ground circuit)
Between (25) and (23) 5 – 15 z
Min. 1 Mz
ground
40-350 28 D31/37-22
Failure code [DWN5KB] Fan EPC solenoid valve: Short circuit SEN04511-00
D31/37-22 40-350 29
SEN04511-00 Failure code [DWN5KY] Fan EPC solenoid valve: Short circuit with power supply line
Failure code [DWN5KY] Fan EPC solenoid valve: Short circuit with
power supply line 1
Action code Failure code Fan EPC solenoid valve: Short circuit with power supply line
Trouble
E02 DWN5KY (HST controller system)
Contents of
• Abnormal current constantly flows to the fan EPC solenoid valve circuit.
trouble
Problem that
• The fan speed is set to the minimum.
appears on
• Tends to overheat.
machine

state (Contact with 24 V) (25) – CN-FAC (female) (1) and chassis Voltage Max. 1 V
ground
40-350 30 D31/37-22
Failure code [DWN5KY] Fan EPC solenoid valve: Short circuit with power supply line SEN04511-00
D31/37-22 40-350 31
SEN04511-00 Failure code [DXA4KA] LF HST pump EPC solenoid valve: Disconnection
Failure code [DXA4KA] LF HST pump EPC solenoid valve:

Disconnection 1
Action code Failure code LF HST pump EPC solenoid valve: Disconnection
Trouble
E03 DXA4KA (HST controller system)
Contents of
• When the signal is output to the LF HST pump EPC solenoid valve, no current flows.
trouble
• Flashes the warning lamp and sounds the warning buzzer.
• Stops outputting the signal to the LF HST pump EPC solenoid valve circuit.
Action of • Stops outputting the signal to the RF HST pump EPC solenoid valve circuit, too.
• Even if the cause of the error disappears, the system does not reset itself until the starting switch is
turned OFF.
• If the machine has been traveling forward, it stops.
Problem that
• If the machine has been stopped, it cannot start forward.
appears on
machine
• Once the machine is stopped, its travel speed is limited to 50%
• The output state (command current, sensed current) to the LF HST pump EPC solenoid valve can be
checked in the monitoring mode.
Related
(Controller: HST, Code: 52401 – LF PUMP, Code: 52409 – LF PUMP FB)
information
• Method of reproducing failure code: Start engine and operate the PCCS lever (in the forward direc-
tion).

If failure code [DXA4KY] is displayed, carry out troubleshooting for it
1 ply line in wiring harness
first.
Defective LF HST pump EPC without turning starting switch.
2 solenoid valve
CN-LF (male) Resistance
value in normal Disconnection in wiring without turning starting switch.
wiring harness or defective (5) and CN-LF (female) (1)
Resistance Max. 1 z
(13) and CN-LF (female) (2)
Between (5) and (13) 5 – 15 z
40-350 32 D31/37-22
Failure code [DXA4KA] LF HST pump EPC solenoid valve: Disconnection SEN04511-00
D31/37-22 40-350 33
SEN04511-00 Failure code [DXA4KB] LF HST pump EPC solenoid valve: Short circuit
Failure code [DXA4KB] LF HST pump EPC solenoid valve: Short circuit 1
Action code Failure code LF HST pump EPC solenoid valve: Short circuit
Trouble
E03 DXA4KB (HST controller system)
Contents of
• When the signal is output to the LF HST pump EPC solenoid valve, an abnormal current flows.
trouble
• Stops outputting the signal to the LF HST pump EPC solenoid valve circuit.
Action of • Stops outputting the signal to the RF HST pump EPC solenoid valve circuit, too.
turned OFF.
Problem that
appears on
machine
• Once the machine is stopped, its travel speed is limited to 50%.
checked in the monitoring mode.
Related
(Controller: HST, Code: 52401 – LF PUMP, Code: 52409 – LF PUMP FB)
information
tion).

Defective LF HST pump EPC
1 solenoid valve CN-LF (male) Resistance
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
and standard Short circuit with chassis without turning starting switch.
value in normal 2 ground in wiring harness Between CN-ST3 (female) (5) – CN-LF
state (Contact with ground circuit) (female) (1) wiring harness and chassis Resistance Min. 1 Mz
ground
3 Defective HST controller CN-ST3 (female) Resistance
Between (5) and (13) 5 – 15 z
40-350 34 D31/37-22
Failure code [DXA4KB] LF HST pump EPC solenoid valve: Short circuit SEN04511-00
D31/37-22 40-350 35
SEN04511-00 Failure code [DXA4KY] LF HST pump EPC solenoid valve: Short circuit with power supply line
Failure code [DXA4KY] LF HST pump EPC solenoid valve: Short circuit
with power supply line 1
Action code Failure code LF HST pump EPC solenoid valve: Short circuit with power supply
Trouble line
E04 DXA4KY (HST controller system)
Contents of
• A current is constantly flowing to the LF HST pump EPC solenoid valve circuit.
trouble
controller • Even if the cause of the error disappears, the system does not reset itself until the starting switch is
turned OFF.
Problem that • The left-hand track keeps rotating forward.
machine • Once the machine is stopped, it cannot start again.
Related checked in the monitoring mode.
information (Controller: HST, Code: 52401 – LF PUMP, Code: 52409 – LF PUMP FB)

and standard Short circuit with power sup- and carry out troubleshooting.
value in normal 1 ply line in wiring harness Between CN-ST3 (female) (5) – CN-LF
state (Contact with 24V circuit) (female) (1) wiring harness and chassis Voltage Max. 1 V
ground.
40-350 36 D31/37-22
Failure code [DXA4KY] LF HST pump EPC solenoid valve: Short circuit with power supply line SEN04511-00
D31/37-22 40-350 37
SEN04511-00 Failure code [DXA5KA] LR HST pump EPC solenoid valve: Disconnection
Failure code [DXA5KA] LR HST pump EPC solenoid valve:

Disconnection 1
Action code Failure code LR HST pump EPC solenoid valve: Disconnection
Trouble
Contents of
• When the signal is output to the LR HST pump EPC solenoid valve, no current flows.
trouble
• Stops outputting the signal to the LR HST pump EPC solenoid valve circuit.
Action of • Stops outputting the signal to the RR HST pump EPC solenoid valve circuit, too.
turned OFF.
• If the machine has been traveling in reverse, it stops.
Problem that
• If the machine has been stopped, it cannot start in reverse.
appears on
machine
• The output state (command current, sensed current) to the LR HST pump EPC solenoid valve can
be checked in the monitoring mode.
Related
(Controller: HST, Code: 52403 – LR PUMP, Code: 52411 – LR PUMP FB)
information
• Method of reproducing failure code: Start engine and operate the PCCS lever (in the reverse direc-
tion).

first.
Defective LR HST pump without turning starting switch.
2 EPC solenoid valve
CN-LR (male) Resistance
wiring harness or defective (6) and CN-LR (female) (1)
Resistance Max. 1 z
(13) and CN-LR (female) (2)
Between (6) and (13) 5 – 15 z
40-350 38 D31/37-22
Failure code [DXA5KA] LR HST pump EPC solenoid valve: Disconnection SEN04511-00
D31/37-22 40-350 39
SEN04511-00 Failure code [DXA5KB] LR HST pump EPC solenoid valve: Short circuit
Failure code [DXA5KB] LR HST pump EPC solenoid valve: Short circuit1
Action code Failure code LR HST pump EPC solenoid valve: Short circuit
Trouble
Contents of
• When the signal is output to the LR HST pump EPC solenoid valve, an abnormal current flows.
trouble
• Stops outputting the signal to the LR HST pump EPC solenoid valve circuit.
Action of • Stops outputting the signal to the RR HST pump EPC solenoid valve circuit, too.
turned OFF.
• If the machine has been traveling in the reverse, it stops.
Problem that
appears on
machine
Related
(Controller: HST, Code: 52403 – LR PUMP, Code: 52411 – LR PUMP FB)
information
tion).

Defective LR HST pump
1 EPC solenoid valve CN-LR (male) Resistance
value in normal 2 ground in wiring (Contact Between CN-ST3 (female) (6) – CN-LR
state with ground circuit) (female) (1) wiring harness and chassis Resistance Min. 1 Mz
ground
Between (6) and (13) 5 – 15 z
40-350 40 D31/37-22
Failure code [DXA5KB] LR HST pump EPC solenoid valve: Short circuit SEN04511-00
D31/37-22 40-350 41
SEN04511-00 Failure code [DXA5KY] LR HST pump EPC solenoid valve: Short circuit with power supply line
Failure code [DXA5KY] LR HST pump EPC solenoid valve: Short circuit
Action code Failure code LR HST pump EPC solenoid valve: Short circuit with power supply
Trouble line
Contents of
• A current is constantly flowing to the LR HST pump EPC solenoid valve circuit.
trouble
turned OFF.
Problem that • The left-hand track keeps rotating in reverse.
Related be checked in the monitoring mode.
information (Controller: HST, Code: 52403 – LR PUMP, Code: 52411 – LR PUMP FB)

value in normal 1 ply line in wiring harness Between CN-ST3 (female) (6) – CN-LR
ground.
40-350 42 D31/37-22
Failure code [DXA5KY] LR HST pump EPC solenoid valve: Short circuit with power supply line SEN04511-00
D31/37-22 40-350 43
SEN04511-00 Failure code [DXA6KA] RF HST pump EPC solenoid valve: Disconnection
Failure code [DXA6KA] RF HST pump EPC solenoid valve:

Disconnection 1
Action code Failure code RF HST pump EPC solenoid valve: Disconnection
Trouble
Contents of
• When the signal is output to the RF HST pump EPC solenoid valve, no current flows.
trouble
• Stops outputting the signal to the RF HST pump EPC solenoid valve circuit.
Action of • Stops outputting the signal to the LF HST pump EPC solenoid valve circuit, too.
turned OFF.
Problem that
appears on
machine
• The output state (command current, sensed current) to the RF HST pump EPC solenoid valve can
Related
(Controller: HST, Code: 52400 – RF PUMP, Code: 52408 – RF PUMP FB)
information
tion).

first.
Defective RF HST pump without turning starting switch.
CN-RF (male) Resistance
wiring harness or defective (15) and CN-RF (female) (1)
Resistance Max. 1 z
(23) and CN-RF (female) (2)
Between (15) and (23) 5 – 15 z
40-350 44 D31/37-22
Failure code [DXA6KA] RF HST pump EPC solenoid valve: Disconnection SEN04511-00
D31/37-22 40-350 45
SEN04511-00 Failure code [DXA6KB] RF HST pump EPC solenoid valve: Short circuit
Failure code [DXA6KB] RF HST pump EPC solenoid valve: Short circuit1
Action code Failure code RF HST pump EPC solenoid valve: Short circuit
Trouble
Contents of
• When the signal is output to the RF HST pump EPC solenoid valve, an abnormal current flows.
trouble
• Stops outputting the signal to the RF HST pump EPC solenoid valve circuit.
Action of • Stops outputting the signal to the LF HST pump EPC solenoid valve circuit, too.
turned OFF.
Problem that
appears on
machine
Related
(Controller: HST, Code: 52400 – RF PUMP, Code: 52408 – RF PUMP FB)
information
tion).

Defective RF HST pump
1 EPC solenoid valve CN-RF (male) Resistance
value in normal 2 ground in wiring harness Between CN-ST3 (female) (15) – CN-RF
ground
Between (15) and (23) 5 – 15 z
40-350 46 D31/37-22
Failure code [DXA6KY] RF HST pump EPC solenoid valve: Short circuit with power supply line SEN04511-00
Failure code [DXA6KY] RF HST pump EPC solenoid valve: Short circuit
Action code Failure code RF HST pump EPC solenoid valve: Short circuit with power supply line
Trouble
Contents of
• A current is constantly flowing to the RF HST pump EPC solenoid valve circuit.
trouble
turned OFF.
Problem that • The right-hand track keeps rotating forward.
information (Controller: HST, Code: 52400 – RF PUMP, Code: 52408 – RF PUMP FB)

value in normal 1 ply line in wiring harness Between CN-ST3 (female) (15) – CN-RF
ground.
D31/37-22 40-350 47
SEN04511-00 Failure code [DXA7KA] RR HST pump EPC solenoid valve: Disconnection
Failure code [DXA7KA] RR HST pump EPC solenoid valve:

Disconnection 1
Action code Failure code RR HST pump EPC solenoid valve: Disconnection
Trouble
Contents of
• When the signal is output to the RR HST pump EPC solenoid valve, no current flows.
trouble
• Stops outputting the signal to the RR HST pump EPC solenoid valve circuit.
Action of • Stops outputting the signal to the LR HST pump EPC solenoid valve circuit, too.
turned OFF.
• If the machine has been traveling in reverse, it stops.
Problem that
appears on
machine
• The output state (command current, sensed current) to the RR HST pump EPC solenoid valve can
Related
(Controller: HST, Code: 52402 – RR PUMP, Code: 52410 – RR PUMP FB)
information
tion).

first.
Defective RR HST pump without turning starting switch.
CN-RR (male) Resistance
wiring harness or defective (16) and CN-RR (female) (1)
Resistance Max. 1 z
(23) and CN-RR (female) (2)
Between (16) and (23) 5 – 15 z
40-350 48 D31/37-22
Failure code [DXA7KA] RR HST pump EPC solenoid valve: Disconnection SEN04511-00
D31/37-22 40-350 49
SEN04511-00 Failure code [DXA7KB] RR HST pump EPC solenoid valve: Short circuit
Failure code [DXA7KB] RR HST pump EPC solenoid valve: Short circuit1
Action code Failure code RR HST pump EPC solenoid valve: Short circuit
Trouble
Contents of
• When the signal is output to the RR HST pump EPC solenoid valve, an abnormal current flows.
trouble
• Stops outputting the signal to the RR HST pump EPC solenoid valve circuit.
Action of • Stops outputting the signal to the LR HST pump EPC solenoid valve circuit, too.
turned OFF.
• If the machine has been traveling in the reverse, it stops.
Problem that
• If the machine has been stopped, it cannot start in the reverse.
appears on
machine
information (Controller: HST, Code: 52402 – RR PUMP, Code: 52410 – RR PUMP FB)
• Method of reproducing failure code: Start engine and operate the PCCS lever (in the reverse direction).

Defective RR HST pump
1 EPC solenoid valve CN-RR (male) Resistance
value in normal 2 ground in wiring harness Between CN-ST3 (female) (16) – CN-RR
ground
Between (16) and (23) 5 – 15 z
40-350 50 D31/37-22
Failure code [DXA7KB] RR HST pump EPC solenoid valve: Short circuit SEN04511-00
D31/37-22 40-350 51
SEN04511-00 Failure code [DXA7KY] RR HST pump EPC solenoid valve: Short circuit with power supply line
Failure code [DXA7KY] RR HST pump EPC solenoid valve: Short circuit
Action code Failure code RR HST pump EPC solenoid valve: Short circuit with power supply
Trouble line
Contents of
• A current is constantly flowing to the RR HST pump EPC solenoid valve circuit.
trouble
turned OFF.
Problem that • The right-hand track keeps rotating in reverse.
information (Controller: HST, Code: 52402 – RR PUMP, Code: 52410 – RR PUMP FB)

value in normal 1 ply line in wiring harness Between CN-ST3 (female) (16) – CN-RR
ground.
40-350 52 D31/37-22
Failure code [DXK1KA] Left HST motor EPC solenoid valve: Disconnection SEN04511-00
Failure code [DXK1KA] Left HST motor EPC solenoid valve:

Disconnection 1
Action code Failure code Left HST motor EPC solenoid valve: Disconnection
Trouble
E02 DXK1KA (HST controller system)
Contents of
• When the signal is output to the Left HST motor EPC solenoid valve, no current flows.
trouble
• Stops outputting to the Left HST motor EPC solenoid valve circuit.
Action of
• Stops outputting to the Right HST motor EPC solenoid valve circuit, too.
controller
turned OFF.
Problem that
• If the machine has been traveling at high-speed, it decelerates.
appears on
• The machine cannot travel at high-speed.
machine
• The output state (command current, sensed current) to the Left HST motor EPC solenoid valve can
information (Controller: HST, Code: 52302 – L MOTOR, Code: 52304 – L MOTOR FB)
• Method of reproducing failure code: Start engine and travel the machine at high-speed.

If failure code [DXK1KY] is displayed, carry out troubleshooting for it
first.
Defective Left HST motor without turning starting switch.
CN-LME (male) Resistance
state harness (Disconnection or Wiring harness between CN-ST3 (female)
defective contact in (26) and CN-LME (female) (1)
Resistance Max. 1 z
(3) and CN-LME (female) (2)
Between (26) and (3) 5 – 15 z
D31/37-22 40-350 53
SEN04511-00 Failure code [DXK1KB] Left HST motor EPC solenoid valve: Short circuit
Failure code [DXK1KB] Left HST motor EPC solenoid valve: Short
circuit 1
Action code Failure code Left HST motor EPC solenoid valve: Short circuit
Trouble
E02 DXK1KB (HST controller system)
Contents of
• When the signal is output to the Left HST motor EPC solenoid valve, an abnormal current flows.
trouble
• Stops outputting the signal to the Left HST motor EPC solenoid valve circuit.
Action of
• Stops outputting the signal to the Right HST motor EPC solenoid valve circuit, too.
controller
turned OFF.
Problem that
appears on
machine

1 EPC solenoid valve CN-LME (male) Resistance
value in normal 2 ground in wiring harness Between CN-ST3 (female) (26) – CN-LME
ground
Between (26) and (3) 5 – 15 z
40-350 54 D31/37-22
Failure code [DXK1KY] Left HST motor EPC solenoid valve: Short circuit with power supply line SEN04511-00
Failure code [DXK1KY] Left HST motor EPC solenoid valve: Short
circuit with power supply line 1
Action code Failure code Left HST motor EPC solenoid valve: Short circuit with power supply
Trouble line
E04 DXK1KY (HST controller system)
Contents of
• A current is constantly flowing to the Left HST motor EPC solenoid valve circuit.
trouble
turned OFF.
Problem that • The speed of the Left-hand track becomes fast.

value in normal 1 ply line in wiring harness Between CN-ST3 (female) (26) – CN-LME
ground
D31/37-22 40-350 55
SEN04511-00 Failure code [DXK2KA] Right HST motor EPC solenoid valve: Disconnection
Failure code [DXK2KA] Right HST motor EPC solenoid valve:

Disconnection 1
Action code Failure code Right HST motor EPC solenoid valve: Disconnection
Trouble
E02 DXK2KA (HST controller system)
Contents of
• When the signal is output to the Right HST motor EPC solenoid valve, no current flows.
trouble
• Stops outputting to the Right HST motor EPC solenoid valve circuit.
Action of
• Stops outputting to the Left HST motor EPC solenoid valve circuit, too.
controller
turned OFF.
Problem that
appears on
machine
• The output state (command current, sensed current) to the Right HST motor EPC solenoid valve can
information (Controller: HST, Code: 52301 – R MOTOR, Code: 52303 – R MOTOR FB)

If failure code [DXK2KY] is displayed, carry out troubleshooting for it
first.
Defective Right HST motor without turning starting switch.
CN-RME (male) Resistance
state harness (Disconnection or Wiring harness between CN-ST3 (female)
defective contact in (36) and CN-RME (female) (1)
Resistance Max. 1 z
(3) and CN-RME (female) (2)
Between (36) and (3) 5 – 15 z
40-350 56 D31/37-22
Failure code [DXK2KB] Right HST motor EPC solenoid valve: Short circuit SEN04511-00
Failure code [DXK2KB] Right HST motor EPC solenoid valve: Short
circuit 1
Action code Failure code Right HST motor EPC solenoid valve: Short circuit
Trouble
E02 DXK2KB (HST controller system)
Contents of
• When the signal is output to the Right HST motor EPC solenoid valve, an abnormal current flows.
trouble
• Stops outputting the signal to the Right HST motor EPC solenoid valve circuit.
Action of
• Stops outputting the signal to the Left HST motor EPC solenoid valve circuit, too.
controller
turned OFF.
Problem that
appears on
machine

Defective Right HST motor
1 EPC solenoid valve CN-RME (male) Resistance
value in normal 2 ground in wiring harness Between CN-ST3 (female) (36) – CN-RME
ground
Between (36) and (3) 5 – 15 z
D31/37-22 40-350 57
SEN04511-00 Failure code [DXK2KY] Right HST motor EPC solenoid valve: Short circuit with power supply line
Failure code [DXK2KY] Right HST motor EPC solenoid valve: Short
circuit with power supply line 1
Action code Failure code Right HST motor EPC solenoid valve: Short circuit with power sup-
Trouble ply line
E04 DXK2KY (HST controller system)
Contents of
• A current is constantly flowing to the Right HST motor EPC solenoid valve circuit.
trouble
turned OFF.
Problem that • The speed of the Right-hand track becomes fast.

value in normal 1 ply line in wiring harness Between CN-ST3 (female) (36) – CN-RME
ground
40-350 58 D31/37-22
Failure code [DXK2KY] Right HST motor EPC solenoid valve: Short circuit with power supply line SEN04511-00
D31/37-22 40-350 59
SEN04511-00
D31/37-22 Bulldozer
©2008 KOMATSU
All Rights Reserved
40-350 60
SEN04512-01
D31EX-22
D31PX-22
D37EX-22
D37PX-22
D31EX-22 60001 and up
D31PX-22 60001 and up
D37EX-22 60001 and up
D37PX-22 60001 and up
400 Troubleshooting of electrical system

(E-mode)
E-1 Engine does not start (Starting motor does not rotate)............................................................................. 4
E-2 Engine is not preheated ........................................................................................................................... 7
E-3 When starting switch is turned ON, any item does not light up .............................................................. 10
E-4 Charge level caution flashes while engine is running............................................................................. 12
E-5 Emergency warning items flash while engine is running........................................................................ 14
E-6 Preheating pilot lamp does not light up during preheating operation ..................................................... 20
E-7 The coolant temperature gauge does not indicate correctly................................................................... 22
E-8 The HST oil temperature gauge does not indicate correctly. ................................................................. 23
E-9 Fuel level gauge does not indicate properly........................................................................................... 24
E-10 Gear speed, set travel speed, and shift mode indicator does not display normally ............................. 26
E-11 Multi-information unit does not display normally................................................................................... 26
E-12 Caution lamp does not flash or does not go off.................................................................................... 27
E-13 Caution buzzer does not sound or does not stop................................................................................. 28
E-14 Reverse travel speed setting switch does not function ........................................................................ 30
E-15 Shift mode switch does not function ..................................................................................................... 32
E-16 Buzzer cancel switch does not function ............................................................................................... 34
E-17 Information switch does not function .................................................................................................... 36
E-18 The fan cleaning does not operate or cannot be reset......................................................................... 38
E-19 Backup alarm does not sound.............................................................................................................. 40
E-20 The horn does not sound or does not stop........................................................................................... 41
E-21 Work equipment does not move........................................................................................................... 42
D31/37-22 40-400 1
400 Troubleshooting of electrical system (E-mode)
SEN04512-01
E-22 Headlamp or rear lamp does not light up ............................................................................................. 44

E-23 Foot heater does not operate ............................................................................................................... 47
E-24 Air conditioner does not operate........................................................................................................... 50
E-25 Windshield wiper and window washer do not operate.......................................................................... 55
E-26 KOMTRAX system does not operate normally..................................................................................... 68
40-400 2 D31/37-22
SEN04512-01
D31/37-22 40-400 3
SEN04512-01 E-1 Engine does not start (Starting motor does not rotate)
E-1 Engine does not start (Starting motor does not rotate) 1
Trouble When starting switch is turned to START position, starting motor does not rotate.
• Since the engine starting circuit has the neutral safety function, the engine does not start unless the
parking brake lever is in the LOCK position and the travel lever is in the neutral position. (When the
engine can start, [P] is lighted up on the monitor panel.)
• KOMTRAX has start lock function. If start lock is not reset, engine cannot start.
Related
information • If "monitor panel does not light" or "battery relay operation sound is not heard" when starting switch is
turned ON, main power supply system may be defective. Check main power supply system.
• Since the HST controller controls the neutral safety relay with the travel lock limit switch signal, check
that a related failure code is not displayed before carrying out troubleshooting. (If failure code
[D130KA], [D130KB], [DD14KB], or [DDQ2KA] is displayed, carry out troubleshooting for it first.)

Battery voltage Electrolyte specific gravity
1 Low charge level of battery
Min. 24 V Min. 1.26
a Prepare with starting switch OFF (Disconnect CN-T250), then
carry out troubleshooting with starting switch in OFF and START
positions.
Defective starting switch
2 Starting switch Switch position Resistance
Between CN-T250 OFF Min. 1 Mz
and CN-T280 START Max. 1 z
a Prepare with starting switch ON, then carry out troubleshooting in
real-time monitoring mode.
Controller: HST
Defective adjustment of Monitoring code: 50303 S/T LEVER
3
steering lever
PCCS lever Stroke
Neutral 0 ±10%
If there is any abnormality, initialize steering lever.
Possible
causes and a Prepare with starting switch OFF, then turn starting switch ON
standard value and carry out troubleshooting.
Defective neutral safety relay
in normal state 4 Operate the parking brake lever between FREE and LOCK
positions. If the neutral safety relay makes an operating sound, it is
normal.
a Prepare with starting switch OFF (keeping wiring harness con-
nected), then carry out troubleshooting with starting switch in
START position.
Safety relay Voltage
Between CN-T3 and
Power supply input 20 – 30 V
chassis ground
Defective starting motor safety Between CN-4 (1)
Starting input 20 – 30 V
5 relay and chassis ground
(Internal disconnection) Between CN-4 (2)
Charging input Max. 1 V
and chassis ground
Between CN-T4 and
Starting output 20 – 30 V
chassis ground
If the power supply input, starting input, and charging input are
normal and the starting output is not normal, the starting motor
safety relay is defective.
40-400 4
E-1 Engine does not start (Starting motor does not rotate) SEN04512-01

nected), then carry out troubleshooting with starting switch in
START position.
Starting motor Voltage
Defective starting motor Between CN-T1 and
6 Power supply input 20 – 30 V
(Internal defect) chassis ground
Between CN-T2 and
Starting input 20 – 30 V
chassis ground
If the power supply input and starting input are normal and the
starting motor does not rotate, the starting motor is defective.
nected), then carry out troubleshooting with starting switch ON.
Defective alternator
7 Alternator Voltage
Between CN-T16 and chassis
Max. 1 V
ground
Defective diode and carry out troubleshooting.
8
(Internal short circuit) CN-D2 (male) Resistance (Continuity)
Between (1) and (2) Min. 1 Mz (Broken)
Wiring harness between CN-T280 and CN-
Disconnection in wiring Resistance Max. 1 z
11 (female) (3)
Possible harness
causes and 9 (Disconnection in wiring Wiring harness between CN-11 (female) (5)
Resistance Max. 1 z
standard value harness or defective contact and CN-4 (female) (1)
in normal state in connector) Wiring harness between CN-T4 and CN-T2 Resistance Max. 1 z
Wiring harness between CN-T8 and CN-T1 Resistance Max. 1 z
Wiring harness between CN-T1 and CN-T3 Resistance Max. 1 z
Between CN-T280 – CN-11 (female) (3) or
CN-ST3 (female) (10), or CN-G01 (female) Resistance Min. 1 Mz
(27) wiring harness and chassis ground
Between CN-11 (female) (5) – CN-4 (female)
(1) or CN-S03 (female) (7) wiring harness Resistance Min. 1 Mz
Short circuit with chassis and chassis ground
10 ground in wiring harness Between CN-T4 – CN-T2 wiring harness and
(Contact with ground circuit) chassis ground
Between CN-T8 – CN-T1 wiring harness and
chassis ground
Between CN-T1 – CN-T3 wiring harness and
chassis ground
Between CN-ST2 (female) (13) – CN-G01
(female) (20) wiring harness and chassis Resistance Min. 1 Mz
ground
Short circuit with power
11 source in wiring harness Between CN-4 (female) (2) – CN-T16 or CN-
(Contact with 24 V circuit) S04 (female) (9) or CN-ST1 (female) (15) or
Voltage Max. 1 V
CN-G01 (female) (28) wiring harness and
chassis ground
40-400 5
SEN04512-01 E-1 Engine does not start (Starting motor does not rotate)
40-400 6
E-2 Engine is not preheated SEN04512-01
E-2 Engine is not preheated 1
Trouble • Engine is not preheated.

• This troubleshooting is for the case when the intake air heater is not heated during the preheating
operation. (When only the preheater lamp does not light up, carry out troubleshooting for “Preheater
lamp does not light up”.)
• Preheating system has "automatic preheating function" and "manual preheating function".
Related When either of those functions operates, preheater lamp lights.
information • If "monitor panel does not light" or "battery relay operation sound is not heard" when starting switch is
turned ON, main power supply system may be defective. Check main power supply system.
• Before carrying out troubleshooting, check that no related failure code is displayed.
(If failure code [CA153], [CA154], [CA2555] or [CA2556] is displayed, carry out troubleshooting for it
first.)

carry out troubleshooting with starting switch in OFF and HEAT
positions.
and CN-T255 HEAT Max. 1 z
Disconnection of fuse
2 (CN-F01 (12), CN-106 (1) If fuse is broken, circuit probably has ground fault etc.
and (3))
Defective preheater relay
3 Replace preheater relay RHR with another relay when intake air
temperature is –5°C or lower. If preheating starts, preheater relay
RHR is defective.
Possible nected), then carry out troubleshooting with starting switch in
causes and HEAT position.
standard value Heater relay Voltage
in normal state
Between CN-T12
Power supply input 20 – 30 V
Defective heater relay and chassis ground
4
(Internal defect) Between CN-T5 and
Preheating input 20 – 30 V
chassis ground
Between CN-T6 and
Preheating output 20 – 30 V
chassis ground
If the power supply input and preheating input are normal and the
preheating output is not normal, the heater relay is defective.
Defective diode without turning starting switch.
5
Defective intake air heater without turning starting switch.
6
(Internal disconnection) Intake air heater Continuity
Between terminals There is continuity
40-400 7
SEN04512-01 E-2 Engine is not preheated

Wiring harness between CN-T255 – CN- Resis-
Disconnection in wiring Max. 1 z
RHR (female) (3) – CN-T5 tance
harness
Wiring harness between CN-F01 (12) outlet Resis-
7 (Disconnection in wiring Max. 1 z
– CN-RHR (female) (5) tance
harness or defective contact
in connector) Resis-
Wiring harness between CN-T1 and CN-T12 Max. 1 z
tance
Possible Resis-
Wiring harness between CN-T6 and CN-RH Max. 1 z
causes and tance
standard value a Prepare with starting switch OFF, then carry out troubleshooting
in normal state without turning starting switch.
Between CN-T255 – CN-RHR (female) (3) – Resis-
Min. 1 Mz
CN-T5 wiring harness and chassis ground tance
Short circuit with chassis Between CN-F01 (12) outlet – CN-RHR
Resis-
8 ground in wiring harness (female) (5) wiring harness and chassis Min. 1 Mz
tance
(Contact with ground circuit) ground
Between CN-T1 – CN-T12 wiring harness Resis-
Min. 1 Mz
and chassis ground tance
Between CN-T6 – CN-RH wiring harness Resis-
Min. 1 Mz
40-400 8
E-2 Engine is not preheated SEN04512-01
40-400 9
SEN04512-01 E-3 When starting switch is turned ON, any item does not light up
E-3 When starting switch is turned ON, any item does not light up 1
Trouble • When starting switch is turned ON, any item does not light up.
Related • When the starting switch is turned ON, the gear speed/Set travel speed/Shift mode indicator section,
information multi-information section, gauge section, and lamp section light up for approx 2 seconds.

1 Low charge level of battery
Battery voltage (2pieces) Electrolyte specific gravity
Min. 24 V Min. 1.26
Disconnection of fuse If the fuse is broken, the circuit probably has a grounding fault, etc.
2
(CN-F01 (9C), (16E)) (See Cause 5.)
carry out troubleshooting with starting switch in OFF and ON
positions.
Between CN-T250 OFF Min.1 Mz
and CN-T270 ON Max.1 z
Wiring harness between battery (–) terminal Resis-
Max. 1 z
Wiring harness between battery (+) terminal Resis-
Disconnection in wiring har- Max. 1 z
– CN-T7, – CN-F01 (9C) (16E) tance
ness
Wiring harness between CN-F01 (16) and Resis-
4 (Disconnection in wiring har- Max. 1 z
CN-S03 (5) (6) tance
ness or defective contact in
Possible Wiring harness between CN-S03 (3) (4) and Resis-
connector) Max. 1 z
causes and chassis ground (CN-T36) tance
standard value
in normal state Max. 1 z
CN-T250 tance
Wiring harness between CN-T270 and CN- Resis-
Max. 1 z
S03 (1) (2) tance
Between battery (+) terminal – CN-T7 – CN-
Resis-
F01 (9C) (16E) wiring harness and chassis Min. 1 Mz
tance
ground
Between CN-F01 (16) – CN-S03 (5) or (6) or
Short circuit with chassis Resis-
another related circuit wiring harness and Min. 1 Mz
5 ground in wiring harness tance
chassis ground
(Contact with ground circuit)
Between CN-F01 (9) – CN-T250 or another
Resis-
related circuit wiring harness and chassis Min. 1 Mz
tance
ground
Between CN-T270 – CN-S03 (5) or (6) or
Resis-
another related circuit wiring harness and Min. 1 Mz
tance
chassis ground
a Prepare with starting switch OFF, then turn starting switch OFF
and ON and carry out troubleshooting.
Starting
6 Defective monitor panel CN-S03 Voltage
switch
Between (5), (6) and (3), (4) OFF 20 – 30 V
Between (1), (2) and (3), (4) ON 20 – 30 V
40-400 10
E-3 When starting switch is turned ON, any item does not light up SEN04512-01
40-400 11
SEN04512-01 E-4 Charge level caution flashes while engine is running
E-4 Charge level caution flashes while engine is running 1
Trouble • Charge level caution flashes while engine is running.

Related
• The charge caution lamp flashes when abnormality is detected while the engine is running.
information

troubleshooting.
Defective alternator
1 Alternator Engine speed Voltage
(Defective generation)
Between CN-T16 Above medium (half)
20 – 30 V
and chassis ground speed
harness
Wiring harness between CN-S04 (female) Resis-
(9) and CN-T16 tance
Possible harness or defective contact
in connector) Between CN-T17 and CN-T20A wiring har- Resis-
causes and Max. 1 z
standard value ness and chassis ground tance
in normal state a Prepare with starting switch OFF, then carry out troubleshooting
Short circuit with chassis Between CN-S04 (female) (9) – CN-T16 or
3 ground in wiring harness CN-4 (female) (2) or CN-ST1 (female) (15)
(Contact with ground circuit) Resis-
or CN-G01 (female) (28) or CN-ST3 Min. 1 Mz
tance
(female) (4) or CN-T260 or CN-T13 wiring
harness and chassis ground
troubleshooting.
4 Defective monitor panel CN-S04 Engine speed Voltage
Between (9) and Above medium (half)
20 – 30 V
chassis ground speed
40-400 12
E-4 Charge level caution flashes while engine is running SEN04512-01
40-400 13
SEN04512-01 E-5 Emergency warning items flash while engine is running
E-5 Emergency warning items flash while engine is running 1
Trouble (1) Engine oil pressure caution lamp flashes.

• When any abnormality is detected during engine running, the engine oil pressure caution lamp
Related
flashes and the alarm buzzer sounds.
information
• The engine oil pressure switch signal is used to communicate with the engine controller.
Cause Standard value in normal state / Remarks on troubleshooting

Reduction of engine oil pres- Check the engine oil pressure as the drop of engine oil pressure is
1 sure detected.
Possible (When system is normal) • Carry out the troubleshooting of “S-12 The oil pressure drops.”
causes and
standard value When the possible cause 1 is not the real cause, the engine oil pres-
in normal state Defective engine oil pressure sure switch circuit is supposed to be defective. So, carry out the
2
system troubleshooting of “Failure code [CA435] Abnormal engine oil pres-
sure switch.”
3 Defective monitor panel Since this is an internal defect, it cannot be diagnosed.
Trouble (2) Engine coolant temperature caution lamp flashes.

• When any abnormality is detected while engine is running, the coolant temperature caution lamp
Related • The coolant temperature caution lamp flashes or goes out in accordance with an indication on the
information engine coolant temperature gauge.
• The input state (temperature) from the coolant temperature sensor can be checked in the monitoring mode.
(Controller: ENGINE, Code: 04107 COOLANT TEMP)

Since the coolant overheat is detected, check the coolant tempera-
Coolant overheats
1 ture. (At the coolant temperature over 105°C, the lamp flashes and
Possible (When system is normal)
the buzzer sounds. Over 102°C, just the lamp flashes.)
causes and
standard value When the cause 1 is not the real cause, the coolant temperature
Defective coolant temperature
in normal state sensor circuit is supposed to be defective. So, carry out the trouble-
2 sensor system
shooting of “E-7 The coolant temperature gauge does not indicate
(Engine controller circuit)
correctly.”
40-400 14
E-5 Emergency warning items flash while engine is running SEN04512-01
Trouble (3) HST oil temperature caution lamp flashes.

• When any abnormality is detected while engine is running, the HST oil temperature caution lamp
• The HST oil temperature caution lamp flashes or goes out in accordance with indication on the HST
Related oil temperature gauge.
information • The input state (temperature) from the HST oil temperature sensor can be checked at monitoring mode.
(Controller: HST, Code: 04401 HST TEMP)
• Before starting the troubleshooting, validate that the related failure code is not displayed.
(If the failure code [DGS1KA] or [DGS1KX] is displayed, firstly diagnose the displayed code.)

Since the HST oil overheat is detected, check the HST oil tempera-
HST oil overheats
1 ture. (At the HST oil temperature over 110°C, the lamp flashes and
the buzzer sounds. Over 100°C, just the lamp flashes.)
causes and
standard value When the cause 1 is not the real cause, the HST oil temperature
Defective HST oil temperature
in normal state sensor circuit is supposed to be defective. So, carry out the trouble-
2 sensor circuit
shooting of “E-8 The HST oil temperature gauge does not indicate
(Monitor panel circuit)
correctly”
Trouble (4) The caution lamp of water level in the fuel filter lights up.
Related • The caution lamp of water level in the fuel filter lights up when the water level in the water separator
information located under the fuel preheater rises, and goes out by draining the water.

The water level in the water
Since the water in the water separator is detected, check the water
Possible 1 separator rises.
separator and drain the water.
causes and (When the system is normal.)
standard value Defective fuel filter sensor When the possible cause 1 is not the real cause, the fuel filter circuit
in normal state 2 circuit is supposed to be defective. So, carry out the troubleshooting of
(Engine controller circuit) "Failure codes [CA428] [CA429] Abnormal water detection sensor"
40-400 15
Trouble (5) HST charge filter clogging caution lamp flashes.

• If abnormality is detected while the engine is running, the HST charge filter clogging caution lamp
flashes and the caution buzzer sounds.
Related • The signals from the HST charge filter clogging switch are received from the HST controller through
information the communication system.
• The input state (ON/OFF) from the HST charge filter clogging switch can be checked in the monitor-
ing mode. (Controller: HST, Code: 40910 D-IN [3])

Clogging of HST charge filter
1 Since clogging of the HST charge filter is detected, check it.
(When system is normal)
a Prepare with starting switch OFF, then hold starting switch OFF
and start engine and carry out troubleshooting.
Difference between
Defective HST charge filter CN-CFS (male) inlet and outlet pres- Resistance
2 clogging switch sures of HST filter
(Internal short circuit) Max. 0.2 MPa
Min. 1 Mz
{Max. 2 kg/cm2}
Between (1) and (2)
Min. 0.2 MPa
Max. 1 z
{Min. 2 kg/cm2}
Possible
Short circuit with chassis without turning starting switch ON.
causes and
standard value 3 ground in wiring harness Between CN-ST1 (female) (5) – CN-CFS
in normal state (female) (1) wiring harness and chassis Min. 1 Mz
tance
ground
a Prepare with starting switch OFF, then hold starting switch ON
and start engine and carry out troubleshooting.
Difference between
CN-ST1 inlet and outlet pres- Voltage
4 Defective HST controller sures of HST filter
Max. 0.2 MPa
5 – 11 V
Between (5) and {Max. 2 kg/cm2}
chassis ground Min. 0.2 MPa
Max. 1 V
{Min. 2 kg/cm2}
If none of causes 1 – 4 is the cause of the trouble, the monitor panel
5 Defective monitor panel may be defective (Troubleshooting cannot be carried out since the
defect is in the monitor panel).
40-400 16
40-400 17
Trouble (6) HST charge pressure caution lamp flashes.

• If abnormality is detected while the engine is running, the HST charge pressure caution lamp flashes
and the caution buzzer sounds.
Related
information • Input state (pressure) from HST charge pressure sensor (brake oil pressure sensor) can be checked
in monitoring mode.
(Controller: HST, Code: 91902 BRAKE PRESS)

Low HST charge
1 pressure Since low HST charge pressure is detected, check it.
causes and
standard value If cause 1 is not detected, brake oil pressure sensor system may
Defective brake oil
in normal state 2 be defective. Carry out troubleshooting for [DDP6KA], [DDP6KB]
pressure sensor system
and [DDP6KY].
Troubleshooting cannot be carried out since the defect is in the
monitor panel.
40-400 18
40-400 19
SEN04512-01 E-6 Preheating pilot lamp does not light up during preheating operation
E-6 Preheating pilot lamp does not light up during preheating operation1
Trouble • Preheating pilot lamp does not light up during preheating operation.
• This troubleshooting is for the case when the preheating pilot lamp does not light up during the pre-
heating operation. (When the intake air heater is not heated, carry out troubleshooting for “Engine is
not preheated”.)
Related
• Preheating system has "automatic preheating function" and "manual preheating function". When
information
either of those functions operates, preheater lamp lights.
• The input state (ON/OFF) from the heater relay can be checked in the monitoring mode. (Controller:
MONITOR PANEL, Code: 40921 D-IN [2])

1 (Disconnection in wiring
harness or defective contact Max. 1 z
in connector) (9) and CN-T5 tance
Possible a Prepare with starting switch OFF, then carry out troubleshooting
causes and Short circuit with chassis without turning starting switch.
standard value 2 ground in wiring harness
(Contact with ground circuit) Between CN-S03 (female) (9) – CN-T5 Resis-
in normal state Min. 1 Mz
wiring harness and chassis ground tance
a Prepare with starting switch OFF, then hold starting switch in OFF
and HEAT position and carry out troubleshooting.
3 Defective monitor panel CN-S03 Starting switch Voltage
Between (9) and OFF Max. 1 V
chassis ground HEAT 20 – 30 V
40-400 20
E-6 Preheating pilot lamp does not light up during preheating operation SEN04512-01
40-400 21
SEN04512-01 E-7 The coolant temperature gauge does not indicate correctly.
E-7 The coolant temperature gauge does not indicate correctly. 1
(1)Although the coolant temperature is rising normally, the indication of the coolant temperature stays in
white range (a).
Trouble
(2)Although the coolant temperature is stabilized normally, the indication of the coolant temperature
rises to red range (c).
• Signals of the coolant temperature sensor are input into the engine controller and that information is
transmitted to the monitor panel through communication system.
Related
information • The input state (temperature) from the coolant temperature sensor can be checked in the monitoring
mode.
(Controller: ENGINE, Code: 04107 COOLANT TEMP)

Since the coolant temperature sensor circuit is supposed to be
Possible Defective coolant temperature
1 defective, carry out the troubleshooting of failure codes [CA144] and
causes and sensor circuit
[CA145].
standard value
in normal state When the possible cause 1 is not the real cause, the monitor panel
2 Defective monitor panel is supposed to be defective. (As it is an internal defect, it cannot be
diagnosed.)
(3)The coolant temperature does not match to the indication of coolant temperature gauge.
Trouble
(4)The coolant temperature gauge does not match with the indication of coolant temperature monitor.
• Signals of the coolant temperature sensor are input into the engine controller and that information is
Related transmitted to the monitor panel through communication system.
information • The input state (temperature) from the coolant temperature sensor can be checked in the monitoring
mode. (Controller: ENGINE, Code: 04107 COOLANT TEMP)
Possible a Diagnose with starting switch ON or with engine started.

causes and Caution lamp (d)
standard value 1 Defective monitor panel OFF Flashing
in normal state
White range (a)
Red range (c)
Green range (b)
Coolant temperature gauge and caution lamp
40-400 22
E-8 The HST oil temperature gauge does not indicate correctly. SEN04512-01
E-8 The HST oil temperature gauge does not indicate correctly. 1
(1)Although the HST oil temperature is rising normally, the indication of the HST oil temperature stays in
white range (a).
Trouble
(2)Although the HST oil temperature is stabilized normally, the indication of the HST oil temperature
rises to red range (c).
• Signals of the HST oil temperature sensor are input into the HST controller and that information is
information • The input state (temperature) from the HST oil temperature sensor can be checked in the monitoring mode.
(Controller: HST, Code: 04401 HST TEMP)

Since the HST oil temperature sensor circuit is supposed to be
Possible Defective HST oil temperature
1 defective, carry out the troubleshooting of failure codes [DGS1KA]
causes and sensor circuit
and [DGS1KX].
standard value
in normal state When the possible cause 1 is not the real cause, the monitor panel
2 Defective monitor panel is supposed to be defective. (As it is an internal defect, it cannot be
diagnosed.)
(3)The HST oil temperature does not match to the indication of HST oil temperature gauge.
Trouble
(4)The HST oil temperature gauge does not match with the indication of HST oil temperature monitor.
• Signals of the HST oil temperature sensor are input into the HST controller and that information is
information • The input state (temperature) from the HST oil temperature sensor can be checked in the monitoring
mode. (Controller: HST, Code: 04001 HST TEMP)
Possible a Diagnose with starting switch ON or with engine started.

causes and Caution lamp (d)
standard value 1 Defective monitor panel OFF Flashing
in normal state
White range (a)
Red range (c)
Green range (b)
HST oil temperature gauge and caution lamp
40-400 23
SEN04512-01 E-9 Fuel level gauge does not indicate properly
E-9 Fuel level gauge does not indicate properly 1
Trouble • Fuel level gauge does not indicate properly

Related The Input state (voltage signal) from the fuel level sensor can be checked in monitoring mode.
information (Controller: MONITOR PANEL, Code: 04200 FUEL SENSOR)

Defective fuel level sensor
1 (Internal disconnection or CN-13 (male) Fuel tank Resistance
short circuit) Full Max. 10 z
Between (1) and (2)
Empty Min. 73 z
Disconnection between fuel a Prepare with starting switch OFF, then carry out troubleshooting
level sensor and chassis without turning starting switch.
2 ground
Between CN-13 (male) (2) and chassis Resis-
(Internal disconnection or Max. 1 z
defect of installation) ground tance
Possible harness or defective contact Max. 1 z
in connector) (10) and CN-13 (female) (1) tance
causes and
in normal state Short circuit with chassis without turning starting switch.
4 ground in wiring harness Between CN-S04 (female) (10) – CN-13
(female) (1) wiring harness and chassis Min. 1 Mz
tance
ground
Short circuit with power and carry out troubleshooting.
5 source in wiring harness Between CN-S04 (female) (10) – CN-13
(Contact with 24 V circuit) (female) (1) wiring harness and chassis Voltage Max. 1 V
ground
CN-S03 (female)
6 Defective monitor panel Fuel tank Resistance
CN-S04 (female)
Between CN-S04 Full Max. 10 z
(10) and CN-S03 (3) Empty Min. 73 z
40-400 24
E-9 Fuel level gauge does not indicate properly SEN04512-01
40-400 25
SEN04512-01 E-10 Gear speed, set travel speed, and shift mode indicator does not display normally
E-10 Gear speed, set travel speed, and shift mode indicator does not
display normally 1
Trouble • Gear speed, set travel speed, and shift mode indicator does not display normally.
Related • Display information of the gear speed, set travel speed, and shift mode indicator is received from the
information HST controller through the communication system.
Possible Cause Standard value in normal state/Remarks on troubleshooting

causes and
standard value Troubleshooting cannot be carried out since the defect is in the
in normal state monitor panel.
E-11 Multi-information unit does not display normally 1
Trouble (1) Service meter does not move forward while engine is running.
Related • Service meter starts counting when monitor panel receives engine start signal (alternator R signal).
information • While the service meter is moving forward, the hourglass mark is displayed.

Possible If the charge caution lamp blinks while engine is running, carry out
Defective alternator speed
causes and 1 the troubleshooting for "E-4 Charge level caution flashes while
signal sensor
standard value engine is running" first.
in normal state Troubleshooting cannot be carried out since the defect is in the
monitor panel.
Trouble (2) Multi-information section does not display any item.

Related
information

causes and
40-400 26
E-12 Caution lamp does not flash or does not go off SEN04512-01
E-12 Caution lamp does not flash or does not go off 1
Trouble • Caution lamp does not flash or does not go off.

Related
information

causes and
40-400 27
SEN04512-01 E-13 Caution buzzer does not sound or does not stop
E-13 Caution buzzer does not sound or does not stop 1
Trouble • Caution buzzer does not sound or does not stop.

Related • If there is a short circuit in the caution buzzer system, a failure code is [DV00KB] displayed. No fail-
information ure codes are displayed when other troubles occur, however.

carry out troubleshooting with starting switch in OFF and ON
position.
and CN-T270 ON Max. 1 z
Defective caution buzzer • Remove the buzzer, then connect +24V to CN-CB (male) (1) and
2 (Internal disconnection or GND to CN-CB (male) (2).
short circuit)
Alarm buzzer sounds Alarm buzzer is normal
Alarm buzzer does not sound Defective alarm buzzer
Possible Disconnection in wiring without turning starting switch.
causes and harness
standard value 3 (Disconnection in wiring Max. 1 z
CB (male) (1) tance
in normal state harness or defective contact
in connector) Wiring harness between CN-CB (male) (2) Resis-
Max. 1 z
and CN-S03 (female) (18) tance
Between CN-T270 – CN-CB (male) (1) or
CN-S03 (female) (1) or (2) wiring harness Min. 1 Mz
and chassis ground
Between CN-CB (male) (2) – CN-S03
Resis-
tance
ground
5 Defective monitor panel CN-S03 Caution buzzer Voltage
Between (18) and Stopped 20 – 30 V
chassis ground Operated (Sounded) Max. 3 V
40-400 28
E-13 Caution buzzer does not sound or does not stop SEN04512-01
40-400 29
SEN04512-01 E-14 Reverse travel speed setting switch does not function
E-14 Reverse travel speed setting switch does not function 1
Trouble • Reverse travel speed setting switch does not function.

• If there is a short circuit in the reverse travel speed setting system, a failure code [DDDCKB] is dis-
Related played. No failure codes are displayed when other troubles occur, however.
information • Input state (ON/OFF) from reverse travel speed setting switch can be checked in monitoring mode.
(Controller: HST, Code: 40912-D-IN [16]: Deceleration (Left), [17]: Acceleration (Right))

Reverse travel speed
CN-REV (male) Resistance
setting switch
Defective reverse travel speed
setting switch Neutral, Higher speed
1 Min. 1 Mz
(Internal disconnection or Between (4) and (5) (Right)
short circuit) Lower speed (Left) Max. 1 z
Neutral, Lower speed
Min. 1 Mz
Between (5) and (6) (Left)
Higher speed (Right) Max. 1 z
Disconnection in wiring Wiring harness between CN-ST2 (female) Resis-
harness Max. 1 z
(35) and CN-REV (female) (4) tance
in connector) (25) and CN-REV (female) (6) tance
Possible
causes and Max. 1 z
standard value (10) and CN-REV (female) (5) tance
Between CN-ST2 (female) (35) – CN-REV
ground
Between CN-ST2 (female) (25) – CN-REV
Resis-
tance
ground
Reverse travel speed
CN-ST1, CN-ST2 Voltage
setting switch
Neutral, Higher speed
4 Defective HST controller Between CN-ST2 5 – 11 V
(Right)
(35) and CN-ST1 (10)
Lower speed (Left) Max. 1 V
Neutral, Lower speed
(Left)
(25) and CN-ST1 (10)
Higher speed (Right) Max. 1 V
40-400 30
E-14 Reverse travel speed setting switch does not function SEN04512-01
40-400 31
SEN04512-01 E-15 Shift mode switch does not function
E-15 Shift mode switch does not function 1
Trouble • Shift mode switch does not function.

• If there is a short circuit in the shift mode switch system, a failure code [DDT0L4] is displayed. No fail-
Related ure codes are displayed when other troubles occur, however.
information • Input state (ON/OFF) from shift mode switch can be checked in monitoring mode.
(Controller: HST, Code: 40913-D-IN [24]: Quick shift mode (Right), [25]: Variable shift mode (Left))

CN-MTS (male) Shift mode switch Resistance
Defective shift mode switch Center and quick shift
Min. 1 Mz
1 (Internal disconnection or Between (4) and (5) (Right)
short circuit) Variable shift (Left) Max. 1 z
Center and variable
Min. 1 Mz
Between (6) and (5) shift (Left)
Quick shift (Right) Max. 1 z
Disconnection in wiring Wiring harness between CN-ST2 (female) Resis-
harness Max. 1 z
(27) and CN-MTS (female) (4) tance
Possible harness or defective contact Max. 1 z
in connector) (37) and CN-MTS (female) (6) tance
causes and
standard value Max. 1 z
in normal state (10) and CN-MTS (female) (5) tance
Short circuit with chassis
Between CN-ST2 (female) (27) – CN-MTS Resis-
3 ground in wiring harness Min. 1 Mz
(female) (4) wiring harness and chassis ground tance
Between CN-ST2 (female) (37) – CN-MTS Resis-
Min. 1 Mz
(female) (6) wiring harness and chassis ground tance
CN-ST1, CN-ST2 Shift mode switch Voltage
Center and quick shift
4 Defective HST controller (Right)
(27) and CN-ST1 (10)
Variable shift (Left) Max. 1 V
Center and variable
shift (Left)
(37) and CN-ST2 (10)
Quick shift (Right) Max. 1 V
40-400 32
E-15 Shift mode switch does not function SEN04512-01
40-400 33
SEN04512-01 E-16 Buzzer cancel switch does not function
E-16 Buzzer cancel switch does not function 1
Trouble • Buzzer cancel switch does not function.

Related
information

Defective buzzer cancel CN-BUZ (male) Buzzer cancel switch Resistance
switch Neutral, U (Left) Min. 1 Mz
1
(Internal disconnection or Between (5) and (6)
short circuit) t (Right) Max. 1 z
Neutral, t (Right) Min. 1 Mz
Between (5) and (4)
U (Left) Max. 1 z
Disconnection in wiring Wiring harness between CN-S03 (female) Resis-
harness Max. 1 z
(17) and CN-BUZ (female) (6) tance
in connector) (16) and CN-BUZ (female) (4) tance
Max. 1 z
(5) (6)and CN-BUZ (female) (5) tance
Possible
causes and Between CN-S03 (female) (17) – CN-BUZ
standard value (female) (6) wiring harness and chassis Min. 1 Mz
in normal state ground
Between CN-S03 (female) (16) – CN-BUZ
Resis-
tance
ground
Short circuit with power
(female) (6) wiring harness and chassis Voltage Max. 1 V
4 source in wiring harness
ground
(female) (4) wiring harness and chassis Voltage Max. 1 V
ground
CN-S03 Buzzer cancel switch Voltage
5 Defective monitor panel Between (17) and Neutral, U (Left) Max. 1 V
ground t (Right) 20 – 30 V
Between (16) and Neutral, t (Right) Max. 1 V
ground U (Left) 20 – 30 V
40-400 34
E-16 Buzzer cancel switch does not function SEN04512-01
40-400 35
SEN04512-01 E-17 Information switch does not function
E-17 Information switch does not function 1
Trouble • Information switch does not function.

Related
information

CN-CUR (male) Information switch Resistance
Defective information switch
1 (Internal disconnection or Neutral, < (Left) Min. 1 Mz
Between (5) and (6)
short circuit) > (Right) Max. 1 z
Neutral, > (Right) Min. 1 Mz
Between (5) and (4)
< (Left) Max. 1 z
Disconnection in wiring Wiring harness between CN-S03 (female) Resis-
harness Max. 1 z
(15) and CN-CUR (female) (6) tance
in connector) (14) and CN-CUR (female) (4) tance
Possible
causes and Max. 1 z
standard value (3) (4) and CN-CUR (female) (5) tance
Between CN-S03 (female) (15) – CN-CUR
ground
Between CN-S03 (female) (14) – CN-CUR
Resis-
tance
ground
CN-S03 Information switch Voltage
4 Defective monitor panel Between (15) and Neutral, < (Left) 5 – 11 V
(3) (4) > (Right) Max. 1 V
Between (14) and Neutral, > (Right) 5 – 11 V
(3) (4) < (Left) Max. 1 V
40-400 36
E-17 Information switch does not function SEN04512-01
40-400 37
SEN04512-01 E-18 The fan cleaning does not operate or cannot be reset
E-18 The fan cleaning does not operate or cannot be reset 1
Trouble The fan cleaning does not operate or cannot be reset.

a This troubleshooting describes the procedures to be followed when the fan rotation selector switch is
abnormal.
• In case fan operation confirmation lamp correctly lights up and goes off by switch operation, but fan
does not reverse or reverses, carry out troubleshooting for failure codes [DW7BKA], [DW7BKB],
Related
[DW7EKY].
information
• If there is a short circuit in the fan rotation selector switch, a failure code [DD1NL4] is displayed. No
failure codes are displayed when other troubles occur, however.
• The input state (ON/OFF) from the rotation selector switch can be checked in the monitoring mode.
(Controller: HST, Code: 40913 D-IN, [26]: Reverse (Right), [27]: Forward (Left))
Cause Standard value when normal and remarks for troubleshooting

Fan rotation selector
CN-FAN (male) Resistance
Defective fan rotation selec- switch
tor switch Neutral, reverse
1 Min. 1 Mz
(Internal disconnection or (Right)
Between (4) and (5)
short circuit)
Forward (Left) Max. 1 z
Neutral, forward (Left) Min. 1 Mz
Between (6) and (5)
Reverse (Right) Max. 1 z
Disconnection in wiring harness Wiring harness between CN-ST2 (female) Resis-
Max. 1 z
(Disconnection in wiring har- (7) – CN-FAN (female) (4) tance
2
ness or defective contact in Wiring harness between CN-ST2 (female) Resis-
connector) Max. 1 z
(17) and CN-FAN (female) (6) tance
Possible
Wiring harness between CS-ST1 (female) Resis-
causes and Max. 1 z
standard value (10) and CN-FAN (female) (5) tance
Between CN-ST2 (female) (7) – CN-FAN
ground
Between CN-ST2 (female) (17) – CN-FAN
Resis-
tance
ground
and carry out troubleshooting ON.
Fan rotation selector
CN-ST1, CN-ST2 Voltage
switch
4 Defective HST controller Neutral, reverse
Between CN-ST2 (7) 5 – 11 V
(Right)
and CN-ST1 (10)
Forward (Left) Max. 1 V
Between CN-ST2 Neutral, forward (Left) 5 – 11 V
(17) and CN-ST1 (10) Reverse (Right) Max. 1 V
40-400 38
E-18 The fan cleaning does not operate or cannot be reset SEN04512-01
40-400 39
SEN04512-01 E-19 Backup alarm does not sound
E-19 Backup alarm does not sound 1
Trouble • Backup alarm does not sound.

• If there is a short circuit in the backup alarm system, a failure code [DV20KB] is displayed. No failure
Related codes are displayed when other troubles occur, however.
information • Output state (ON/OFF, voltage) to backup alarm buzzer can be checked in monitoring mode.
(Controller: HST, Code: 40918 D-OUT [5], Code: 70401 BACK ALARM)

harness
(18) and CN-14 (female) (1) tance
in connector) Wiring harness between CN-14 (female) (2) Resis-
Possible Max. 1 z
and chassis ground (CN-TG1) tance
causes and
standard value
in normal state
CN-ST3 PCCS lever Voltage
Neutral Max. 1 V
Between (18) and
chassis ground Reverse travel
20 – 30 V
position
If neither of causes 1 and 2 is the cause of the trouble, judge the
3 Defective backup alarm
backup alarm defective.
40-400 40
E-20 The horn does not sound or does not stop SEN04512-01
E-20 The horn does not sound or does not stop 1
Trouble • The horn does not sound or does not stop.

Related
information

1
CN-F01 (2A) (See cause 4)
Defective horn switch
2 (Internal disconnection or Terminal (switch) Horn switch Resistance
short circuit) OFF Min. 1 Mz
CN-T37 and CN-T38
ON Max. 1 z
Disconnection in wiring harness without turning starting switch.
(Disconnection in wiring har- Wiring harness between CN-F01 (2) and Resis-
3 Max. 1 z
Possible ness or defective contact in CN-T37 tance
causes and connector) Resis-
standard value Wiring harness between CN-T38 and CN-21 Max. 1 z
tance
in normal state
Between CN-F01 (2) – CN-T37 wiring har- Resis-
ness and chassis ground tance
Between CN-T38 – CN21 wiring harness Resis-
Min. 1 Mz
Short circuit with power and carry out troubleshooting.
5 source in wiring harness
(Contact with 24 V circuit) Between CN-T38 – CN21 wiring harness
Voltage Max. 1 V
and chassis ground
Defective horn If neither of causes 1 – 5 is the cause of the trouble, the horn may
6
(Internal defect) be defective.
40-400 41
SEN04512-01 E-21 Work equipment does not move
E-21 Work equipment does not move 1
Trouble • Work equipment does not move

• This troubleshooting procedure is for case where work equipment lock solenoid valve is not excited
Related
when work equipment lock lever is set in FREE position. (If work equipment does not move while work
information
equipment lock solenoid valve is excited, carry out troubleshooting "H-11. No work equipment moves".

Disconnection of fuse a If the fuse is broken, the circuit probably has a grounding fault,
1
(CN-F01 (3A)) etc. (See cause 7.)
Defective work equipment CN-PLS (male) Resistance
2 lock solenoid valve
(Internal defect) Between (1) and (2) 40 – 60 z
Between (1), (2) and chassis
Min. 1 Mz
ground
Work equipment lock lever
Defective work equipment CN-PSW (male) FREE LOCK
3 lock switch
(Upper position) (Lower position)
(Internal defect)
Between (A) and (C) Max. 1 z Min. 1 Mz
Between (A), (C) and
Min. 1 Mz Min. 1 Mz
chassis ground
Possible Defective installation of work Work equipment lock switch may be installed defectively. Check it
causes and 4
equipment lock switch directly (See Testing and adjusting).
standard value
in normal state
5
Disconnection in wiring Wiring harness between CN-F01 (3) and CN- Resis-
harness Max. 1 z
PSW (female) (A) tance
Wiring harness between CN-PSW (female) Resis-
in connector) (C) and CN-PSL (female) (1) tance
Wiring harness between CN-PSL (female) Resis-
Max. 1 z
(2) and chassis ground (CN-T35) tance
Short circuit with chassis Between CN-F01 (3) – CN-PSW (female) (A) Resis-
Min. 1 Mz
7 ground in wiring harness wiring harness and chassis ground tance
(Contact with ground circuit) Between CN-PSW (female) (C) – CN-PSL
Resis-
tance
ground
40-400 42
E-21 Work equipment does not move SEN04512-01
40-400 43
SEN04512-01 E-22 Headlamp or rear lamp does not light up
E-22 Headlamp or rear lamp does not light up 1
Trouble • Headlamp or rear lamp does not light up.

Related
information

Defective left headlamp
If only the left headlamp does not light up, it may have a bad contact
1 (Bad contact or breakage of
or a broken bulb. Check it directly.
bulb)
Defective center headlamp
If only the center headlamp does not light up, it may have a bad con-
tact or a broken bulb. Check it directly.
bulb)
Defective right headlamp
If only the right headlamp does not light up, it may have a bad con-
tact or a broken bulb. Check it directly.
bulb)
Defective left rear lamp
If only left rear lamp does not light up, cause may be defective con-
4 (Defective contact or broken
tact or broken bulb. Check them directly.
bulb)
Defective right rear lamp
If only right rear lamp does not light up, cause may be defective con-
5 (Defective contact or broken
tact or broken bulb. Check them directly.
bulb)
6
(CN-F01 (1)) (See Cause 12.)
Possible
causes and a Prepare with starting switch OFF, then carry out troubleshooting
standard value without turning starting switch.
in normal state CN-FWL (male) Working lamp switch Resistance
Defective working lamp switch
7 Between (5) and (6) F/R Max. 1 z
Between (5) and (6)
Neutral Min. 1 Mz
Between (5) and (4)
Between (5) and (4) F Max. 1 z
Defective headlamp relay and working lamp switch F and carry out troubleshooting.
8
(Internal defect) Replace headlamp relay (No. at right) with rear lamp
CN-54
relay. If headlamp becomes normal, relay is defective.
Defective rear lamp relay and working lamp switch F/R and carry out troubleshooting.
9
(Internal defect) Replace rear lamp relay (No. at right) with headlamp
CN-54B
relay. If rear lamp becomes normal, relay is defective.
10
(Internal disconnection) CN-WLD (male) Continuity
Between (2) and (1) Secured
40-400 44
E-22 Headlamp or rear lamp does not light up SEN04512-01

Wiring harness between CN-F01 (1) and CN- Resis-
Max. 1 z
54 (female) (1) tance
Max. 1 z
54B (female) (1) tance
Max. 1 z
FWL (female) (5) tance
Wiring harness between CN-FWL (female) Resis-
Max. 1 z
Max. 1 z
(6) and CN-54B (female) (5) tance
Max. 1 z
(4) and CN-WLD (female) (1) tance
Max. 1 z
(6) and CN-WLD (female) (2) tance
Wiring harness between CN-54 (female) (6) Resis-
Max. 1 z
and CN-FG (female) tance
Disconnection in wiring har- Wiring harness between CN-54B (female) Resis-
ness Max. 1 z
(6) and CN-FG (female) tance
11 (Disconnection in wiring har-
ness or defective contact in Max. 1 z
connector) and CN-LMP1 (female) (2) tance
Possible
causes and Max. 1 z
and CN-LMP2 (female) (2) tance
standard value
in normal state Wiring harness between CN-54 (female) (2) Resis-
Max. 1 z
Wiring harness between CN-FG (female) Resis-
Max. 1 z
Max. 1 z
Max. 1 z
Wiring harness between CN-54B (female) Resis-
Max. 1 z
(2) and CN-LMP3 (female) (2) tance
Wiring harness between CN-54B (female) Resis-
Max. 1 z
(2) and CN-LMP4 (female) (2) tance
Max. 1 z
Max. 1 z
Between CN-F01 (1) – CN-54 (female) (1) Resis-
Short circuit with chassis Min. 1 Mz
12 ground in wiring harness
(Contact with ground circuit) Between CN-F01 (1) – CN-54B (female) (1) Resis-
Min. 1 Mz
Between CN-F01 (1) – CN-FWL (female) (5) Resis-
Min. 1 Mz
40-400 45
SEN04512-01 E-22 Headlamp or rear lamp does not light up
40-400 46
E-23 Foot heater does not operate SEN04512-01
E-23 Foot heater does not operate 1
Trouble • Foot heater does not operate.

• This troubleshooting is for the case when the blower motor does not rotate. (When the blower motor
Related
rotates but air is not heated, hot water may not flow in from the engine. In this case, check the hot
information
water system.)

1
(CN-F01 (13)) (See Cause 6.)
CN-HET (male) Foot heater switch Resistance
Defective foot heater switch
2 Between (5) and (6) HI Max. 1 z
Between (5) and (6)
Neutral Min. 1 Mz
Between (5) and (4)
Between (5) and (4) LO Max. 1 z
Defective heater HI relay and set heater switch in HI position and carry out troubleshooting.
3
(Internal defect) Replace heater HI relay (No. at right) with heater LO
CN-HRH
relay. If heater HI becomes normal, relay is defective.
Possible a Prepare with starting switch OFF, then turn starting switch ON
causes and and set heater switch in LO position and carry out troubleshoot-
Defective heater LO relay ing.
standard value 4
(Internal defect)
in normal state Replace heater LO relay (No. at right) with heater HI
CN-HRL
relay. If heater LO becomes normal, relay is defective.
Max. 1 z
CN-HET (female) (5) tance
Disconnection in wiring har- Max. 1 z
CN-HEAT1 (female) (C) tance
ness
Wiring harness between CN-HET (female) Resis-
(4) and CN-AC8 (female) (2) tance
connector) Wiring harness between CN-HET (female) Resis-
Max. 1 z
Wiring harness between CN-HRL (female) Resis-
Max. 1 z
Wiring harness between CN-HRH (female) Resis-
Max. 1 z
40-400 47
SEN04512-01 E-23 Foot heater does not operate

Max. 1 z
HET (female) (2) tance
Max. 1 z
HRH (female) (2) tance
HRL (female) (2) tance
harness
(3) and CN-HEAT1 (female) (A) tance
harness or defective contact in
connector) Wiring harness between CN-HRL (female) Resis-
Max. 1 z
(3) and CN-HEAT1 (female) (B) tance
Max. 1 z
Possible
Wiring harness between CN-HRL (female) Resis-
causes and Max. 1 z
standard value (5) and CN-FG (female) tance
Between CN-F01 (13) – CN-HET (female) Resis-
Min. 1 Mz
(5) wiring harness and chassis ground tance
Between CN-F01 (13) – CN-HEAT1 (female) Resis-
Short circuit with chassis Min. 1 Mz
(C) wiring harness and chassis ground tance
(Contact with ground circuit) Between CN-HRH (female) (3) – CN-HEAT1
Resis-
(female) (A) wiring harness and chassis Min. 1 Mz
tance
ground
Between CN-HRL (female) (3) – CN-HEAT1
Resis-
(female) (B) wiring harness and chassis Min. 1 Mz
tance
ground
Defective heater unit If none of causes 1 – 6 is the cause of the trouble, the heater unit
7
(Internal defect) may be defective.
40-400 48
E-23 Foot heater does not operate SEN04512-01
40-400 49
SEN04512-01 E-24 Air conditioner does not operate
E-24 Air conditioner does not operate 1
Trouble (1) Air does not come out.

Related
information

1 If the fuse is broken, the circuit probably has a grounding fault, etc.
(CN-F01 (4))
Blower selector
CN-AC4 (male) Resistance
switch
OFF Min. 1 Mz
Defective blower selector Between (2) and (4)
HI Max. 1 z
switch
2 OFF Min. 1 Mz
(Internal disconnection or
Between (1) and (4)
short circuit) MID2 Max. 1 z
OFF Min. 1 Mz
Between (6) and (4)
MID1 Max. 1 z
OFF Min. 1 Mz
Between (3) and (4)
LO Max. 1 z
CN-ACR (male) Resistance
Between (1) and (2) Approx. 1.5 z
3 Defective resistor
Between (1) and (3) Approx. 3.8 z
Possible Between (1) and (4) Approx. 5.7 z
causes and
standard value a Prepare with starting switch OFF, then turn starting switch ON
in normal state and carry out troubleshooting.
4 Defective blower motor
When the air flow selector switch is set in the "LO" position, if the
blower motor rotates, the blower motor is normal.
Max. 1 z
AC4 (female) (4) tance
Max. 1 z
AC4 (female) (7) tance
Disconnection in wiring Wiring harness between CN-AC4 (female) Resis-
harness Max. 1 z
Wiring harness between CN-AC4 (female) Resis-
in connector) (1) and CN-AC6 (female) (5) tance
Max. 1 z
Max. 1 z
Max. 1 z
and CN-AC6 (female) (1) tance
If the cause is not found out, a mistake may be made in check of the
6 Mistake in checking trouble
trouble. In this case, carry out troubleshooting for "Air is not cooled".
40-400 50
E-24 Air conditioner does not operate SEN04512-01
Trouble (2) Air is not cooled.

Related
information

1 If the fuse is broken, the circuit probably has a grounding fault, etc.
(CN-F01 (4))
Defective blower selector
switch Blower selector
2 CN-AC4 (male) Resistance
(Internal disconnection or switch
Between (5) and (4)
Other than OFF Max. 1 z
Defective mode selector without turning starting switch.
switch CN-AC5 (male) Mode selector switch Resistance
3
short circuit COOL Min. 1 Mz
Between (1) and (3)
A/C Max. 1 z
a Prepare with starting switch OFF, then turn starting switch and
blower switch ON and carry out troubleshooting.
Defective heater mode relay
4 CN-ACR1 (male) Mode selector switch Voltage
(Contact side)
Between (87A) and
Other than HEAT 20 – 30 V
chassis ground
Defective compressor clutch without turning starting switch.
Possible
5 relay
causes and CN-ACR2 (male) Resistance
(Coil side)
standard value Between (86) and (85) 305 ± 15 z
in normal state
Defective compressor clutch without turning starting switch.
6 relay
CN-ACR2 (male) Resistance
(Contact side)
Between (30) and (87A) Max. 1 z
Defective condenser fan relay blower switch ON and carry out troubleshooting.
7
(Coil side) CN-ACR3 (male) Resistance
Between (86) and (85) 305 ± 15 z
Defective condenser fan relay
(Contact side)
Between (87) and
Other than HEAT 20 – 30 V
chassis ground
9 Defective condenser motor Turn blower switch ON and set mode selector switch in position
other than HEAT. If condenser motor rotates at this time, condenser
motor is normal.
Defective compressor
10 The compressor magnetic clutch may be defective. Check it directly
magnetic clutch
11 Defective compressor The compressor may be defective. Check it directly.
40-400 51

Possible Disconnection in wiring Max. 1 z
causes and harness
standard value 12 (Disconnection in wiring Max. 1 z
in normal state (5) and CN-AC6 (female) (4) tance
in connector) Wiring harness between CN-AC6 (female) Resis-
Max. 1 z
Max. 1 z
Trouble (3) Air is not heated

Related
information

Defective blower selector
switch Blower selector
1 CN-AC4 (male) Resistance
(Internal disconnection or switch
Between (5) and (4)
Other than OFF Max. 1 z
Defective mode selector without turning starting switch.
switch CN-AC5 (male) Mode selector switch Resistance
2
short circuit) COOL Min. 1 Mz
Between (1) and (4)
HEAT Max. 1 z
Defective speed regulator without turning starting switch.
Possible causes
switch
and standard 3 Temperature regula-
(Internal disconnection or CN-AC3 (male) Resistance
value in normal tor switch
short circuit)
state Between (A) and (C) Any position Max. 1 z
Defective heater mode relay without turning starting switch.
4
(Coil side) CN-ACR1 (male) Resistance
Between (86) and (85) 305 ± 15 z
Defective heater mode relay
(Contact side)
Between (87) and
HEAT 20 – 30 V
chassis ground
Defective A/C mode diode without turning starting switch.
6
(Internal disconnection) CN-AC9 (male) Continuity
40-400 52
E-24 Air conditioner does not operate SEN04512-01

Defective foot heater LO without turning starting switch.
7 diode
CN-AC8 (male) Continuity
Defective foot heater HI diode without turning starting switch.
8
(Internal disconnection) CN-AC7 (male) Continuity
Max. 1 z
Max. 1 z
Max. 1 z
Possible causes
and standard Wiring harness between CN-AC6 (female) Resis-
Max. 1 z
value in normal (10) and CN-AC5 (female) (3) tance
state Wiring harness between CN-AC1 (male) (5) Resis-
Max. 1 z
Disconnection in wiring har- Wiring harness between CN-AC1 (male) (6) Resis-
ness Max. 1 z
connector) (1) and CN-AC3 (female) (C) tance
Max. 1 z
(1) and CN-AC3 (female) (C) tance
Max. 1 z
(1) and CN-AC3 (female) (C) tance
Max. 1 z
(2) and CN-AC3 (female) (B) tance
Max. 1 z
(1) and CN-F01 (4) tance
Max. 1 z
Max. 1 z
(A) and CN-FG (female) tance
40-400 53
40-400 54
E-25 Windshield wiper and window washer do not operate SEN04512-01
E-25 Windshield wiper and window washer do not operate 1
Trouble (1) No windshield wipers and window washers do not operate.

Related
information

1
(CN-F01 (7), (8)) (See cause 3).
harness
Possible 2 (Disconnection in wiring Max. 1 z
Fuse (B) tance
causes and harness or defective contact
in connector) Wiring harness between CN-F01 (8) and Resis-
standard value Max. 1 z
in normal state Fuse (B) tance
Between CN-F01 (7) – Fuse (B) wiring har- Resis-
Between CN-F01 (8) – Fuse (B) wiring har- Resis-
Min. 1 Mz
40-400 55
SEN04512-01 E-25 Windshield wiper and window washer do not operate
Trouble (2) Front windshield wiper does not operate.

• If fuse (FUSE (5)) is broken, operations of both front windshield wiper and rear windshield wiper
Related
become defective.
information
• Carry out troubleshooting with front wiper switch ON.

Disconnection of fuse (FUSE
1 If fuse is broken, circuit probably has ground fault (See cause 6).
(5))
Defective front wiper motor CN-A23 Front wiper switch Voltage
2
(Internal defect)
Between (3) and (1) ON 20 – 30 V
If voltage is normal but wiper does not operate, motor is defective.
Defective front wiper switch CN-A14 (male) Front wiper switch Resistance
3
OFF Min. 1 Mz
Between (2) and (3)
ON Max. 1 z
Defective front wiper selector
4 Replace front wiper selector relay (Right No.) with
relay (Internal defect)
another relay. If front wiper becomes normal at this time, CN-A28
intermittent selector relay is defective.
causes and without turning starting switch.
standard value
Wiring harness between FUSE (5) and CN- Resis-
A14 (female) (3) tance
Wiring harness between CN-A28 (female) Resis-
Max. 1 z
(1) and CN-A14 (female) (2) tance
Disconnection in wiring Wiring harness between CN-A28 (female) Resis-
harness Max. 1 z
(2) and GND3 tance
harness or defective contact in Max. 1 z
connector) (3) and CN-A23 (female) (3) tance
Max. 1 z
Max. 1 z
Max. 1 z
(1) and GND1 tance
Between FUSE (5) – CN-A14 (female) (3) Resis-
Min. 1 Mz
40-400 56
Trouble (3) Rear windshield wiper does not operate (Continuous operation is defective).
• If fuse (FUSE (5)) is broken, operations of both front windshield wiper and rear windshield wiper
Related
become defective.
information
• Carry out troubleshooting with rear wiper switch ON.

Disconnection of fuse (FUSE If the fuse is broken, the circuit probably has a grounding fault, etc.
1
(5)) (See cause 6).
Defective rear wiper motor CN-A37 Rear wiper switch Voltage
2
(Internal defect)
Defective rear wiper switch CN-A12 (male) Rear wiper switch Resistance
3
OFF Min. 1 Mz
Between (2) and (3)
ON Max. 1 z
Defective rear wiper selector
4 Replace rear wiper selector relay (Right No.) with
relay (Internal defect)
another relay. If rear wiper becomes normal at this time, CN-A32
intermittent selector relay is defective.
causes and without turning starting switch.
standard value
Max. 1 z
Disconnection in wiring Wiring harness between CN-A32 (female) Resis-
harness Max. 1 z
(2) and GND3 tance
harness or defective contact in Max. 1 z
connector) (3) and CN-A37 (female) (3) tance
Max. 1 z
Max. 1 z
Max. 1 z
(1) and GND4 tance
Min. 1 Mz
40-400 57
Trouble (4) Right door wiper does not operate (Continuous operation is defective).
Related • If fuse (FUSE (6)) is broken, operations of both right door wiper and left door wiper become defective.
information • Carry out troubleshooting with right door wiper switch ON and intermittent switch OFF.

1
(6)) (See cause 7).
Defective right door wiper Right door wiper
2 motor CN-A17 Voltage
switch
(Internal defect)
3 switch CN-A13 (male) Resistance
switch
OFF Min. 1 Mz
Between (2) and (3)
ON Max. 1 z
Defective right door wiper
4 intermittent selector relay Replace right door wiper intermittent selector relay
(Internal defect) (Right No.) with another relay. If right door wiper
CN-A31
becomes normal at this time, intermittent selector relay
Possible is defective.
in normal state
5 intermittent relay Replace right door wiper intermittent relay (Right No.)
(Internal defect) with another relay. If right door wiper becomes normal at CN-A30
this time, intermittent relay is defective.
Max. 1 z
Max. 1 z
harness
(6) and GND3 tance
in connector) Wiring harness between CN-A30 (female) Resis-
Max. 1 z
Max. 1 z
Max. 1 z
Max. 1 z
(1) and GND7 tance
40-400 58

Possible without turning starting switch.
causes and Short circuit with chassis
standard value Between FUSE (6) – CN-A13 (female) (3) Resis-
in normal state wiring harness and chassis ground tance
Min. 1 Mz
40-400 59
Trouble (5) Right door wiper does not operate intermittently.

• Before carrying out troubleshooting, check that continuous operation is normal.
Related
• Carry out troubleshooting with right door wiper switch and intermittent switch ON.
information
• During intermittent operation, wiper stops for 5 seconds after each cycle of operation.

Defective intermittent switch CN-A11 (male) Intermittent switch Resistance
1
OFF Min. 1 Mz
Between (5) and (6)
ON Max. 1 z
2 intermittent selector relay Replace right door wiper intermittent selector relay
(Internal defect) (Right No.) with another relay. If right door wiper
CN-A31
becomes normal at this time, intermittent selector relay
is defective.
Possible Defective right door wiper and carry out troubleshooting.
causes and 3 intermittent relay Replace right door wiper intermittent relay (Right No.)
standard value (Internal defect) with another relay. If right door wiper becomes normal at CN-A30
in normal state this time, intermittent relay is defective.
harness
in connector) Wiring harness between CN-A31 (female) Resis-
Max. 1 z
(2) and GND3 tance
Max. 1 z
40-400 60
Trouble (6) Left door wiper does not operate (Continuous operation is defective).
Related • If fuse (FUSE (6)) is broken, operations of both right door wiper and left door wiper become defective.
information • Carry out troubleshooting with left door wiper switch ON and intermittent switch OFF.

1
(6)) (See cause 7).
Defective left door wiper
2 motor CN-A24 Left door wiper switch Voltage
(Internal defect) Between (3) and (1) ON 20 – 30 V
3 switch CN-A15 (male) Left door wiper switch Resistance
(Internal disconnection) OFF Min. 1 Mz
Between (2) and (3)
ON Max. 1 z
Defective left door wiper and carry out troubleshooting.
4 intermittent selector relay Replace left door wiper intermittent selector relay (Right
(Internal defect) No.) with another relay. If left door wiper becomes nor- CN-A27
mal at this time, intermittent selector relay is defective.
5 intermittent relay Replace left door wiper intermittent relay (Right No.) with
(Internal defect) another relay. If left door wiper becomes normal at this CN-A26
Possible
causes and time, intermittent relay is defective.
in normal state without turning starting switch.
Max. 1 z
Max. 1 z
harness
(6) and GND3 tance
connector) Wiring harness between CN-A26 (female) Resis-
Max. 1 z
Max. 1 z
Max. 1 z
Max. 1 z
(1) and GND6 tance
Min. 1 Mz
40-400 61
Trouble (7) Left door wiper does not operate intermittently.

• Before carrying out troubleshooting, check that continuous operation is normal.
Related
• Carry out troubleshooting with left door wiper switch and intermittent switch ON.
information
• During intermittent operation, wiper stops for 5 seconds after each cycle of operation.

Defective intermittent switch CN-A11 (male) Intermittent switch Resistance
1
OFF Min. 1 Mz
Between (5) and (6)
ON Max. 1 z
2 intermittent selector relay Replace left door wiper intermittent selector relay (Right
(Internal defect) No.) with another relay. If left door wiper becomes nor- CN-A27
mal at this time, intermittent selector relay is defective.
Possible 3 intermittent relay (Internal Replace left door wiper intermittent relay (Right No.) with
causes and defect) another relay. If left door wiper becomes normal at this CN-A26
standard value time, intermittent relay is defective.
in normal state
harness
connector) Wiring harness between CN-A27 (female) Resis-
Max. 1 z
(2) and GND3 tance
Max. 1 z
Short circuit with chassis without turning starting switch.
(Contact with ground circuit) Between FUSE (6) – CN-A11 (female) (5) Resis-
Min. 1 Mz
40-400 62
Trouble (8) Water does not come out from front window washer.
• Before carrying out troubleshooting, check that windshield wiper operates normally.
Related
information • If fuse (FUSE (5)) is broken, operations of both front window washer and rear window washer
become defective.

1
(5)) (See cause 5).
Defective front window
2 washer motor CN-362 Front wiper switch Voltage
(Internal defect) Between (1) and (2) ON (Wash position) 20 – 30 V
If voltage is normal but washer does not operate, motor is defective.
Defective front wiper switch CN-A14 (male) Front wiper switch Resistance
3
Possible (Internal disconnection)
causes and OFF Min. 1 Mz
Between (5) and (6)
standard value ON (Wash position) Max. 1 z
in normal state
Disconnection in wiring Wiring harness between FUSE (5) and CN- Resis-
harness Max. 1 z
connector) (6) and CN-362 (female) (1) tance
Max. 1 z
and GND8 tance
Min. 1 Mz
40-400 63
Trouble (9) Water does not come out from rear window washer.
Related
information • If fuse (FUSE (5)) is broken, operations of both front window washer and rear window washer
become defective.

1
(5)) (See cause 5).
Defective rear window washer
2 motor CN-364 Rear wiper switch Voltage
Defective rear wiper switch CN-A12 (male) Rear wiper switch Resistance
3
Possible (Internal disconnection)
causes and OFF Min. 1 Mz
Between (5) and (6)
in normal state
harness Max. 1 z
Max. 1 z
and GND8 tance
Min. 1 Mz
40-400 64
Trouble (10) Water does not come out from right door washer.
Related
information • If fuse (FUSE (6)) is broken, operations of both right door washer and left door washer become defec-
tive.

1
(6)) (See cause 5).
Defective right door washer Right door wiper
2 motor CN-363 Voltage
switch
(Internal defect)
Between (1) and (2) ON (Wash position) 20 – 30 V
Possible 3 switch CN-A13 (male) Resistance
switch
causes and (Internal disconnection)
standard value OFF Min. 1 Mz
Between (5) and (6)
in normal state ON (Wash position) Max. 1 z
harness Max. 1 z
in connector) (6) and CN-363 (female) (1) tance
Max. 1 z
and GND8 tance
Min. 1 Mz
40-400 65
Trouble (11) Water does not come out from left door washer.
Related
information • If fuse (FUSE (6)) is broken, operations of both right door washer and left door washer become defec-
tive.

1
(6)) (See cause 5).
Defective left door washer
2 motor CN-361 Left door wiper switch Voltage
3 switch CN-A15 (male) Left door wiper switch Resistance
Possible
(Internal disconnection) OFF Min. 1 Mz
causes and Between (5) and (6)
in normal state
Disconnection in wiring har- Wiring harness between FUSE (6) and CN- Resis-
ness Max. 1 z
Max. 1 z
and GND8 tance
Min. 1 Mz
40-400 66
40-400 67
SEN04512-01 E-26 KOMTRAX system does not operate normally
E-26 KOMTRAX system does not operate normally 1
Trouble KOMTRAX system does not operate normally.

• If KOMTRAX system administrator makes request for checking system on machine side for trouble,
carry out following troubleshooting.
Related
• Even if KOMTRAX system has trouble, it does not particularly appear on machine.
information
• LED display of KOMTRAX can be checked in monitoring mode, too.
(Controller: KOMTRAX, Code: 20300 - LED STATUS)
a) ORBCOMM specification KOMTRAX (TC301)

1 Defective power supply CN-G01 Signal Voltage
Between (39), (40) Constant power
20 – 30 V
and (37), (38) supply
a Start engine and carry out troubleshooting.
LED (1) Normal state
LED-C1 ON
Defective starting switch ACC troubleshooting.
2
signal and alternator R signal CN-G01 Signal Voltage
Between (36) and Starting switch
20 – 30 V
(37), (38) ACC supply
Between (28) and
Alternator R 20 – 30 V
(37), (38)
Possible and carry out troubleshooting.
causes and Defective starting switch C
standard value 3 CN-G01 Signal Voltage
signal
in normal state Between (27) and
Starting switch C 20 – 30 V
(37), (38)
a Turn starting switch ON and carry out troubleshooting.
LED-C4 ON
4 State of CAN connection
a Prepare with starting switch OFF and carry out troubleshooting.
CN-G01 (female) Signal Resistance
Between (7) and (8) CAN 40 – 80 z
Number of mails not
5 LED (7) Normal state
transmitted yet
7-segment 0–9
a Turn starting switch ON and carry out troubleshooting
6 State of positioning with GPS Dot ON

In an outdoor location within radio waves' penetration range, it
sometimes takes more than a minute from turning on of the starting
switch to completion of the positioning.
40-400 68
E-26 KOMTRAX system does not operate normally SEN04512-01
LED display unit G01 connector
LED lamps for CPU

1. LED-C1 (State of R or ACC signal)
2. LED-C1 (Starting output state)
3. LED-C1 (State of S-NET or C signal)
4. LED-C1 (CAN state)
5. LED-C1 (Download write state)
6. LED-C1 (Download write state)
7-segment and dot displays for CPU

7. 7 segments (Number of unsent mails)
8. Dot (GPS positioning state)
40-400 69
SEN04512-01 E-26 KOMTRAX system does not operate normally
b) GPRS specification KOMTRAX (TC530)

1 Defective power supply CN-CK0B Signal Voltage
Between (6), (7) and Constant power
20 – 30 V
(1), (2) supply
a Start engine and carry out troubleshooting.
LED-1 ON
Defective starting switch ACC troubleshooting.
2
signal and alternator R signal CN-CK0B Signal Voltage
Between (3) and Starting switch
20 – 30 V
(1), (2) ACC supply
Between (4) and
Alternator R 20 – 30 V
(1), (2)
Possible
in normal state Defective starting switch C
3 CN-CK0B Signal Voltage
signal
Between (11) and
Starting switch C 20 – 30 V
(1), (2)
a Prepare with starting switch OFF and carry out troubleshooting.
CN-CK0A (female) Signal Resistance
4 State of CAN connection
Between (10) and
CAN 40 – 80 z
(11)
Number of mails not
5 LED (5) Normal state
transmitted yet
7-segment 0–9
a Turn starting switch ON and carry out troubleshooting
6 State of positioning with GPS Dot ON

In an outdoor location within radio waves' penetration range, it
sometimes takes more than a minute from turning on of the starting
switch to completion of the positioning.
40-400 70
E-26 KOMTRAX system does not operate normally SEN04512-01
LED display unit CK0A, CK0B connector
LED for CPU

1. LED-1 (state of starting switch ACC signal and
alternator R signal)
2. LED-2 (lock)
3. LED-3 (state of starting switch and C signal)
4. LED-4 (state of CD line)
Segment and dot for CPU

5. 7 segment (number of emails not yet having
been sent)
6. Dot (state of GPS communication)
LED for KOMTRAX communication module

7. Power supply (state of GPRS module power
supply)
8. Start (state of GPRS module starting)
40-400 71
SEN04512-01
D31/37-22 Bulldozer
©2014 KOMATSU
All Rights Reserved
40-400 72
SEN04513-00
D31EX-22
D31PX-22
D37EX-22
D37PX-22
D31EX-22 60001 and up
D31PX-22 60001 and up
D37EX-22 60001 and up
D37PX-22 60001 and up
500 Troubleshooting of hydraulic and

mechanical system (H-mode)
Information in troubleshooting table................................................................................................................ 3
H-1 Right and left travel systems do not operate forward and in reverse (No travel systems operate) .......... 4
H-2 Right or left travel system does not operate forward and in reverse
(Only right or left travel system does not operate) ................................................................................... 6
H-3 Right or left travel system does not operate forward or in reverse (Only 1 system does not operate)..... 7
H-4 Speed or power of travel is low ................................................................................................................ 8
H-5 Gear is not shifted .................................................................................................................................... 9
H-6 Large shocks are made when machine starts and stops travel ............................................................. 10
H-7 Machine deviates largely during travel....................................................................................................11
H-8 Hydraulic drift of travel is large ............................................................................................................... 12
H-9 Engine stalls or engine speed lowers extremely during travel ............................................................... 13
H-10 Abnormal sound comes out from around HST pump and motor.......................................................... 14
H-11 Work equipment dose not operate at all............................................................................................... 15
H-12 Speed or power of whole work equipment is low ................................................................................. 16
H-13 Speed or power of lifting blade is low................................................................................................... 17
H-14 Speed or power of tilting blade is low................................................................................................... 18
H-15 Speed or power of angling blade is low................................................................................................ 19
H-16 Time lag in lifting blade is large ............................................................................................................ 20
H-17 Hydraulic drift of lifting blade is large.................................................................................................... 20
H-18 Hydraulic drift of tilting blade is large ................................................................................................... 20
H-19 Abnormal sound comes out from around work equipment pump and control valve ............................ 21
D31/37-22 40-500 1
500 Troubleshooting of hydraulic and mechanical system (H-mode)
SEN04513-00
H-20 HST oil temperature (Hydraulic oil temperature) rises too high ........................................................... 22
H-21 Fan speed is abnormal (High, low, or 0 rpm) ....................................................................................... 24
H-22 Abnormal sound is heard from around fan ........................................................................................... 25
40-500 2 D31/37-22
Information in troubleshooting table SEN04513-00
Information in troubleshooting table 1
a The following information is summarized in the

troubleshooting table. Before carrying out trou-
bleshooting, understand that information fully.
Contents of
Trouble which occurred in the machine
trouble
Related
Information related to the detected trouble or troubleshooting
information
Possible causes
and standard 2 Possible causes of trouble
<Contents of description>
value in normal (Given numbers are
• Standard value in normal state to judge possible causes
state reference numbers, which do
• Remarks on judgment
3 not indicate priority)
D31/37-22 40-500 3
SEN04513-00 H-1 Right and left travel systems do not operate forward and in reverse (No travel systems operate)
H-1 Right and left travel systems do not operate forward and in reverse
(No travel systems operate) 1
Contents of
• Right and left travel systems do not operate forward and in reverse (No travel systems operate).
trouble
• Check that the oil level in the hydraulic tank is normal before carrying out troubleshooting.
How to guess
• When fan is in fan cleaning mode, when turbocharger protect function works, or when error of action
code [E04] occurs, “N blinks” on gear speed display section and machine cannot travel even if travel
operation is performed.
1) If work equipment does not move and fan is stopped, HST pump may be stopped. Check for
Related cause 1.
information 2) When parking brake lever is set in FREE position, if charge pressure low caution is turned ON
and work equipment does not move and fan continues running at high speed, charge pressure
may be low. Check for causes 2, 3, 4 and 5.
3) When travel operation is performed, if relief sound is heard from HST pump and engine speed
lowers, parking brake in HST motor may not be released. Check for causes 6 and 7.
4) When travel operation is performed and machine is steered, if either track moves, HST pump
EPC connector may be connected wrongly. Check for cause 9.

1 Defect in rear damper The rear damper may have a defect in it. Check it directly.
2 Defect in charge pump The charge pump may have a defect in it. Check it directly.
The charge filter may be clogged. Check it directly. Clogging of the
3 Clogging of charge filter charge filter can be checked in the monitoring mode
(Controller: HST 40910-D-IN [3]).
a Prepare with engine stopped, then run engine at high idle, set
parking brake lever in FREE position, and carry out troubleshoot-
ing.
Monitor panel
HST charge circuit
Defective adjustment or (Real-time PCCS lever
pressure
malfunction of oil cooler monitoring mode)
4
bypass valve Controller: HST
Possible causes 3.23 ± 0.29 MPa
(charge safety valve) 91902-BRAKE Neutral
and standard {33 ± 3 kg/cm2}
value in normal PRESS
state If the oil pressure does not become normal after the adjustment, the
charge safety valve of the oil cooler bypass valve may have mal-
function or defect in it. Check the charge safety valve directly.
a Prepare with engine stopped, then run engine at high idle, per-
form travel operation, and carry out troubleshooting.
Monitor panel
HST charge circuit
(Real-time PCCS lever
pressure
Defective adjustment or monitoring mode)
5 malfunction of HST motor Controller: HST
(charge relief valve) 3.04 ± 0.49 MPa
91902-BRAKE Forward or reverse
{31 ± 5 kg/cm2}
PRESS
If the oil pressure does not become normal after the adjustment, the
charge relief valve of the HST motor may have malfunction or defect
in it. Check the charge relief valve directly.
40-500 4 D31/37-22
H-1 Right and left travel systems do not operate forward and in reverse (No travel systems operate) SEN04513-00

a Prepare with engine stopped, then run engine at high idle and
Parking brake
Parking brake lever Slow brake solenoid
Malfunction of parking brake solenoid valve output
and brake pedal valve output pressure
6 solenoid valve or slow brake pressure
solenoid valve Lever: Free position 3.23 ± 0.49 MPa 3.23 ± 0.49 MPa
Possible causes Pedal: Released {33 ± 5 kg/cm2} {33 ± 5 kg/cm2}
and standard Lever: Lock position 0 MPa 0 MPa
value in normal Pedal: Pressed fully {0 kg/cm2} {0 kg/cm2}
state
Wrong operation of towed The towed valve of 5-spool valve may be operated (changed over)
7
valve of 5-spool valve wrongly. Check it directly.
Defect in HST pump The pump unit of the HST pump may have a defect in it. Check it
8
(pump unit) directly.
Pair of RF and LR or LF and RR may be connected in reverse.
Wrong connection of HST Check that color bands of connectors are correct.
9
pump EPC connector • Color bands
LF: Yellow, RF: Green, LR: Red, RR: Blue
D31/37-22 40-500 5
H-2 Right or left travel system does not operate forward and in reverse (Only right or left travel system
SEN04513-00 does not operate)
H-2 Right or left travel system does not operate forward and in reverse
(Only right or left travel system does not operate) 1
Contents of • Right or left travel system does not operate forward and in reverse
trouble (Only right or left travel system does not operate).
Related
information

Malfunction of HST pump The servo valve of the HST pump (on 1 side) may be malfunction-
1
(servo valve) ing. Check it directly.
Wrong operation of HST The towed valve of the HST pump (on 1 side) may be operated
2
Possible causes pump (towed valve) (opened) wrongly. Check it directly.
and standard Defect in HST pump The pump unit of the HST pump (on 1 side) may have a defect in it.
3
value in normal (pump unit) Check it directly.
state Defect in HST pump The parking brake of the HST motor (on 1 side) may have a defect
4
(parking brake) in it. Check it directly.
Defect in HST motor The motor unit of the HST motor (on 1 side) may have a defect in it.
5
(motor unit) Check it directly.
6 Defect in final drive The final drive (on 1 side) may have a defect in it. Check it directly.
40-500 6 D31/37-22
H-3 Right or left travel system does not operate forward or in reverse (Only 1 system does not
operate) SEN04513-00
H-3 Right or left travel system does not operate forward or in reverse
(Only 1 system does not operate) 1
Contents of
• Right or left travel system does not operate forward or in reverse (Only 1 system does not operate).
trouble
• If this trouble occurs just after the initial adjustment of the pump, the pump may be adjusted wrongly.
In this case, perform the initial adjustment of the pump again.
(During idle travel: TUNING 1, 3001-F-PUMP LINE, 3002-R-PUMP LINE) or
(During actual travel: 3003-F-PUMP RUN1, 3004-R-PUMP RUN1, 3005-F-PUMP RUN2, 3006-R-
PUMP RUN2)
• HST pump capacity command value and HST pump EPC current command value can be checked in
Related
Controller: HST
information
Capacity command Current command
value value
Right forward 52404 52400 RF PUMP
Left forward 52405 52401 LF PUMP
Right reverse 52406 52402 RR PUMP
Left reverse 52407 52403 LR PUMP

a Prepare with starting switch ON, then run engine at high idle and
Monitor panel HST main circuit
PCCS lever
Malfunction of HST pump (Tuning mode) pressure
1
(safety-suction valve) 2.0 – 4.9 MPa
3016-STALL CHECK Neutral
{20 – 50 kg/cm2}
(Stall pressure test
mode) 39.2 – 45.1 MPa
Forward or Reverse
{400 – 460 kg/cm2}
Possible causes
and standard a Prepare with engine stopped, then run engine at high idle and
value in normal carry out troubleshooting.
state PCCS lever EPC valve output pressure
Malfunction of HST pump
2 F1 (Travel)
(EPC valve) Min. 1.0 MPa {Min. 10 kg/cm2}
N (Neutral) 0 MPa {0 kg/cm2}
R1 (Travel) Min. 1.0 MPa {Min. 10 kg/cm2}
The servo valve of the HST pump (on 1 side) may be malfunction-
3 ing.
(servo valve)
Check it directly.
Defect in HST pump The pump unit of the HST pump (on 1 side) may have a defect in it.
4
(pump unit) Check it directly.
D31/37-22 40-500 7
SEN04513-00 H-4 Speed or power of travel is low
H-4 Speed or power of travel is low 1
Contents of
• Speed or power of travel is low.
trouble
• If this trouble occurs just after the initial adjustment of the pump or motor, the pump may be adjusted
wrongly. In this case, perform the initial adjustment of the pump or motor again.
(TUNING 1 3001-F-PUMP LINE, 3002-R-PUMP LINE, 3024-MOTOR LINE)
• HST motor capacity command value and HST motor EPC current command value can be checked in
Related
information
Controller: HST
Motor capacity command value: 52300 MOTOR
Right motor EPC current command value: 52301 R MOTOR
Left motor EPC current command value: 52302 L MOTOR

The charge pump and engine front PTO may have a defect in it.
1 Defect in charge pump
Check it directly.
(Controller: HST, Code 40910-D-IN [3]).
ing.
Monitor panel
HST charge circuit
pressure
3
(charge safety valve) 3.23 ± 0.29 MPa
91902-BRAKE Neutral
{33 ± 3 kg/cm2}
PRESS
Possible causes a Prepare with engine stopped, then run engine at high idle, per-
and standard form travel operation, and carry out troubleshooting.
value in normal
Monitor panel
state HST charge circuit
pressure
{31 ± 5 kg/cm2}
PRESS
PCCS lever
5
3016-STALL CHECK Neutral
{20 – 50 kg/cm2}
(Stall pressure test
mode) 39.2 – 45.1 MPa
Forward or Reverse
{400 – 460 kg/cm2}
Loosened charged air cooler Clamp of charged air cooler piping may be loosened and air may be
6
piping leaking. Check piping directly.
40-500 8 D31/37-22
H-5 Gear is not shifted SEN04513-00
H-5 Gear is not shifted 1
Contents of
• When gear speed is set to 2nd or higher, travel speed is not increased.
trouble
• If gear stopped shifting just after initial adjustment of HST motor, perform initial adjustment again
since it may have been performed wrongly.
(TUNING 1: 3024-MOTOR LINE)
• HST motor capacity command value and HST motor EPC current command value can be checked in
Related
information
Controller: HST
Motor capacity command value: 52300 MOTOR
Right motor EPC current command value: 52301 R MOTOR
Left motor EPC current command value: 52302 L MOTOR

a Prepare with engine stopped, then carry out troubleshooting.
Output pressure of
Travel speed and
Travel mode right and left HST
travel condition
Possible causes motor EPC valves
and standard Malfunction of 5-spool valve Stop and travel in 1st
1 0 MPa {0 kg/cm2}
value in normal (HST motor EPC valve)
state 1.47 ± 0.49 MPa
Travel in 2nd
Quick shift mode {15 ± 5 kg/cm2}
2.16 ± 0.49 MPa
Travel in 3rd
{22 ± 5 kg/cm2}
2 Malfunction of HST motor HST motor may be malfunctioning. Check it directly.
D31/37-22 40-500 9
SEN04513-00 H-6 Large shocks are made when machine starts and stops travel
H-6 Large shocks are made when machine starts and stops travel 1
Contents of
• Large shocks are made when machine starts and stops travel.
trouble
Related
information

Defective air bleeding from
1 Air may be left in the servo valve of the HST pump. Bleed air again.
HST pump
Warm up the engine (to the green range of the HST oil
2 Low HST oil temperature thermometer).
Possible causes
and standard HST oil thermometer Green range
value in normal The initial adjustment of the pump may be defective. Adjust the
state pump again.
a If failure is still not corrected, adjust in fine Tuning mode.
Defective initial adjustment
3 Change of forward pump start adjustment value (Change right
of pump
and left sides simultaneously) 3037-F-PUMP MAP2
Change of reverse pump start adjustment value (Change right
and left sides simultaneously) 3038-R-PUMP MAP2
40-500 10 D31/37-22
H-7 Machine deviates largely during travel SEN04513-00
H-7 Machine deviates largely during travel 1
Contents of
• Machine deviates largely during travel.
trouble
Related
information

1
Wrong operation of HST The towed valve of the HST pump (on 1 side) may be operated
2
pump (towed valve) (opened) wrongly. Check it directly.
Defect in HST pump The pump unit of the HST pump (on 1 side) may have a defect in it.
3
(pump unit) Check it directly.
a Prepare with engine stopped, then carry out troubleshooting.
Output pressure of
Travel speed and
travel condition
motor EPC valves
Malfunction of 5-spool valve
4 (HST motor EPC valve) Stop and travel in 1st 0 MPa {0 kg/cm2}
1.47 ± 0.49 MPa
Travel in 2nd
2.16 ± 0.49 MPa
Travel in 3rd
{22 ± 5 kg/cm2}
Defect in HST pump The parking brake of the HST motor (on 1 side) may have a defect
5
(parking brake) in it. Check it directly.
Malfunction of HST motor The charge relief valve of the HST motor (on 1 side) may be mal-
6
Possible causes (charge relief valve) functioning. Check it directly.
and standard Defect in HST motor The motor unit of the HST motor (on 1 side) may have a defect in it.
7
value in normal (motor unit) Check it directly.
state Defective HST motor If failure code [DLM1KB], [DLM1MA], [DLM2KB], or [DLM2MA] is
8
(speed sensor) displayed, carry out troubleshooting for it.
HST pump
Initial adjustment of HST pump may have been performed wrongly.
Perform it again.
a If there is still travel deviation at low travel speed, adjust in fine
Defective initial adjustment tuning mode.
10
of HST pump Change of forward pump start adjustment value (Change right and
left sides separately) 3035-F-PUMP MAP1
Change of reverse pump start adjustment value (Change right and
left sides simultaneously) 3036-R-PUMP MAP1
Defective initial adjustment Initial adjustment of HST motor may have been performed wrongly.
11
of HST motor Perform it again.
• Prepare with starting switch ON, then carry out troubleshooting in
real-time monitoring mode.
Controller: HST
Defective adjustment of Monitoring code: 50303 S/T LEVER
12
steering lever
PCCS lever Stroke
Neutral 0 ±10%
If there is any abnormality, initialize steering lever.
D31/37-22 40-500 11
SEN04513-00 H-8 Hydraulic drift of travel is large
H-8 Hydraulic drift of travel is large 1
Contents of
• Hydraulic drift of travel is large.
trouble
Related
information

Monitor panel PCCS lever HST relief pressure
1 1.96 – 4.9 MPa
(safety-suction valve) Neutral
Stall pressure test {20 – 50 kg/cm2}
Possible causes mode [3016] 39.2 – 45.1 MPa
Forward and reverse
and standard {400 – 460 kg/cm2}
value in normal
Wrong operation of HST The towed valves of the HST pumps (on both sides) may be oper-
state 2
pump (towed valve) ated (opened) wrongly. Check it directly.
Defect in HST pump Oil may be leaking in the pump unit of the HST pump (on both
3
(pump unit) sides). Check the pump unit directly.
Malfunction of HST pump The neutral positions of the servo valves of the HST motors (on both
4
(servo valve) sides) may be adjusted wrongly. Check them directly.
Leakage in HST motor Oil may be leaking in the motor units of the HST motors (on both
5
(motor unit) sides). Check the motor units directly.
40-500 12 D31/37-22
H-9 Engine stalls or engine speed lowers extremely during travel SEN04513-00
H-9 Engine stalls or engine speed lowers extremely during travel 1
Contents of
• Engine stalls or engine speed lowers extremely during travel.
trouble
Related
information

PCCS lever EPC valve output pressure
1 F1 (Travel)
(EPC valve) Min. 1.0 MPa {Min. 10 kg/cm2}
N (Neutral) 0 MPa {0 kg/cm2}
R1 (Travel) Min. 1.0 MPa {Min. 10 kg/cm2}
2
Possible causes Defect in HST pump (pump The pump unit of the HST pump (on 1 side) may have a defect in it.
3
and standard unit) Check it directly.
value in normal a Prepare with engine stopped, then carry out troubleshooting.
state
Output pressure of
Travel speed and
travel condition
motor EPC valves
Malfunction of 5-spool valve Stop and travel in 1st
4 0 MPa {0 kg/cm2}
(HST motor EPC valve)
1.47 ± 0.49 MPa
Travel in 2nd
2.16 ± 0.49 MPa
Travel in 3rd
{22 ± 5 kg/cm2}
The motor unit of the HST motor (on one side) may have a defect in
Internal defect of HST motor
5 it.
(motor unit)
Check it directly.
D31/37-22 40-500 13
SEN04513-00 H-10 Abnormal sound comes out from around HST pump and motor
H-10 Abnormal sound comes out from around HST pump and motor 1
Contents of
• Abnormal sound comes out from around HST pump and motor.
trouble
Related
information

Low oil level in hydraulic tank The oil level in the hydraulic tank may be low or improper oil may be
1
or use of improper oil used. Check the oil directly.
Clogging of charge pump
2 The charge pump suction strainer may be clogged. Check it directly.
suction strainer
Loosening of charge pump
3 The charge pump suction piping may be loosened. Check it directly.
suction piping
The charge filter may be clogged. Check it directly.
5 Clogging of charge filter Clogging of charge filter can be checked in monitoring mode.
(Controller: HST, Code: 40910-D-IN [3])
ing.
Monitor panel
HST charge circuit
pressure
6
91902-BRAKE Neutral
{33 ± 3 kg/cm2}
PRESS
Possible causes charge safety valve of the oil cooler bypass valve may have mal-
and standard function or defect in it. Check the charge safety valve directly.
value in normal
state
Monitor panel
HST charge circuit
pressure
{31 ± 5 kg/cm2}
PRESS
8
Loosening of piping between The piping between the HST pump and HST motor may be loos-
9
HST pump and HST motor ened. Check it directly.
The motor unit of the HST motor may have a defect in it. Check it
Defect in HST motor directly.
10
(motor unit) Troubleshooting cannot be carried out since the defect is in the
motor unit.
HST pump
Loosened charged air cooler Clamp of charged air cooler piping may be loosened and air may be
12
piping leaking. Check piping directly.
40-500 14 D31/37-22
H-11 Work equipment dose not operate at all SEN04513-00
H-11 Work equipment dose not operate at all 1
Contents of
• Work equipment dose not operate at all.
trouble
How to guess
1) When the engine is started and the work equipment lock lever is set in the FREE position, if the
Related work equipment PPC lever does not hold itself in the FLOAT position, the PPC basic pressure
information may be low.If the fan is rotating at high speed at this time, the charge pressure may be low. Check
for 2, 3 and 4.If the fan is rotating at the normal speed, check for 5.
2) If the machine cannot travel and the fan is stopped, the HST pump may be stopped. Check for 1.
3) If the machine can travel but the fan is stopped, check for 6, 7 and 8.

1 Defect in rear damper The rear damper may have a defect in it. Check it directly.
The charge pump may have a defect in it.
2 Defect in charge pump
Check it directly.
3 Clogging of charge filter charge filter can be checked in the monitoring mode.
(Controller: HST, Code 40910-D-IN [3])
ing.
Monitor panel
HST charge circuit
Defective adjustment or (Real-time monitor- PCCS lever
pressure
malfunction of oil cooler ing mode)
4
91902-BRAKE Neutral
{33 ± 5 kg/cm2}
PRESS
If the oil pressure does not become normal after adjustment, the
Possible causes a Prepare with engine stopped, then run engine at high idle and
and standard carry out troubleshooting.
value in normal
Work equipment lock solenoid
state Work equipment lock lever
valve output pressure
Malfunction of 5-spool valve
5 (Work equipment lock LOCK 0 MPa {0 kg/cm2}
solenoid valve)
FREE 3.23 ± 0.49 MPa {33 ± 5 kg/cm2}
When the work equipment lock lever is set in the FREE position, if
the work equipment lock solenoid valve is not energized, carry out
troubleshooting for "Work equipment does not move" in the E-mode.
Defect in work equipment
6 The work equipment pump may have a defect in it. Check it directly.
pump
Malfunction of control valve The unload valve of the control valve may be malfunctioning. Check
7
(unload valve) it directly.
Work equipment pump relief
Blade control lever
Defective adjustment or mal- pressure
8 function of control valve Relieve blade circuit
(main relief valve) 27.4 ± 1.0 MPa {280 ± 10 kg/cm2}
(by lifting or tilting).
main relief valve may have a malfunction or a defect in it. Check the
main relief valve directly.
D31/37-22 40-500 15
SEN04513-00 H-12 Speed or power of whole work equipment is low
H-12 Speed or power of whole work equipment is low 1
Contents of
• Speed or power of whole work equipment is low.
trouble
Related
information

(Controller: HST, Code 40910-D-IN [3]).
ing.
Monitor panel
HST charge circuit
pressure
3
91902-BRAKE Neutral
{33 ± 3 kg/cm2}
Possible causes PRESS
and standard If the oil pressure does not become normal after the adjustment, the
value in normal charge safety valve of the oil cooler bypass valve may have mal-
state function or defect in it. Check the charge safety valve directly.
Defect in work equipment
4 The work equipment pump may have a defect in it. Check it directly.
pump
Malfunction of control valve The unload valve of the control valve may be malfunctioning. Check
5
(unload valve) it directly.
Blade control lever
Defective adjustment or pressure
6 malfunction of control valve Relief of blade circuit
(by lifting or tilting)
40-500 16 D31/37-22
H-13 Speed or power of lifting blade is low SEN04513-00
H-13 Speed or power of lifting blade is low 1
Contents of
• Speed or power of lifting blade is low.
trouble
Related
• Check that the blade has not been modified before carrying out troubleshooting.
information

Blade control lever PPC valve output pressure
Malfunction of boom PPC
1 Raising stroke end
valve (lift) Min. 1.65 MPa {Min. 16.8 kg/cm2}
Lowering position Min. 1.37 MPa {Min. 14.0 kg/cm2}
Floating stroke end Min. 2.01 MPa {Min. 21.0 kg/cm2}
Possible causes Malfunction of blade lift The spool of the blade lift control valve may be malfunctioning.
2
and standard control valve (spool) Check it directly.
value in normal Malfunction of blade lift
state control valve The pressure compensation valve of the blade lift control valve may
3
(pressure compensation be malfunctioning. Check it directly.
valve)
Malfunction of blade lift The suction valve of the blade lift control valve may be malfunction-
4
control valve (suction valve) ing. Check it directly.
5 Defect in blade lift cylinder
Blade lift cylinder Leakage from cylinder
Relief by lowering 6.6 cc/min
D31/37-22 40-500 17
SEN04513-00 H-14 Speed or power of tilting blade is low
H-14 Speed or power of tilting blade is low 1
Contents of
• Speed or power of tilting blade is low.
trouble
Related
information

Malfunction of boom PPC Blade control lever PPC valve output pressure
1
valve (tilt)
Left tilting stroke end Min. 1.72 MPa {Min. 17.5 kg/cm2}
Right tilting stroke end Min. 1.72 MPa {Min. 17.5 kg/cm2}
Possible causes Malfunction of blade lift con- The spool of the blade lift control valve may be malfunctioning.
and standard 2
trol valve (spool) Check it directly.
value in normal
state Malfunction of blade tilt
control valve The pressure compensation valve of the blade tilt control valve may
3
(pressure compensation be malfunctioning. Check it directly.
valve)
carry out troubleshooting
4 Defect in blade tilt cylinder
Blade tilt cylinder Leakage from cylinder
Relief by tilting right 6.6 cc/min
40-500 18 D31/37-22
H-15 Speed or power of angling blade is low SEN04513-00
H-15 Speed or power of angling blade is low 1
Contents of
• Speed or power of angling blade is low.
trouble
Related
information

Malfunction of boom PPC Blade control lever PPC valve output pressure
1
valve (angle)
Left angling stroke end Min. 1.96 MPa {Min. 20.0 kg/cm2}
Right angling stroke end Min. 1.96 MPa {Min. 20.0 kg/cm2}
Malfunction of blade angle The spool of the blade angle control valve may be malfunctioning.
Possible causes 2
control valve (spool) Check it directly.
and standard
value in normal Malfunction of blade angle
state control valve The pressure compensation valve of the blade angle control valve
3
(pressure compensation may be malfunctioning. Check it directly.
valve)
Malfunction of blade angle The safety valve of the blade angle control valve may be malfunc-
4
control valve (safety valve) tioning. Check it directly.
Malfunction of blade angle The suction valve of the blade angle control valve may be malfunc-
5
control valve (suction valve) tioning. Check it directly.
Defect in blade angle The blade angle cylinder may have a malfunction or a defect in it.
6
cylinder Check the blade angle cylinder directly.
D31/37-22 40-500 19
SEN04513-00 H-16 Time lag in lifting blade is large
H-16 Time lag in lifting blade is large 1
Contents of
• Time lag in lifting blade is large.
trouble
Related
information

and standard
value in normal Malfunction of blade lift con- The suction valve of the blade lift control valve may be malfunction-
1
state trol valve (suction valve) ing. Check it directly.
H-17 Hydraulic drift of lifting blade is large 1
Contents of
• Hydraulic drift of lifting blade is large.
trouble
Related
information

Defective seal of blade lift The seal of the blade lift control valve may be defective. Check it
Possible causes 1
control valve (spool) directly.
and standard
value in normal
Defective seal of blade lift carry out troubleshooting.
state 2
cylinder Blade lift cylinder Leakage from cylinder
Relief by lowering 6.6 cc/min
H-18 Hydraulic drift of tilting blade is large 1
Contents of
• Hydraulic drift of tilting blade is large.
trouble
Related
information

Defective seal of blade tilt The seal of the blade tilt control valve may be defective. Check it
Possible causes 1
control valve (spool) directly.
and standard
value in normal
Defective seal of blade tilt carry out troubleshooting.
state 2
cylinder Blade tilt cylinder Leakage from cylinder
Relief by tilting right 6.6 cc/min
40-500 20 D31/37-22
H-19 Abnormal sound comes out from around work equipment pump and control valve SEN04513-00
H-19 Abnormal sound comes out from around work equipment pump
and control valve 1
Contents of
• Abnormal sound comes out from around work equipment pump and control valve.
trouble
Related
information

1
Clogging of work equipment The work equipment pump suction strainer may be clogged. Check
2
pump suction strainer it directly.
Looseness of work The work equipment suction piping may be loosened. Check it
3
equipment suction piping directly.
Possible causes carry out troubleshooting.
and standard Work equipment pump relief
value in normal Blade control lever
state 4 malfunction of control valve Relief of blade circuit
Defect in work equipment The pump unit of the work equipment pump may have a defect in it.
5
pump (pump unit) Check it directly.
Loosening of piping between The piping between the HST pump and HST motor may be loos-
6
HST pump and HST motor ened. Check it directly.
D31/37-22 40-500 21
SEN04513-00 H-20 HST oil temperature (Hydraulic oil temperature) rises too high
H-20 HST oil temperature (Hydraulic oil temperature) rises too high 1
Contents of
• HST oil temperature (Hydraulic oil temperature) rises too high.
trouble
Related
information

1
Clogging of hydraulic oil The fins and cores of the hydraulic oil cooler may be clogged.
2
cooler Check them directly.
Monitor panel
HST charge circuit
pressure
{31 ± 5 kg/cm2}
PRESS
Possible causes PCCS lever
and standard 4
value in normal 3016-STALL CHECK Neutral
{20 – 50 kg/cm2}
state (Stall pressure test
mode) 39.2 – 45.1 MPa
Forward or Reverse
{400 – 460 kg/cm2}
5
Blade control lever
6 malfunction of control valve Relief of blade circuit
Defect in work equipment The pump unit of the work equipment pump may have a defect in it.
7
pump (pump unit) Check it directly.
Wrong installed direction of
8 See fan from rear of machine and check that its vanes are concave.
fan
Wrong installed direction of Open rear mask and see fan net on core side. Check that fan net is
9
fan net on upper side when triangular plate is closed. (See Fig. A.)
40-500 22 D31/37-22
H-20 HST oil temperature (Hydraulic oil temperature) rises too high SEN04513-00

If coolant temperature is too high, fan speed may be low.
Raise oil temperature to above 50°C and D31-22 1,800 rpm

check fan speed at high idle in fan 100%
mode. D37-22 2,000 rpm
a If the HST oil temperature is below 45°C and the engine coolant
temperature is below 60°C, the fan EPC command current
becomes 1,000 mA and the fan speed lowers below 200 rpm
even in the fan 100% mode. In this case, raise the oil temperature
to above 55°C and the coolant temperature to above 65°C and
Possible causes
then check again.
and standard
10 Low fan speed Tuning code:
value in normal Fan 100% mode
state 3032 – FAN MODE
Controller: HST
Fan speed Real-time monitoring code:
10007 (rpm) – FAN SPEED
If fan speed does not reach standard value in 1 minute, initialize fan.
Tuning code:
Initialization of fan
3030 – FAN AMP SET
Engine: High idle Oil temperature: 50 – 60°C
a If the fan speed cannot be set to the standard range by repeating
initialization, perform the troubleshooting for H-21.
11 Oil cooler bypass valve Oil cooler bypass valve may be malfunctioning. Check it directly.
Fig.A
1. Rear mask
2. Fan net
3. Triangular plate
D31/37-22 40-500 23
SEN04513-00 H-21 Fan speed is abnormal (High, low, or 0 rpm)
H-21 Fan speed is abnormal (High, low, or 0 rpm) 1
• Fan speed is abnormally high.

Contents of • Fan speed is not set to standard value in 1 minute after set in fan 100% mode.
trouble Standard value: 2,000 rpm (Oil temperature: Min. 50°C, Engine: High idle)
• While engine is running, fan is stopped (Failure code DLM3KB is indicated).
• If travel or work equipment is also abnormal, carry out troubleshooting for it first.
• When engine is started for the first time after hydraulic oil is replaced, fan speed may become high
momentarily. This phenomenon is not abnormal.
• Fan 100% mode Tuning code: 3032 – FAN MODE
• Fan speed Controller: HST, Real-time monitoring mode: 10007 (rpm) – FAN SPEED
Related • If the HST oil temperature is below 45°C and the engine coolant temperature is below 60°C, the fan
information EPC command current is set to 1,000 mA and the fan speed lowers below 200 rpm even in the fan
100% mode. In this case, raise the oil temperature to above 55°C and the coolant temperature to
above 65°C and then check again.
• HST oil temperature: Controller: HST, Real-time monitoring code: 04401 (°C) – HST TEMP.
• Engine coolant temperature: Controller: ENG, Real-time monitoring code: 04107 (°C) – COOLANT
TEMP.

Since fan may be initialized defectively, initialize it again.
1 Defective initialization of fan Tuning code 3033 – FAN AMP SET
Oil temperature 50 – 60°C, Engine: High idle
Malfunction of fan control Fan control valve (Fan EPC valve) may be malfunctioning. Check it
2
valve (Fan EPC valve) directly.
Malfunction of fan control
3 Fan control valve (Spool) may be malfunctioning. Check it directly.
Possible causes valve (Spool)
and standard Malfunction of fan control
value in normal Fan control valve (Pressure compensation valve) may be malfunc-
4 valve (Pressure compensa-
state tioning. Check it directly.
tion valve)
Malfunction of fan control Fan control valve (Safety valve) may be malfunctioning. Check it
5
valve (Safety valve) directly.
Malfunction of fan motor Fan motor (Directional spool) may be malfunctioning. Check it
6
(Directional spool) directly.
Malfunction of fan motor
7 Fan motor (Suction valve) may be malfunctioning. Check it directly.
(Suction valve)
8 Defect in fan motor Fan motor may have trouble in it. Check it directly.
40-500 24 D31/37-22
H-22 Abnormal sound is heard from around fan SEN04513-00
H-22 Abnormal sound is heard from around fan 1
Contents of
• Abnormal sound is heard from around fan.
trouble
Related • When work equipment is operated, click may be heard. This click is closing sound of suction valve in
information fan motor and does not indicate abnormality.

Fan may be unbalanced and vibrated by mud etc. sticking to inside
1 Vibration of ring fan
Possible causes of fan ring. Clean fan.
and standard Loosened fan or fan motor Fan or fan motor mounting area may be loosened and play may be
2
value in normal mounting area made. Check them directly.
state Interference of fan speed There may be interference between fan speed sensor and speed
3
sensor and shroud sensing plate or between shroud and fan. Check them directly.
4 Defect in fan motor Fan motor may have defect in it. Check it directly.
D31/37-22 40-500 25
SEN04513-00
D31/37-22 Bulldozer
©2008 KOMATSU
All Rights Reserved
40-500 26
SEN04514-01
D31EX-22
D31PX-22
D37EX-22
D37PX-22
D31EX-22 60001 and up
D31PX-22 60001 and up
D37EX-22 60001 and up
D37PX-22 60001 and up
600 Troubleshooting of engine (S-mode)

Method of using troubleshooting charts .......................................................................................................... 3
S-1 Starting performance is poor .................................................................................................................... 6
S-2 Engine does not start ............................................................................................................................... 7
S-3 Engine does not pick up smoothly.......................................................................................................... 10
S-4 Engine stops during operations ...............................................................................................................11
S-5 Engine does not rotate smoothly ............................................................................................................ 12
S-6 Engine lacks output (or lacks power) ..................................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion).................................................................................. 14
S-8 Oil consumption is excessive (or exhaust smoke is blue) ...................................................................... 15
S-9 Oil becomes contaminated quickly ......................................................................................................... 16
S-10 Fuel consumption is excessive............................................................................................................. 17
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 18
S-12 Oil pressure drops ................................................................................................................................ 19
S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 20
S-14 Coolant temperature becomes too high (overheating) ......................................................................... 21
S-15 Abnormal noise is made....................................................................................................................... 22
S-16 Vibration is excessive ........................................................................................................................... 23
D31/37-22 40-600 1
SEN04514-01
40-600 2 D31/37-22
Method of using troubleshooting charts SEN04514-01
Troubleshooting of engine (S-mode) 1
Method of using troubleshooting charts 1
The troubleshooting chart consists of the “ques-

tions”, “check items”, “causes”, and “troubleshoot-
ing” blocks.
The questions and check items are used to pinpoint
high probability causes by simple inspection or
from phenomena without using troubleshooting
tools.
Next, troubleshooting tools or direct inspection are
applied to check the narrowed causes in order from
the most probable one to make final confirmation
according to the troubleshooting procedure.
[Questions]:
Items to be drawn from the user or operator.
They correspond to A and B in the chart on the
right.
The items in A are basic ones.
The items in B can be drawn from the user or
operator, depending on their level.
[Check items]:
Items to be simply checked by the serviceman
to narrow down causes.
They correspond to C in the chart on the right.
[Causes]:
Items to be narrowed from the questions and
check items.
The serviceman narrows down the probable
causes from A, B, and C.
[Troubleshooting]:
Items to finally verify whether the narrowed
down causes are undoubtedly the real causes
using the troubleshooting tools and direct
inspections.
Items listed in the [Questions] and [Check items] or related to the [Causes] are marked with E, Q, or w.
E: Causes to be referred to for questions and check items
Q: Causes related to questions and check items
w: Causes highly probable among ones marked with Q
a When narrowing the “causes”, apply the items marked with w before those marked with Q.
When narrowing the causes, do not apply the items marked with E.
(If no items have other marks and the causes cannot be narrowed, however, you may apply them.)
D31/37-22 40-600 3
SEN04514-01 Method of using troubleshooting charts
<Example of troubleshooting> Exhaust smoke is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. 3 symptoms have
causal relationship with this problem: [Color of exhaust gas gradually became black], [Power was lost gradu-
ally], and [Air cleaner clogging caution lamp is flashing].
40-600 4 D31/37-22
Method of using troubleshooting charts SEN04514-01
If we look from these 3 symptoms to find the causes, we find that there is a relationship with 5 causes. Let us
explain here the method of using this causal relationship to pinpoint the most probable cause.
D31/37-22 40-600 5
SEN04514-01 S-1 Starting performance is poor
S-1 Starting performance is poor 1
General causes why starting performance is poor Causes

q Defective electrical system
Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap
Defective contact of valve and valve seat
Defective alternator (generator section)

q Insufficient supply of fuel
Defective alternator (regulator section)

q Insufficient intake of air
Stuck, seized supply pump plunger
Defective intake air heater system
Defective or deteriorated battery

q Improper selection of fuel
a The common rail fuel injection system (CRI) controls the
Clogged air cleaner element
Worn piston ring, cylinder

fuel injection timing electrically. Accordingly, even if the
starting operation is carried out, the engine may not start
until the crankshaft revolves 2 turns at maximum. This phe-
Clogged fuel filter
Defective injector
nomenon does not indicate a trouble, however.
Confirm recent repair history

Degree of use of machine Operated for long period E E E
Became worse gradually Q w w Q
Starting performance
Engine starts easily when warm w w
Questions
Non-specified fuel is being used Q Q Q

Replacement of filters has not been carried out according to Operation and
w w Q Q
Maintenance Manual
Oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor does not
indicate normally (if monitor is installed) w
During operation, charge level monitor indicates abnormal charge (if monitor is installed) w w
Dust indicator is red (if indicator is installed) w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w Q
When priming pump is operated, it makes no reaction or it is heavy w Q
Starting motor cranks engine slowly w
If air bleeding plug of fuel filter is removed, fuel does not
While engine is cranked flow out w
with starting motor,
If spill hose from injector is disconnected, little fuel spills w
Check items
When exhaust manifold is touched immediately after starting engine, temperature of w

some cylinders is low
Engine does not pick up smoothly and combustion is irregular Q Q w
There is hunting from engine (rotation is irregular) Q w Q
Blow-by gas is excessive w
Inspect air cleaner directly q

When compression pressure is measured, it is found to be low q q
When air is bled from fuel system, air comes out q
Inspect fuel filter directly q
Troubleshooting
Carry out troubleshooting according to code display “No-pressure feed by supply pump q
(*1)”
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
change q
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Is voltage 20 – 30 V between alternator terminal B and terminal E with Yes q
engine at low idle? No q
When specific gravity of electrolyte and voltage of battery are measured, they are low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
*1: Failure code of code display [CA559] and code [CA2249]
40-600 6 D31/37-22
S-2 Engine does not start SEN04514-01
S-2 Engine does not start 1
a) Engine does not turn Causes
Defective connection of battery terminal
Defective starting motor (motor section)

General causes why engine does not turn
q Seized parts inside engine
Defective or deteriorated battery
Defective steering circuit wiring

o See “S-4 Engine stops during operations”
q Defective electrical system (starting circuit)
Broken flywheel ring gear

Problem in drive devices on machine side
Defective battery relay

q
Defective safety relay

o Check them directly.

Questions
Degree of use of machine Operated for long period E E
Condition of horn when Horn does not sound Q Q w

starting switch is turned ON Horn volume is low w
Battery electrolyte is low w
Battery terminal is loose w
When starting switch is turned ON, there is no operating sound from battery relay Q w
When starting switch is turned to START, starting pinion does not move out Q Q w
Check items
Speed of rotation is low w

When starting switch is Makes grating noise w w
turned to START, starting
pinion moves out, but Soon disengages again w
Makes rattling noise and does not turn Q Q Q
Inspect flywheel ring gear directly q
Carry out troubleshooting in E-mode

There is not voltage (20 – 30 V) between battery relay terminal B and
q
terminal E
Troubleshooting
When terminal B and terminal C of starting switch are connected, q

engine starts
Turn starting switch OFF,
When terminal B and terminal C at safety relay outlet are connected,
connect cord, and carry out engine starts q
troubleshooting at ON
Even if terminal B and terminal C at safety relay outlet are connected,
q
engine does not start
When terminal at safety switch and terminal B at starting motor are q
connected, engine starts
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
D31/37-22 40-600 7
SEN04514-01 S-2 Engine does not start
b) Engine turns but no exhaust smoke comes out Causes
Defective operation of overflow valve (Does not close)

General causes why engine turns but no exhaust smoke comes
out
q Fuel is not being supplied

q Supply of fuel is extremely small
Defective common rail pressure limiter

q Improper selection of fuel (particularly in winter)
Seized, abnormally worn feed pump

Defective supply pump MPROP
Broken supply pump shaft
Insufficient fuel in tank
Defective fuel injector

Use of improper fuel
Clogged fuel filter

Questions
Exhaust smoke suddenly stopped coming out (when starting again) w Q w w E

Fuel other than specified one is used w
Non-specified fuel is being used w
w E Q
Maintenance Manual
When fuel tank is inspected, it is found to be empty w
Rust and water are found when fuel tank is drained Q E E E
When fuel filter is removed, there is not fuel in it w w
w
Check items
Fuel is leaking from fuel piping

If air bleeding plug of fuel filter is removed, fuel does not Q Q w Q
While engine is cranked with flow out
starting motor,
If spill hose from injector is disconnected, little fuel spills Q w w w Q

Inspect feed pump directly q
Troubleshooting
Carry out troubleshooting according to code display “No-pressure feed by supply q q

pump (*1)”
Carry out troubleshooting according to code display “Abnormality in supply pump IMV q
(*2)”
Inspect overflow valve directly q
Engine can be started in reduced cylinder mode q
Fuel flows out when pressure limiter return piping is disconnected q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Add
Remedy
*1: Failure code of code display [CA559] and [CA2249]

40-600 8 D31/37-22
S-2 Engine does not start SEN04514-01
c) Exhaust smoke comes out but engine does not start Causes
Worn dynamic valve system (Valve, rocker lever, etc.)

(fuel is being injected)
Defective coolant temperature sensor, wiring harness

General causes why exhaust smoke comes out but engine does
Leaking or clogged fuel system, entry of air

not start

q Lack of rotating force due to defective electrical system
Defective intake air heater system

Clogged injector, defective spray
Defective, deteriorated battery

Clogging of fuel filter

Use of improper fuel
Suddenly failed to start w w Q
Questions
Non-specified fuel is being used Q Q

Maintenance Manual w w

When engine is preheated or when temperature is low, preheating monitor does not
w
indicate normally
Dust indicator is red w
Air breather hole of fuel tank cap is clogged Q
Rust and water are found when fuel tank is drained w
When fuel filter is removed, there is not fuel in it w
Fuel is leaking from fuel piping w
Starting motor cranks engine slowly w
When engine is cranked, abnormal sound is generated around cylinder head w
Check items
If air bleeding plug of fuel filter is removed, fuel does not Q w

While engine is cranked with flow out
starting motor,
If spill hose from injector is disconnected, little fuel spills w
When exhaust manifold is touched immediately after starting engine, temperature of
some cylinders is low w

Inspect dynamic valve system directly q
When compression pressure is measured, it is found to be low q
q
Troubleshooting
When air is bled from fuel system, air comes out

Carry out troubleshooting according to code display “No-pressure feed by supply pump q
(*1)”
Engine can be started in reduced cylinder mode q
Coolant temperature gauge does not indicate normally q
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Remedy
D31/37-22 40-600 9
SEN04514-01 S-3 Engine does not pick up smoothly
S-3 Engine does not pick up smoothly 1
General causes why engine does not pick up smoothly Causes

Seized turbocharger, interference of turbocharger

q Defective condition of fuel injection

q Controller is controlling in derate mode

Clogged injector, defective spray
(limiting injection rate (output) because of an error in electrical system)

Improper valve clearance

Degree of use of machine Operated for long period E E E E
Questions
Engine pick-up suddenly became worse w Q Q Q

Non-specified fuel is being used w w w
Replacement of filters has not been carried out according to Operation and Maintenance
Manual w w

Rust and water are found when fuel tank is drained w
When exhaust manifold is touched immediately after starting engine, temperature of some
Q w
cylinders is low
Blue under light load w
Color of exhaust gas is
w Q w w
Check items
Black
When engine is cranked, interference sound is generated around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w
There is hunting from engine (rotation is irregular) Q Q Q

Troubleshooting
Inspect valve clearance directly q

When turbocharger is rotated by hand, it is found to be heavy q
Carry out troubleshooting according to code display “No-pressure feed by supply pump (*1)” q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change q
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Remedy
40-600 10 D31/37-22
S-4 Engine stops during operations SEN04514-01
S-4 Engine stops during operations 1
General causes why engine stops during operations Causes

Internal parts of engine seized
Broken dynamic valve system (valve, rocker arm, etc.)

q
Broken auxiliary equipment (pump, compressor, etc.)

q There is overheating
Defective engine controller power supply wiring

q Defective HST pump

Broken, seized piston, connecting rod

Broken, seized crankshaft bearing
Clogging feed pump gauze filter
Defective starting switch wiring

Leaking, clogged fuel piping
Broken, seized feed pump

Broken supply pump shaft
Broken, seized gear train
Defective HST pump

Abnormal noise was heard and engine w w w w Q w Q w w
stopped suddenly
w Q Q
Questions
Condition when engine Engine overheated and stopped

stopped
Engine stopped slowly w Q Q Q Q
There was hunting and engine stopped w Q Q Q Q Q Q
Non-specified fuel is being used Q Q Q Q
Replacement of filters has not been carried out according to Operation
and Maintenance Manual w w
Fuel level monitor indicates low level w
Rust and water are found when fuel tank is drained w w
Metal particles are found when oil pan is drained w w Q Q
Check items
Does not turn at all w w

When engine is cranked by Turns in opposite direction w
hand Moves by amount of gear backlash w w
Supply pump shaft does not turn w
Engine turns, but stops when load is applied to machine w

Carry out troubleshooting in H mode
Inspect piston, connecting rod directly q

Inspect crankshaft bearing directly q
Inspect gear train directly q
Troubleshooting

Inspect feed pump gauge filter directly q
Inspect feed pump directly q
Carry out troubleshooting according to code display “No-pressure feed q q
by supply pump (*1)”
Engine rotates when pump auxiliary equipment (pump, compressor, etc.) q
is removed
Check controller power supply wiring q
Check starting switch wiring q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Clean
Add
Remedy
D31/37-22 40-600 11
SEN04514-01 S-5 Engine does not rotate smoothly
S-5 Engine does not rotate smoothly 1
General causes why engine does not rotate smoothly Causes

q Air in fuel system
Clogged injector, defective spray (dirt in injector)
Defective Bkup speed sensor, wiring harness

q Defective speed sensor (Error at degree that it is not indicated)
Defective Ne speed sensor, wiring harness


Degree of use of machine Operated for long period E
Q Q
Questions
Occurs at a certain speed range

Occurs at low idle Q Q Q Q Q
Hunting
Occurs even when speed is raised Q Q Q
Occurs on slopes w
Replacement of filters has not been carried out according to Operation and Maintenance Manual w
Check items
Rust and water are found when fuel tank is drained Q


Troubleshooting

Carry out troubleshooting according to code display “Abnormality in Ne speed sensor (*1)” q
Carry out troubleshooting according to code display “Abnormality in Bkup speed sensor (*2)” q
Replace
Replace
Replace
Replace
Replace
Clean
Add
Remedy
*1: Failure code of code display [CA689]

*2: Failure code of code display [CA778]
40-600 12 D31/37-22
S-6 Engine lacks output (or lacks power) SEN04514-01
S-6 Engine lacks output (or lacks power) 1
General causes why engine lacks output Causes

Clogged injector, defective spray (dirt in injector)
Defective boost pressure sensor, wiring harness

Defective installation of boost pressure sensor
Defective drive of injector (signal, solenoid)



Air leakage from air intake piping

o See “S-14 Coolant temperature becomes too
Leaking, clogged fuel piping

high (Overheating)“

Clogged fuel spill piping


(limiting injection rate (output) because of an
error in electrical system)
(air leakage)
Suddenly Q w Q Q Q Q
Questions
Power was lost

Gradually Q Q Q Q Q Q
Non-specified fuel is being used Q Q Q
w w
Maintenance Manual
Oil must be added more frequently Q Q
Dust indicator is red w w
Output becomes insufficient after short stop of operation w
Black w w
When exhaust manifold is touched immediately after starting engine, temperature of
some cylinders is low w w
w
Check items
When engine is cranked, interference sound is generated around turbocharger

High idle speed is too high Q
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w Q Q
Engine does not pick up smoothly and combustion is irregular w w Q Q w
There is hunting from engine (rotation is irregular) Q Q Q Q Q
Blow-by gas is excessive w w

Inspect air intake piping directly q
When boost pressure is measured, it is found to be low q q q
Troubleshooting
Inspect fuel piping q

Inspect spill port check valve directly q
Carry out troubleshooting according to code display “No-pressure feed by supply q
pump (*1)”
When a cylinder is cut out for reduced cylinder mode operation, engine speed does q q
not change
Inspect charge pressure sensor mount directly q
Carry out troubleshooting according to code display “Abnormality in charge q
pressure sensor (*2)”
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Adjust
Clean
Clean
Remedy

D31/37-22 40-600 13
SEN04514-01 S-7 Exhaust smoke is black (incomplete combustion)
S-7 Exhaust smoke is black (incomplete combustion) 1
General causes why exhaust smoke is black Causes
Leakage of air between turbocharger and cylinder head



o See “S-14 Coolant temperature becomes too high
(Overheating)“

Improper fuel injection pressure

(limiting injection rate (output) because of an error in

Crushed, clogged muffler
Abnormally worn injector

Improper injection timing
electrical system)
Clogged, seized injector

Suddenly became black w w Q Q Q
w Q Q
Questions
Color of exhaust gas is Gradually became black

Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Air leaks between turbocharger and cylinder head, clamp is loosened w
Engine is operated in low-temperature mode at normal temperature Q Q Q
When exhaust manifold is touched immediately after starting engine, temperature of some Q w
cylinders is low
Check items

Pump relief speed is high (Fuel is injected excessively) Q
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q w
If spill hose from injector is disconnected, abnormally much fuel spills w

When turbocharger is rotated by hand, it is fount to be heavy q
Troubleshooting

When muffler is removed, exhaust sound improves q
Carry out troubleshooting according to code display “No-pressure feed by supply pump (*1)” q q
Carry out troubleshooting according to code display “Abnormality in coolant temperature q
sensor (*2)”
Confirm with INSITE or with monitoring function on applicable machine side q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Remedy

40-600 14 D31/37-22
S-8 Oil consumption is excessive (or exhaust smoke is blue) SEN04514-01
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1
General causes why oil consumption is excessive Causes

q Abnormal consumption of oil
Turbocharger
Oil leakage from oil pan, cylinder head, etc.

Worn, damaged valve (stem, guide, seal)
q Long-time operation of engine at low idle or high idle
(Do not run engine at idle for more than 20 minutes
Dust sucked in from intake system

continuously)
Clogged breather, breather hose

q External leakage of oil
Oil leakage from oil drain plug

Worn, damaged rear oil seal
q Wear of pats in lubrication system
Oil leakage from oil cooler
Oil leakage from oil piping

Worn seal at turbine end
Worn seal at blower end
Oil leakage from oil filter

Broken piston ring
Broken oil cooler

E E E E
Questions
Degree of use of machine Operated for long period

Oil consumption suddenly increased w Q
Oil must be added more frequently w Q
Oil becomes contaminated quickly Q Q w
Outside of engine is dirty with oil w w w w w
There are loose piping clamps in intake system w
Inside of turbocharger intake outlet pipe is dirty with oil w
Inside of turbocharger exhaust outlet pipe is dirty with oil Q w
Check items
There is oil in coolant w

Oil level in damper chamber is high w
Exhaust smoke is blue under light load w w
Excessive Q Q w w
Amount of blow-by gas
None w
When intake manifold is removed, dust is found inside q

When intake manifold is removed, inside is found to be dirty abnormally q
Troubleshooting
Excessive play of turbocharger shaft q q

Check breather and breather hose directly q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q q
There is external leakage of oil from engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
D31/37-22 40-600 15
SEN04514-01 S-9 Oil becomes contaminated quickly
S-9 Oil becomes contaminated quickly 1
General causes why oil becomes contaminated quickly Causes

q Entry of exhaust gas into oil due to internal wear
Clogged turbocharger lubrication drain tube

Defective seal at turbocharger turbine end
q Clogging of lubrication passage
q Use of improper fuel
q Use of improper oil
Clogged breather, breather hose

q Operation under excessive load
Defective oil filter safety valve

Worn valve, valve guide
Exhaust smoke is bad

Clogged oil cooler
Clogged oil filter
Questions

Metal particles are found when oil filter is drained Q Q w
Inside of exhaust pipe is dirty with oil w
Engine oil temperature rises quickly w
Check items

Black w
Excessive Q Q w Q
Amount of blow-by gas
None w
Excessive play of turbocharger shaft q

Troubleshooting
Check breather and breather hose directly q
See S-7
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
—
Remedy
40-600 16 D31/37-22
S-10 Fuel consumption is excessive SEN04514-01
S-10 Fuel consumption is excessive 1
General causes why fuel consumption is excessive Causes

q Leakage of fuel

q Defective condition of fuel injection (fuel pressure, injection timing)
q Excessive injection of fuel
Fuel leakage from fuel filter, piping, etc.
Defective common rail pressure

Fuel leakage inside head cover
Defective supply pump plunger
Defective operation of injector

Defective feed pump oil seal
Defective spray by injector
Improper injection timing

E E E
Questions

More than for other machines of same model Q Q Q Q
Condition of fuel Gradually increased Q Q
consumption
Suddenly increased Q Q
There is external leakage of fuel from engine w
Combustion is irregular w
Engine oil level rises and oil smells of diesel fuel w w
When exhaust manifold is touched immediately after starting engine, temperature of some
w
cylinders is low
Check items
Low idle speed is high Q

Pump relief speed is high Q
Black Q Q Q Q
White Q
Remove head cover and inspect directly q

Inspect feed pump oil seal directly q
Troubleshooting
Carry out troubleshooting according to code display “No-pressure feed by supply pump (*1)” q
If spill hose from injector is disconnected, much fuel spills q
Carry out troubleshooting according to code display “Abnormality in coolant temperature sensor q
(*2)”
Confirm with INSITE or with monitoring function on applicable machine side q q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy

D31/37-22 40-600 17
SEN04514-01 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
General causes why oil is in coolant Causes
q Internal leakage in lubrication system
Broken cylinder head, head gasket

q Internal leakage in cooling system
Broken oil cooler core, O-ring

Broken hydraulic oil cooler or
Cracks inside cylinder block
Holes caused by pitting
power train oil cooler

E E
Questions

Suddenly rose Q Q Q
Oil level
Gradually rose Q Q
Hard water is being used as coolant Q Q
Oil level has risen and oil is milky Q Q w
There are excessive air bubbles in radiator, coolant spurts back w
Check items
Hydraulic oil or power train oil side is milky w

When hydraulic oil or power train oil is drained, water is found w
Carry out troubleshooting

Pressure-tightness test of cylinder head shows there is leakage q
Troubleshooting
in H-mode
Inspect cylinder block directly q q
Pressure-tightness test of oil cooler shows there is leakage q

Replace
Replace
Replace
Replace
—
Remedy
40-600 18 D31/37-22
S-12 Oil pressure drops SEN04514-01
S-12 Oil pressure drops 1
General causes why oil pressure drops Cause

q Leakage, clogging, wear of lubricating system
Defective oil level sensor, defective wiring harness

q Defective oil pressure control
q Selection of oil by the temperature etc. specified in the Operation
Leaking, crushed, clogged hydraulic piping

and Maintenance is not observed.
q Deterioration of oil due to overheating
Clogged, broken pipe inside oil pan

Clogged strainer inside oil pan
Defective regulator valve

Worn bearing journal
Defective oil pump

Lack oil in oil pan
Clogged oil filter

Water, fuel in oil
Degree of use of
E E E
Questions
Operated for long period

machine
Oil level monitor indicates drop in oil pressure (when monitor is installed) Q w
Non-specified oil is being used Q Q
Replacement of filters has not been carried out according to Operation & Maintenance Manual w
indicates oil pressure drop at low idle w
Oil pressure moni- indicates oil pressure drop at low idle and high idle Q w w w Q
tor (when monitor
is installed) indicates oil pressure drop on slopes w
sometimes indicates oil pressure drop w Q
Oil level monitor indicates low amount of oil (when monitor is installed) w w
Oil level in oil pan is low w
There is crushing, external leakage from hydraulic piping w
Check items
Oil is cloudy white and smells of diesel oil w

Metal particles are found when oil in oil pan is drained w
Metal particles are found when oil inside oil filter is drained w Q
Metal particles are found in oil filter q

Troubleshooting
Check oil pan strainer and pipe directly q q

See S-13
Oil pump rotation is heavy, there is play q

Deterioration, damage of valve, spring in regulator valve q
Check oil filter directly q
When oil level sensor is replaced, oil level monitor displays normally q
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
—
Action
Add
D31/37-22 40-600 19
SEN04514-01 S-13 Oil level rises (Entry of coolant or fuel)
S-13 Oil level rises (Entry of coolant or fuel) 1
General causes why oil level rises Causes

q Coolant in oil (milky)
Defective seal of auxiliary equipment (pump, compressor)

q Fuel in oil (smells diluted diesel fuel)
a If oil is in coolant, carry out troubleshooting for “S-11 Oil is in coolant”
Broken oil cooler core, O-ring

Worn, damaged rear oil seal
Cracks inside cylinder block
Defects in supply pump

Broken injector, O-ring
Questions

Fuel must be added more frequently w w
Coolant must be added more frequently Q Q
There is oil in coolant Q Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q Q
When engine is started, drops of water come from muffler Q
When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles appears,
w Q
Check items
or coolant spurts back

Exhaust smoke is white Q
Oil level in damper chamber is low w
Oil level in hydraulic tank is low w

Remove injector and inspect O-ring. q
Troubleshooting
Inspect cylinder block directly q q

Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q
Remove and inspect supply pump directly q
Inspect seal of auxiliary equipment directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
40-600 20 D31/37-22
S-14 Coolant temperature becomes too high (overheating) SEN04514-01
S-14 Coolant temperature becomes too high (overheating) 1
General causes why coolant temperature becomes too high Causes

q Lack of cooling air (deformation, damage of fan)
Rise in power train oil temperature side

Defective radiator cap (pressure valve)
Defective coolant temperature gauge

q Drop in heat dissipation efficiency
Defective operation of thermostat

q Problem in coolant circulation system
Slipping fan belt, worn fan pulley

Clogged, crushed radiator fins
q Rise in oil temperature in power train
o Carry out troubleshooting in H-mode
Clogged, broken oil cooler

Clogged radiator core

Broken water pump
Lack of coolant
Questions
Sudden overheated Q w Q
Condition overheating
Always tends to overheat Q w w Q
Rises quickly Q w
Coolant temperature gauge
Does not go down from red range w
Coolant level in reservoir tank is low w
Engine oil level has risen, oil is milky w Q
Fan belt tension is low w
When fan pulley is turned, it has play w
Milky oil is floating on coolant w
There are excessive air bubbles in radiator, coolant spurts back w
Check items
When light bulb is held behind radiator core, no light passes through w
Radiator shroud, inside of underguard side are clogged with dirt or mud w w
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w
Power train oil temperature enters red range faster than engine coolant temperature w

Inspect cylinder block directly q Carry out troubleshooting in H-mode
Inspect oil cooler directly q
Troubleshooting
Temperature difference between upper and lower tanks of radiator is large q

When operation of thermostat is carried out, it does not open at cracking temperature q
Temperature difference between upper and lower tanks of radiator is slight q
Inspect radiator core directly q
When operation of radiator cap is carried out, its cracking pressure is low q
Inspect fan belt, pulley directly q
When coolant temperature is measured, it is found to be normal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Add
Remedy
D31/37-22 40-600 21
SEN04514-01 S-15 Abnormal noise is made
S-15 Abnormal noise is made 1
General causes why abnormal noise is made Causes

q Abnormality due to defective parts
Deformed cooling fan, loose fan belt, interference of fan belt

Defective inside of muffler (dividing board out of position)
q Abnormal combustion
Leakage of air between turbocharger and cylinder head

q Air sucked in from intake system
Improper fuel injection timing (abnormality in coolant

a Judge if the noise is an internal noise or an external
Broken dynamic valve system (valve, rocker arm)

Interference of turbocharger, seized turbocharger
temperature sensor, boost temperature sensor)

noise before starting troubleshooting.
a The engine is operated in the low-temperature mode
while it is not warmed up sufficiently. Accordingly, the
Excessive wear of piston ring, cylinder

engine sound becomes a little larger. This does not indi-
cate abnormality, however.
a When the engine is accelerated, it is operated in the
Excessive gear train backlash

acceleration mode and its sound becomes a little larger
Removed, seized bushing

Clogged, seized injector

for up to about 3 seconds. This does not indicate abnor-
Dirt caught in injector

mality, however.

Degree of use of machine Operated for long period E
Questions
Gradually occurred Q Q
Condition of abnormal noise
Suddenly occurred Q Q Q
Non-specified fuel is being used Q
Metal particles are found when oil filter is drained w w
Air leaks between turbocharger and cylinder head w
When engine is cranked, abnormal sound is generated around cylinder head w w
When engine is cranked, beat noise is generated around muffler w
Check items
When exhaust manifold is touched immediately after starting engine, temperature of w Q

some cylinders is low
Black Q w Q
Engine does not pick up smoothly and combustion is irregular w w
Abnormal noise is loud when engine is accelerated Q Q Q Q
When turbocharger is rotated by hand, it is found to be heavy q

When muffler is removed, abnormal noise disappears q
q
Troubleshooting
Inspect valve clearance directly

Inspect gear train directly q q
Inspect fan and fan belt directly q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
not change q q
Abnormal noise is heard only when engine is started q

Confirm with monitoring function q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Remedy
40-600 22 D31/37-22
S-16 Vibration is excessive SEN04514-01
S-16 Vibration is excessive 1
General causes why vibration is excessive Causes

q Defective parts (abnormal wear, breakage)
Improper fuel injection timing (abnormality in coolant temperature

q Misalignment between engine and drive device
q Abnormal combustion
a If abnormal noise is made and vibration is excessive, carry out trou-
Misalignment between engine and engine drive devices

bleshooting for “S-15 Abnormal noise is made”, too.
Stuck dynamic valve system (valve, rocker lever)
Loose engine mounting bolts, broken cushions

Worn main bearing, connecting rod bearing
Broken output shaft, parts in damper

sensor, boost temperature sensor)
Improper gear train backlash
Worn camshaft bushing
E E E
Questions

Suddenly increased Q Q
Condition of vibration
Gradually increased Q Q Q
Non-specified oil is being used Q Q
Metal particles are found when oil filter is drained w w
Metal particles are found when oil pan is drained w w
Oil pressure is low at low idle Q Q
Check items
Vibration occurs at mid-range speed Q Q

Vibration follows engine speed Q Q Q Q
Exhaust smoke is black w Q

Inspect main bearing and connecting rod bearing directly q
Troubleshooting
Inspect gear train directly q

Inspect camshaft bushing directly q
Confirm with monitoring function q
Inspect engine mounting bolts and cushions directly q
When alignment is checked, radial runout or facial runout is detected q
Inspect output shaft or inside of damper directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Remedy
D31/37-22 40-600 23
SEN04514-01
D31/37-22 Bulldozer
©2009 KOMATSU
All Rights Reserved
40-600 24
SEN04724-01
D31EX-22
D31PX-22
D37EX-22
D37PX-22
D31EX-22 60001 and up
D31PX-22 60001 and up
D37EX-22 60001 and up
D37PX-22 60001 and up
50 Disassembly and assembly 50
100 General information on disassembly

and assembly
How to read this manual ................................................................................................................................. 2
Coating materials list....................................................................................................................................... 4
Special tools list .............................................................................................................................................. 7
Sketches of special tools .............................................................................................................................. 10
D31/37-22 50-100 1
100 General information on disassembly and assembly
SEN04724-01 How to read this manual
How to read this manual 1 (Rev.2009.01)
1. Removal and installation of assemblies

Removal
Special tools q In “Removal” section, the work procedures,
q Special tools which are necessary for precautions and know-how to do the work, and
r e m o v a l o r i n s ta l l a t i o n o f pa r ts a r e the amount of oil and coolant to be drained are
described as A1,•••X1 etc. and their part descibed.
numbers, part names and quantities are q Common tools that are necessary for removal
described in the special tool list. are described as [1], [2]••• etc. and their part
q Also the following information is described numbers, part names and quantities are not
in the special tool list. described.
1) Necessity q Various symbols used in “Removal” section
t : Special tools that cannot be substi- are explained and listed below.
tuted and should always be used
q : Special tools that will be useful if avail- k : Precautions related to work safety
able and are substitutable with tools a: Guidance or precautions for the work
available on themarket. [*1] : This mark shows that instructions or precau-
2) Distinction of new and existing special tions for parts installation work are given in
tools “Installation” section.
N: Tools newly developed for this 6 : Amount of oil or coolant to be drained
model. They have a new part num- 4 : Weight of part or component
ber respectively.
R: Tools made available by redesign-
ing the existing tools which were Installation
developed for other models. Each q Unless otherwise instructed, installation of parts
of them has a new part number is to be done in the reverse order to removal.
assigned by setting forward the q Instructions and precautions for parts installa-
part number of the existing tool. tion is shown with the mark ([*1], [*2]...) which
Blank: Tools already available for other corresponds to the mark in “Removal” section.
models. They can be used without q Common tools that are necessary for installa-
any modification. tion are described as [1], [2]••• etc. and their
3) Circle mark Q in sketch column: part numbers, part names and quantities are
q The sketch of the special tool is pre- not described.
sented in the section of "Sketches of q Marks shown in the “Installation” section stand
special tools". for the following.
q Part No. of special tools starting with
79 T- - : k : Precautions related to work safety
* *** ****
means that they are not available a: Guidance or precautions for the work
from Komatsu Ltd. (i.e. tools to be 2 : Type of coating material
made locally). 3 : Tightening torque
5 : Amount of oil or coolant to be replemished
Sketches of special tools

q Various special tools are illustrated for the local
manufacture..
50-100 2 D31/37-22
How to read this manual SEN04724-01
2. Disassembly and assembly of assem-

blies
Special tools Disassembly

q Special tools which are necessary for dis- q In "Disassembly" section, the work procedures,
assembly and assembly of parts are precautions and know-how to do the work,and
described as A1, ••• X1 etc. and their part the amount of the oil and coolant drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for disas-
q Also the following information is described sembly are described as [1], [2]••• etc. and
in the special tool list. their part numbers, part names and quantities
1) Necessity are not described.
t : Special tools that cannot be substituted q The meanings of the symbols used in
and should always be used. “Disassembly”section are as follows.
q : Special tools that will be useful if avail-
able and are substitutable with tools k : Precautions related to work safety
available on the market. a: Guidance or precautions for the work
2) Distinction of new and existing special 6: Amount of oil or coolant drained
tools
N : Tools newly developed for this
model. They have a new part Assembly
number respectively. q In “Assembly” section, the work procedures,
R : Tools made available by redesign- precautions and know-how to do the work, and
ing the existing tools which were the amount of oil and coolant to be replenished
developed for other models. Each are described.
of them has a new part number q Common tools that are necessary for assem-
assigned by setting forward the bly are described as [1], [2]••• etc. and their
part number of the existing tool. part numbers, part names and quantities are
Blank : Tools already available for other not described.
models. They can be used without q The meanings of the symbols used in "Assem-
any modification. bly" section are as follows.
3) Circle mark Q in sketch column:
q The sketch of the special tool is pre- k : Precautions related to work safety
sented in the section of "Sketches of a: Guidance or precautions for the work
special tools". 2 : Type of coating material
q Part No. of special tools starting with 3 : Tightening torque
79 T- -
* *** **** : 5 : Amount of oil or coolant to be replenished
means that they are not available
from Komatsu Ltd. (i.e. tools to be
made locally). Sketches of special tools
q Various special tools are illustrated for the local
manufacture.
D31/37-22 50-100 3
SEN04724-01 Coating materials list
Coating materials list (Rev. 2009.02)1
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene, poly-
propylene, tetrafluoroethylene and vinyl chlo-
20 g Polyethylene
LT-1B 790-129-9050 ride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
tant sealant.
LG-6 790-129-9160 200 g Tube • Used to seal flange surfaces and threaded
portions.
Gasket sealant
• Used to seal oil pan, final drive case, etc.

• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9170 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
• Features: Silicon-based, heat and cold-resis-
LG-8
tant, vibration-resistant, impact-resistant seal-
ThreeBond 419-15-18131 100 g Tube
ant.
1207B
• Used to seal transfer case, etc.
• Used for rough surfaces such as the circle
LG-9 gear top seal which does not need to be
ThreeBond 790-129-9310 200 g Tube clamped, water resistance of the clearance at
1206D the welded area, etc.
• Can be coated with paint.
50-100 4 D31/37-22
Coating materials list SEN04724-01
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
LG-10 • Used as lubricant/sealant when the radiator
ThreeBond 790-129-9320 200 g Tube hoses are inserted.
Gasket sealant
1206E • Can be coated with paint.

LG-11 • Feature: Can be used together with gaskets.
ThreeBond 790-129-9330 200 g Tube • Used for covers of the transmission case and
1121 steering case etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
• Used to prevent scuffing and seizure of press-fit-
ted portions, shrink-fitted portions, and threaded
LM-P 09940-00040 200 g Tube
portions.
Molybdenum
• Used to lubricate linkages, bearings, etc.

lubricant
disulfide
• Spray type
• Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuff-
— 09995-00250 190 g Can
ing each other.
• Applicable for the propeller shaft splines, needle
bearings, pins and bolts of various links, etc.
• Feature: Seizure and scuffing prevention com-
prevention
compound
Seizure
pound with metallic super-fine-grain, etc.

LC-G
— — Can • Used for the mounting bolt in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the turbo-
charger, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI • Feature: Lithium grease with extreme pressure
SYG2-160LI
G0-LI Various Various lubrication performance.
SYGA-160CNLI
*: For cold district • General purpose type.
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
• Used for parts under heavy load.
Caution:
Molybdenum SYG2-400M 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like
disulfide grease SYG2-400M-A 400 g x 20 container swing circle bearings, etc. and spline.
LM-G (G2-M) SYGA-16CNM 16 kg Can • The grease should be applied to work equipment
pins at their assembly only, not applied for
greasing afterwards.
SYG2-400T-A • Seizure resistance, heat resistance and water

Hyper White
Grease
400 g Bellows-type resistance higher than molybdenum disulfide

Grease G2-T, SYG2-16CNT
container grease.
G0-T (*) SYG0-400T-A (*)
16 kg Can • Not conspicuous on machine since color is
*: For cold district SYG0-16CNT (*)
white.
Biogrease SYG2-400B
G2-B, G2-BT (*) SYGA-16CNB 400 g Bellows-type • Since this grease is decomposed by natural bac-
*: For use at high SYG2-400BT (*) container teria in short period, it has less effects on micro-
temperature and SYGA-16CNBT 16 kg Can organisms, animals, and plants.
under high load (*)
• Feature: Silicone grease with wide using tem-
G2-S perature range, high resistance to thermal-oxi-
ThreeBond — 200 g Tube dative degradation and performance to prevent
1855 deterioration of rubber and plastic parts.
• Used for oil seals of the transmission, etc.
• Feature: Urea (organic system) grease with heat
G2-U-S resistance and long life. Enclosed type.
427-12-11871 2 kg Can
ENS grease • Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
D31/37-22 50-100 5
SEN04724-01 Coating materials list
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
SUNSTAR • Used as primer for cab side.
Glass
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
container
580 SUPER facture)
SUNSTAR 417-926-3910
• Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 container
facture)
Adhesive for cab glass

SUPER
• Used as primer for painted surface on cab
SUNSTAR
Glass side.
Primer
PAINT PRIMER 22M-54-27230 20 ml

container (Using limit: 4 months after date of manu-
435-95
facture)
• Used as primer for black ceramic-coated
SUNSTAR
surface on glass side and for hard polycar-
GLASS
22M-54-27240 150 ml Can bonate-coated surface.
PRIMER
(Using limit: 4 months after date of manu-
435-41
facture)
SUNSTAR • Used as primer for sash (Almite).
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months after date of manu-
container
GP-402 facture)
SUNSTAR • “S” is used for high-temperature season
PENGUINE and “W” for low-temperature season as
Polyethylene
SEAL 580 417-926-3910 320 ml adhesive for glass.
container
SUPER “S” or (Using limit: 4 months after date of manu-
“W” facture)
Adhesive
• Used as adhesive for glass.

Sika Japan, Polyethylene
20Y-54-39850 310 ml (Using limit: 6 months after date of manu-
Sikaflex 256HV container
Adhesive for cab glass
facture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months after date of manu-
container
SEAL No. 2505 facture)
Caulking material
SEKISUI • Used to seal front window.

Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months after date of manu-
container
SEALANT facture)
• Used to seal joint of glasses.
GE TOSHIBA
Translucent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Using limit: 12 months after date of manu-
TOSSEAL 381
facture)
50-100 6 D31/37-22
Special tools list SEN04724-01
Special tools list 1
a Tools with part number 79QT-QQQ-QQQQ can not be supplied (they are items to be locally manufac-
tured).
a Necessity: t ........... Cannot be substituted, should always be installed (used)

q ............ Extremely useful if available, can be substituted with commercially available
part.
a New/Remodel: N............ Tools with new part numbers, newly developed for this mode.
R:........... Tools with upgraded part numbers, remodeled from items already available for
other models.
Blank: ... Tools already available for other models, used without any modification
a Tools marked Q in the Sketch column are tools introduced in special sketches (See “Sketches of special
tools”).
New/remodel
Necessity
Symbol
Sketch
Q'ty
Component Part number Part name Nature of work, remarks
1 795T-221-1010 Push tool t 1 N Q Installation of engine front seal

2 795-731-1100 Seal puller assembly q 1 Removal of engine rear seal
Removal and instal-
lation of engine A 3 795T-221-1020 Plate t 1 N Q
front seal
4 790-101-5421 Grip t 1 Installation of engine rear seal
5 01010-51240 Bolt t 1
791-830-1320 Rod t 1
01580-01613 Nut t 1
01643-31645 Washer t 1
Pulling out of planetary pinion
1 790-101-2540 Washer t 1 shaft
790-101-2102 Puller assembly t 1
790-201-2830 Spacer t 1
Disassembly and 790-101-1102 Hydraulic pump t 1
assembly of final J
Removal and installation of
drive assembly 2 791-427-1410 Wrench t 1 round nut
3 791-545-1510 Installer t 1 Installation of floating seal
4 797T-427-1120 Push tool t 1 Q Press fitting of outer bearing
5 791T-627-1360 Sleeve t 1 Q Press fitting of inner bearing
79A-264-0091 or
6 Commercially Push-pull scale t 1 Adjustment of bearing pre-load
available
Disassembly and 1 791T-430-3210 Push tool t 1 Q Press fitting of idler bushing
assembly of idler L
assembly 2 791-675-1510 Installer t 1 Installation of idler floating seal
D31/37-22 50-100 7
SEN04724-01 Special tools list
New/remodel
Necessity
Symbol
Sketch
Q'ty
Press fitting of track roller bush-

3 791T-430-3220 Push tool t 1 Q
ing
Disassembly and
Installation of track roller float-
assembly of track 4 791-651-1510 Installer t 1
roller assembly ing seal
Addition of oil and check for air
5 791-601-1000 Oil pump t 1 leakage
L Installation of carrier roller float-
6 791-430-3230 Installer t 1
ing seal
Disassembly and 7 791-415-5160 Sleeve t 1 Removal of carrier roller shaft
assembly of carrier
roller assembly 8 790-445-3370 Push tool t 1 Press fitting of ring
Press fitting of carrier roller
9 791T-B30-1110 Sleeve t 1 Q
bearing
791-685-8006 Compressor (B) t 1
790-201-2860 Spacer t 1
791-635-3160 Extension t 1 Removal and installation of
1
Cylinder recoil spring
790-101-1600 1
(686 kN {70 ton})
790-101-1102 Hydraulic pump t 1
Disassembly and 790-201-1702 Push tool kit 1
assembly of recoil M
spring assembly 790-201-1781 • Push tool t 1
2 Press fitting of bushing
790-101-5021 • Grip t 1
01010-50816 • Bolt t 1
790-201-1500 Push tool kit 1
790-201-1590 • Plate t 1 Press fitting of spacer and dust
3
790-101-5021 • Grip t 1 seal
01010-50816 • Bolt t 1
790-502-1003 Repair stand t 1
1 Fixing of hydraulic cylinder
Removal and installation of cyl-
2 790-330-1100 Wrench t 1
inder head
Removal and installation of tilt
790-302-1270 Socket t 1 cylinder piston nut (For width
across flats of 50 mm)
Disassembly and 3 Removal and installation of lift
assembly of and angle cylinder piston nut
hydraulic cylinder U 790-302-1390 Socket t 1 (For width across flats of
assembly 46 mm)
4 790-720-1000 Expander t 1 Expansion of piston ring
796-720-1640 Rubber band q 1 Contraction of lift and angle cyl-
inder piston ring (Piston outside
07281-00909 Clamp q 1 diameter: 70 – 80 mm)
5
796-720-1650 Rubber band q 1 Compression of tilt cylinder pis-
ton ring (Piston outside diame-
07281-01029 Clamp q 1 ter: 85 – 95 mm)
50-100 8 D31/37-22
Special tools list SEN04724-01
New/remodel
Necessity
Symbol
Sketch
Q'ty
790-201-1702 Push tool kit 1 Press fitting of bushing

For lift and angle cylinder bush-
790-201-1741 • Push tool t 1
ing inside diameter of 40 mm
6 For tilt cylinder bushing inside
790-201-1751 • Push tool t 1
diameter of 45 mm
790-101-5021 • Grip t 1
Disassembly and Press fitting of bushing
assembly of 01010-50816 • Bolt t 1
U
hydraulic cylinder 790-201-1500 Push tool kit 1 Press fitting of dust seal
assembly
For lift and angle cylinder seal
790-201-1550 • Plate t 1 outside diameter of 52 mm
7 For tilt cylinder seal outside
790-201-1560 • Plate t 1
diameter of 57 mm
790-101-5021 • Grip t 1
Press fitting of dust seal
01010-50816 • Bolt t 1
Removal and instal-
lation of operator X 1 793-498-1210 Lifter t 2 Installation of window glass
cab glass (stuck
glass)
D31/37-22 50-100 9
SEN04724-01 Sketches of special tools
Sketches of special tools 1
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
A1 Push tool
A3 Plate
50-100 10 D31/37-22
Sketches of special tools SEN04724-01
J4 Push tool
J5 Sleeve
D31/37-22 50-100 11
SEN04724-01 Sketches of special tools
L1 Push tool
L3 Push tool
50-100 12 D31/37-22
Sketches of special tools SEN04724-01
L9 Sleeve
D31/37-22 50-100 13
SEN04724-01
D31/37-22 Bulldozer
©2009 KOMATSU
All Rights Reserved
50-100 14
SEN04725-01
D31EX-22
D31PX-22
D37EX-22
D37PX-22
D31EX-22 60001 and up
D31PX-22 60001 and up
D37EX-22 60001 and up
D37PX-22 60001 and up

Removal and installation of fuel supply pump assembly ................................................................................ 2
Removal and installation of fuel injector assembly ......................................................................................... 5
Removal and installation of front seal assembly ............................................................................................. 8
Removal and installation of rear seal assembly............................................................................................ 10
Removal and installation of cylinder head assembly .................................................................................... 13
Removal and installation of engine and HST pump assembly...................................................................... 20
Removal and installation of front guard assembly ........................................................................................ 24
Removal and installation of radiator assembly ............................................................................................. 26
Removal and installation of hydraulic oil cooler assembly ............................................................................ 28
Removal and installation of aftercooler assembly......................................................................................... 30
Removal and installation of cooling fan and motor assembly ....................................................................... 32
Removal and installation of cooling fan drive motor assembly ..................................................................... 34
Removal and installation of fuel tank assembly ............................................................................................ 36
D31/37-22 50-200 1
SEN04725-01 Removal and installation of fuel supply pump assembly
Removal and installation of fuel

supply pump assembly 1
Removal
k Disconnect the cable from the negative (–)
terminal of the battery.
1. Close fuel stop valve (1).
2. Remove 2 hose clamps (2).
3. Disconnect fuel return tube (3) from the fuel fil-

ter.
4. Disconnect engine oil filler tube clamp (4).

a Loosen the mounting nut which is secur- 10. Loosen sleeve nuts (11) and (12) and remove
ing the tube to the cylinder block. high-pressure pipe (13). [*2]
5. Remove mounting bolt (5) and remove engine 11. Remove the pin and disconnect spill hose (14).
oil filler tube (6) from bracket (7).
12. Remove joint bolts (15), (16) and (17) and
6. Remove bracket (7). remove fuel tubes (18) and (19). [*3]
7. Disconnect wiring harness connector (8).
8. Disconnect 2 wiring harness clamps (9).
9. Remove boots (10) from the supply pump and

common rail. [*1]
50-200 2 D31/37-22
Removal and installation of fuel supply pump assembly SEN04725-01
13. Remove fuel return hose clamp (20) and fuel 15. Disconnect the supply pump assembly from
return tube (3). the supply pump gear according to the follow-
ing procedure.
1) Loosen nut (24) and pull out supply pump
gear (25) with gear puller [1]. [*5]
14. Remove the supply pump and pump holder

assembly according to the following proce-
dure.
1) Remove 4 mounting bolts (21) from the 2) Remove 3 nuts (26) and remove supply
gear case. pump (27) from pump holder (28).
2) Fully loosen mounting bolt (22) on the
pump holder side. [*4]
a Mounting bolt (22) cannot be
removed from between the supply
pump and pump holder at this time.
3) Remove supply pump and pump holder
assembly (23).
D31/37-22 50-200 3
SEN04725-01 Removal and installation of fuel supply pump assembly
Installation [*4]
q Carry out installation in the reverse order to a Install M6 supply pump mounting bolts (22)
removal. coated with LT-2.
a When reusing bolts (22), apply adhesive to
[*1] their threaded portions.
k Direct the slit of each boot out and down. 2 Supply pump mounting bolt:
a The boots are installed so that fuel will not Adhesive (LT-2)
spout over the hot parts of the engine to catch
fire when it leaks for some reason. [*5]
3 Pump gear mounting nut:
[*2] 65 – 75 Nm {6.6 – 7.6 kgm}
k Do not bend the fuel high-pressure pipe to
collect before installing.
k Be sure to use the genuine fuel high-pres-
sure pipe clamps and observe the tighten-
ing torque.
k After installing the high-pressure pipe, be
sure to install the boots to the sleeve nuts.
a Before installing the high-pressure pipe, check
it for the following defects. If there is any of
these defects, it can cause fuel leakage.
Accordingly, replace the high-pressure pipe.
q Check the taper seal of the connecting
part (Part [a]: Part of 2 mm from the end)
for visible lengthwise slit [b] and dent [c].
q Check part [d] (End of the taper seal: Part
at 2 mm from the end) for stepped-type
wear (fatigue) which your nail can feel.
3 Sleeve nut on common rail side:

25.5 – 29.4 Nm {2.6 – 3.0 kgm}
3 Sleeve nut on supply pump side:
18 – 23 Nm {1.9 – 2.3 kgm}
50-200 4 D31/37-22
Removal and installation of fuel injector assembly SEN04725-01
Removal and installation of fuel 4. Remove the air conditioner compressor

injector assembly 1
(Air conditioner installation specification)
Removal 1) Disconnect engine oil filler tube clamp
k Disconnect the cable from the negative (–) (3a).
terminal of the battery. 2) Disconnect 4 air conditioner hose clamps
(3).
1. Close fuel stop valve (1). 3) Remove air conditioner compressor (4)
and bracket (5) together.
2. Remove the front guard assembly. For details,

see "Removal and installation of front guard 5. Remove electrical intake air heater relay
assembly". assembly (6) and bracket (7) together from
muffler mounting bracket (8).
3. Remove muffler assembly (2).
6. Remove muffler mounting bracket (8).
7. Remove the fuel filter assembly according to

1) Disconnect 2 fuel hose clamps (9).
2) Remove 2 mounting bolts (10) and fuel fil-
ter assembly (11).
D31/37-22 50-200 5
SEN04725-01 Removal and installation of fuel injector assembly
8. Remove bracket (12). 3) Remove pin (17) and disconnect spill hose
(18).
9. Disconnect atmospheric pressure sensor (13). 4) Loosen sleeve nuts (19) on the injector
side and common rail side and remove
10. Disconnect 4 fuel injector wiring harness con- high-pressure pipe (20). [*2]
nectors (14).
a Disconnect the wiring harness clamps and
move them aside so that they will not be
obstacles.
12. Remove the fuel injector assembly according

to the following procedure. [*3]
1) Remove holder mounting bolt (21) and
holder (22).
11. Remove the high-pressure pipes according to 2) Remove injector assembly (23).
(The removal procedure for the No. 1 cylinder
injector assembly is shown below as an exam-
ple.)
1) Remove high-pressure pipe clamp (15).
2) Remove boots (16) from the injector and
common rail. [*1]
50-200 6 D31/37-22
Removal and installation of fuel injector assembly SEN04725-01
Installation [*3]
q Carry out installation in the reverse order to a If the injector assembly was removed, be sure
removal. to replace seal (24) and gasket (25) with new
ones.
[*1]
k Direct the slit of each boot out and down. q Installation procedure for injector assembly
a The boots are installed so that fuel will not 1) Install seal (24) to injector assembly (23).
spout over the hot parts of the engine to catch 2) Install gasket (25) to injector assembly
fire when it leaks for some reason. (23).
3) Insert injector assembly (23) in the cylin-
[*2] der head.
k Do not bend the fuel high-pressure pipe to a After installing the gasket to the injec-
collect before installing. tor, check that it will not fall by its
k Be sure to use the genuine fuel high-pres- weight before inserting the injector.
sure pipe clamps and observe the tighten- 4) Install holder (22) to injector assembly
ing torque. (23).
k After installing the high-pressure pipe, be 5) Tighten holder (22) with injector mounting
sure to install the boots to the sleeve nuts. bolt (21).
a Before installing the high-pressure pipe, check a Before tightening the bolt, ensure that
it for the following defects. If there is any of holder (22) is fitted to groove (e) of
these defects, it can cause fuel leakage. the injector assembly.
Accordingly, replace the high-pressure pipe. 3 Holder mounting bolt:
q Check the taper seal of the connecting 27– 30 Nm {2.8 – 3.1 kgm}
3 Sleeve nut: 25.5 – 29.4 Nm {2.6 – 3.0 kgm}
D31/37-22 50-200 7
SEN04725-01 Removal and installation of front seal assembly
Removal and installation of front 7. Remove bracket (12).

seal assembly 1
Special tools
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
A 1 795T-221-1010 Push tool t 1 N Q
Removal
1. Remove covers (1) and (2).
8. Loosen alternator fixing bolt (13) and alternator

drive belt tension adjustment bolt (14).
9. Remove alternator drive belt (15). [*1]
10. Remove crankshaft pulley mounting bolt (16)

and remove crankshaft pulley (17). [*2]
2. Disconnect wiring connector (3).
3. Remove buzzer assembly (4).
4. Disconnect engine controller wiring connectors

(5) – (7).
5. Remove engine controller assembly (8) and

bracket (9) together. 11. Remove front oil seal (18). [*3]
50-200 8 D31/37-22
Removal and installation of front seal assembly SEN04725-01
Installation
q Carry out installation in the reverse order to
removal.
[*1]
a For adjustment of the alternator drive belt ten-
sion, see Testing and adjusting, "Adjusting
alternator drive belt tension".
[*2]
3 Crankshaft pulley mounting bolt:
343 – 402 Nm {35 – 41 kgm}
[*3]
q Using tool A1 (Outside diameter: 80 mm),
press fit front oil seal (18) to gear case (19).
a Before installing the oil seal, check that the
crankshaft end corners and oil seal lip sliding
surface are free from flaws, burrs, rust, etc.
a Fill the space between the oil seal lips with
grease of about 2 cc.
2 Front oil seal: Grease (G2-LI)
a Install the oil seal so that it will be flush with the
front side of the front cover.
D31/37-22 50-200 9
SEN04725-01 Removal and installation of rear seal assembly
Removal and installation of rear 2) Sling flywheel cover (2).

seal assembly 1
3) Remove bolts left installed (3).
4) Using forcing screws [1], disconnect fly-
Special tools wheel cover (2) from the flywheel housing.
5) Lift off flywheel cover (2).
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
Seal puller
2 795-731-1100 q 1
assembly
A 795T-221-1020 Plate t 1 N Q
3 790-101-5421 Grip t 1
01010-51240 Bolt t 1
Removal
terminal of the battery. 4. Remove 8 coupling mounting bolts (4) and
coupling (5).
1. Remove the engine and HST pump assembly.
For details, see "Removal and installation of
engine and HST pump assembly".
2. Disconnect engine and HST pump assembly

(1).
5. Remove 6 flywheel mounting bolts (6) and lift

off flywheel (7). [*1]
4 Flywheel assembly: 35 kg
3. Remove flywheel cover (2) according to the

following procedure.
1) Remove mounting bolts (3).
a Leave 2 – 3 bolts installed.
50-200 10 D31/37-22
Removal and installation of rear seal assembly SEN04725-01
6. Remove rear seal (8) from housing according Installation

to the following procedure. q Carry out installation in the reverse order to
a Take care in the removal not to damage removal.
rear seal (8) installation position on hous-
ing and the seal contact face on crank- [*1]
shaft. q Tighten the flywheel mounting bolts according
a Before removing, slightly drive the front to the following procedure.
seal in once to free it from fixation. 4) Apply engine oil to the threaded portions
a When rear seal (8) is fixed too hard to the of the bolts.
housing, carry out the following proce- 5) Tighten the bolts in the order of [1] – [6] as
dure. shown in the figure in 2 times.
1) Drill through a hole of approx. 3 mm 3 Mounting bolt:
dia. on rear seal (8). 1st time: 58.7 – 117.7 Nm
2) Replace the tip of the tool A2 with the {6.0 – 12.0 kgm}
drill type one. 2nd time: 186.4 – 196.2 Nm
3) Insert the top end of tool A2 into the {19.0 – 20.0 kgm}
drilled hole, and remove the rear seal
by the impact of slide hammer (SH)
[1]. (Apply the slide hammer evenly
not to tilt the rear seal.)
a Remove the metal powders completely.
q Measurement of flywheel radial runout

1) Install dial gauge [2] to the flywheel hous-
ing.
2) Set the dial gauge so that its probe will be
applied perpendicularly to faucet joint por-
tion (a) or periphery of the flywheel.
3) Rotate the flywheel 1 turn and measure
the difference between the maximum
readings.
Radial runout: Max. 0.15 mm
D31/37-22 50-200 11
SEN04725-01 Removal and installation of rear seal assembly
q Measurement of flywheel facial runout

1) Similarly to measurement of the radial
runout, set the dial gauge so that its probe
will be applied perpendicularly to end face
(b) of the flywheel near the periphery.
a When measuring, bring the crank-
shaft to the front or rear side so that
an error will not be caused by the end
play.
2) Rotate the flywheel 1 turn and measure
the difference between the maximum
readings.
a After rotating the flywheel 1 turn,
check that the dial gauge reads the
same value as before rotation.
Facial runout: Max. 0.25 mm
[*2]
q Install the rear oil seal (8) according to the fol-
lowing procedure.
Using tool A3 (Outside diameter: 120 mm),
install the rear oil seal (8) to the flywheel hous-
ing (1).
a Fill the space between the rear oil seal lips with
grease of about 3 cc.
2 Rear oil seal: Grease (G2-LI)
50-200 12 D31/37-22
Removal and installation of cylinder head assembly SEN04725-01
Removal and installation of 3) Remove air conditioner compressor (4)

cylinder head assembly 1
and bracket (5) together.
Removal
k When the radiator coolant temperature is
high, you may be scaled. In this case, wait
until the coolant temperature lowers and
then drain the coolant.
1. Drain the coolant.

6 Coolant: Approx. 18 l
2. Close fuel stop valve (1).

6. Disconnect the alternator assembly according
1) Remove 3 heater tube clamps (6)
2) Disconnect heater hose (7) from the water
pump.
3) Remove covers (8) and (9).
4) Disconnect alternator wiring (10) from the
alternator.
a Disconnect wiring clamp (11).
5) Loosen alternator lower mounting bolt
(12).
6) Loosen alternator drive belt tension
adjustment bolt (13) and remove alterna-
tor drive belt (14). [*1]
3. Remove the front guard assembly. For details, 7) Remove alternator mounting bolt (12a).
see "Removal and installation of front guard 8) Disconnect alternator assembly (15) and
assembly". stay (16) together from the cylinder head.
4. Remove muffler assembly (2). 7. Remove 2 coolant tube fixing clamps (17).
8. Remove brackets (18) and (19).
9. Loosen hose clamp (20) and disconnect cool-

ant tube (21).
5. Remove the air conditioner compressor

(Air conditioner installation specification)
1) Disconnect engine oil filler tube clamp
(3a).
2) Disconnect 4 air conditioner hose clamps
(3).
D31/37-22 50-200 13
SEN04725-01 Removal and installation of cylinder head assembly
13. Remove brackets (28) – (30).
14. Remove air connector (31) and electrical

intake air heater together from the air intake
manifold.
15. Disconnect atmospheric pressure sensor con-

nector (32).
16. Disconnect 4 fuel injector wiring connectors

(33).
17. Disconnect coolant temperature sensor con-

nector (34).
10. Remove electrical intake air heater relay (22)
and bracket (23) together from muffler mount- 18. Disconnect wiring clamp (34a).
ing bracket (24).
11. Remove muffler mounting bracket (24).
12. Remove the fuel filter assembly according to

1) Disconnect 2 fuel hose clamps (25).
2) Remove 2 mounting bolts (26) and fuel fil-
ter assembly (27).
50-200 14 D31/37-22
19. Remove the high-pressure pipe according to 21. Remove the fuel injector assembly according
the following procedure. to the following procedure. [*5]
1) Remove high-pressure pipe clamp (35). 1) Remove holder mounting bolt (42) and
2) Remove boots (36) from the injector and holder (43).
common rail. [*2] 2) Remove injector assembly (44).
3) Remove pin (37) and disconnect spill hose 22. Remove the turbocharger assembly according
(38). to the following procedure.
4) Loosen sleeve nuts (39) on the injector 1) Disconnect blow-by hose (45).
side and common rail side and remove 2) Remove bracket (46).
high-pressure pipe (40). [*3] 3) Remove cylinder head cover (47). [*6]
20. Remove air intake manifold (41). 4) Remove bracket (48).

a Since the 8 mounting bolts have different 5) Disconnect air tube (49). [*7]
lengths, record their locations. [*4]
D31/37-22 50-200 15
6) Disconnect lubrication inlet tube (50). [*8] 24. Remove the rocker arm assembly according to
7) Disconnect lubrication outlet tube (51). the following procedure.
1) Loosen locknut (57) and fully loosen
adjustment screw (58). [*10]
a Loosen the adjustment screws of all
the cylinders.
2) Remove 5 mounting bolts (59) and 3
mounting nuts (59a) and remove rocker
arm assembly (60). [*11]
8) Sling turbocharger assembly (52).

9) Remove 8 mounting bolts (53) and
remove turbocharger assembly (52) and
exhaust manifold together. [*9]
25. Pull out push rod (61).
26. Remove cylinder head mounting bolts (62).

[*12]
23. Remove the water pump assembly according

1) Disconnect hose (54).
2) Remove 4 mounting bolts (55) and water
pump assembly (56).
27. Lift off cylinder head assembly (63).

4 Cylinder head assembly: 30 kg
50-200 16 D31/37-22
Installation [*4]
q Carry out installation in the reverse order to q When installing the intake manifold, apply gas-
removal. ket sealant to the intake manifold mounting
face according to the following procedure.
[*1] a Evenly apply a string of gasket sealant about 1
For adjustment of the alternator drive belt tension, mm in diameter without breakage around each
see Testing and adjusting, "Adjusting alternator air intake opening.
drive belt tension". 2 Intake manifold mounting face:
Gasket sealant (LG-7)
[*2]
k Direct the slit of each boot out and down.
a The boots are installed so that fuel will not
spout over the hot parts of the engine to catch
fire when it leaks for some reason.
[*3]
k Do not bend the fuel high-pressure pipe to
collect before installing.
k Be sure to use the genuine fuel high-pres-
sure pipe clamps and observe the tighten-
ing torque.
k After installing the high-pressure pipe, be
sure to install the boots to the sleeve nuts.
a Before installing the high-pressure pipe, check a Install the mounting bolts to their respective
it for the following defects. If there is any of locations recorded when they were removed.
these defects, it can cause fuel leakage.
Accordingly, replace the high-pressure pipe.
q Check the taper seal of the connecting
3 Sleeve nut: 25.5 – 29.4 Nm {2.6 – 3.0 kgm}
D31/37-22 50-200 17
[*5] [*8]
a If the injector assembly was removed, be sure 3 Lubrication inlet tube mounting bolt:
to replace seal (64) and gasket (65) with new 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
ones.
q Installation procedure for injector assembly [*9]
1) Install seal (64) to injector assembly (44). 3 Exhaust manifold mounting bolt:
2) Install gasket (65) to injector assembly 34.3 – 53.9 Nm {3.5 – 5.5 kgm}
(44).
3) Insert injector assembly (44) in the cylin- [*10], [*11]
der head. a Before installing rocker arm assembly (60),
a After installing the gasket to the injec- loosen locknut (57) and fully loosen adjustment
tor, check that it will not fall by its screw (58).
weight before inserting the injector. a When installing rocker arm assembly (60),
4) Install holder (43) to injector assembly ensure that the adjustment screw ball is fitted
(44). to the push rod socket and tighten the mount-
5) Tighten holder (43) with injector mounting ing bolts alternately.
bolt (42). a When installing 3 rocker arm mounting bolts
a Before tightening the bolt, ensure that (59a), check their locations.
holder (43) is fitted to groove (e) of 3 Rocker arm mounting bolts (59), (59a):
injector assembly (44). 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
3 Holder mounting bolt: q For adjustment of the valve clearance, see
27 – 30 Nm {2.8 – 3.1 kgm} Testing and adjusting, "Adjusting valve clear-
ance".
[*6]
3 Cylinder head cover mounting bolt:
7.84 – 9.8 Nm {0.8 – 1.0 kgm}
[*7]
a When installing the clamp, check that the O-
ring is fitted.
3 Clamp mounting bolt:
5.9 – 7.8 Nm {0.6 – 0.8 kgm}
50-200 18 D31/37-22
[*12]
Installation method of cylinder head
1) Clean the threaded holes of the cylinder block.
a Clean the gasket surface and install the
new head gasket.
2) Apply molybdenum disulfide lubricant (LM-P)
to the bolt holes, bolt seats and cylinder head
hole seats.
3) Turn the bolts lightly until they are screwed in
the threaded holes of the cylinder head by 2 –
3 threads in the order of [1] – [17] shown in the
figure.
4) Tighten the bolts in the order of [1] – [17]
shown in the figure according to the following
procedure. p1 denotes a mark on the cylinder head.
3 Cylinder head mounting bolt: p2 denotes a mark on the bolt head.
1st time: 68.6 ± 9.8 Nm
{7.0 ± 1.0 kgm}
2nd time: 107.8 ± 4.9 Nm
{11.0 ± 0.5 kgm}
3rd time: Make marks with paint on
the bolt heads and their
seats on the cylinder head,
and then tighten the bolts
so that the mark of each
bolt will be at 90° (+30°/0°)
to the mark of the cylinder
head.
a After tightening the bolts, make 1 punch mark
"n" on each bolt head.
a If there are 5 punch marks on a bolt, do not
reuse that bolt but replace it.
Meaning of marks in drawings

F denotes the front of the engine.
R denotes the rear of the engine.
(b) denotes a bolt for plastic-region angle tight-
ening.
D31/37-22 50-200 19
SEN04725-01 Removal and installation of engine and HST pump assembly
Removal and installation of 7. Disconnect fuel prefilter outlet hose (2).

engine and HST pump assembly 1
a Move fuel prefilter assembly (3) toward
the chassis.
Removal
k Stop the engine and loosen the hydraulic
tank cap gradually to release the residual
k If the radiator coolant temperature is high,
wait until it decreases and then drain the
coolant, otherwise you may get scalded.
1. Drain the coolant. [*1]

2. Drain the hydraulic oil. [*2] 8. Disconnect heater hose (4).

6 Hydraulic oil: Approx. 60 l
9. Remove heater tube clamps (5).
3. Close fuel stop valve (1). 10. Remove water pump inlet hose (6) from the
water pump. [*3]
4. Remove the front guard assembly. For details,

see "Removal and installation of front guard 11. Disconnect fuel return hose (7).
assembly".
5. Remove the ROPS canopy and operator seat

frame assembly. For details, see "Removal
and installation of ROPS canopy and operator
seat frame assembly". (ROPS canopy specifi-
cation)
6. Remove the ROPS cab and operator seat

and installation of ROPS cab and operator
seat frame assembly". (ROPS cab specifica-
tion)
50-200 20 D31/37-22
Removal and installation of engine and HST pump assembly SEN04725-01
12. Remove right and left brackets (8). (ROPS cab 15. Disconnect the following 7 connectors.
specification) q HST pump right pressure sensor connec-
tor: N-RP (14)
q HST pump left pressure sensor connector:
N-LP (15)
q HST pump EPC solenoid valve (left rear)
connector: CN-LR (16)
q HST pump EPC solenoid valve (left front)
connector: CN-LF (17)
q HST pump EPC solenoid valve (right
front) connector: CN-RF (18)
q HST pump EPC solenoid valve (right rear)
connector: CN-RR (19)
q HST oil temperature sensor connector:
CN-12 (20)
13. Loosen water hose clamp (9) and disconnect

water hose (10) from water tube (11). [*4]
14. Disconnect wiring clamp (12) from bracket

(13).
D31/37-22 50-200 21
SEN04725-01 Removal and installation of engine and HST pump assembly
16. Disconnect drain hoses (21) and (22).
17. Remove air hoses (23) and (24). [*5]
18. Disconnect charge port PR hose (25).
19. Disconnect hose (26).
21. Disconnect work equipment pump suction port

PS hose (28).
22. Disconnect work equipment discharge port

hose (29). 32. Disconnect engine ground cable (40).
23. Loosen the hose clamp and disconnect suction 33. Remove 4 engine mount mounting bolts (41).
hose (30). [*6] [*8]
24. Disconnect hoses (31) and (32).

q Hose (31) color band: Green/Red
q Hose (32) color band: Yellow/Red
25. Disconnect load pressure input port PLS hose

(33).
26. Disconnect right reverse PB2 hose (34). [*7]
27. Disconnect left forward PA1 hose (35). [*7]
28. Disconnect right forward PA2 hose (36). [*7]
29. Disconnect left reverse PB1 hose (37). [*7]

34. Lift off engine and HST pump assembly (42).
a Sling the assembly while checking that all
30. Disconnect hose bracket (38).
the related wires and hoses are discon-
nected or removed.
31. Remove the 3 mounting bolts and move out
EPC solenoid valve and bracket assembly 4 Engine and HST pump assembly:
(39).
600 kg
a Do not disconnect the wiring connector.
50-200 22 D31/37-22
Removal and installation of engine and HST pump assembly SEN04725-01
Installation
removal.
[*1]
[*2]
3 Hydraulic oil drain plug:
153 – 190 Nm {15.5 – 19.5 kgm}
a Add hydraulic oil and run the engine to circu-
late the oil through the piping. Then, check the
oil level again.
[*3]
3 Water pump inlet hose clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*4]
3 Water hose clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*5], [*6]
3 Air hose clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*7]
3 Hose flange mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
[*8]
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
235 – 285 Nm {23.5 – 29.5 kgm}
D31/37-22 50-200 23
SEN04725-01 Removal and installation of front guard assembly
Removal and installation of front 5. Disconnect engine controller wiring connector

guard assembly 1
(9).
Removal 6. Disconnect air conditioner compressor wiring

k Disconnect the cable from the negative (–) connector (10).
7. Remove fuel prefilter assembly (11).
1. Remove covers (1) – (4). a Disconnect the hose clamp and move it
toward the engine.
8. Disconnect wirings (12).
2. Loosen air cleaner hose clamp (5). [*1]
3. Disconnect wiring connectors (6) and (7). 9. Remove the 4 front mounting bolts. [*3]
4. Disconnect 2 wiring clamps (8).
50-200 24 D31/37-22
Removal and installation of front guard assembly SEN04725-01
10. Remove 3 mounting bolts (13) and 1 mounting Installation

bolt (14) on each of the right and left sides. [*2] q Carry out installation in the reverse order to
removal.
[*1]
3 Air cleaner hose clamp:
10.5 ± 0.5 Nm {1.0 ± 0.05 kgm}
[*2]
3 Front guard right and left mounting bolts:
(13): 98 – 123 Nm {10 – 12 kgm}
(14): 235 – 285 Nm {23.5 – 29.5 kgm}
11. Lift off front guard assembly (15).

4 Front guard assembly: 200 kg
[*3]
3 Front guard front mounting bolt:
235 – 285 Nm {23.5 – 29.5 kgm}
D31/37-22 50-200 25
SEN04725-01 Removal and installation of radiator assembly
Removal and installation of 5. Remove radiator upper hose clamp (4) and
radiator assembly 1
disconnect upper hose (5). [*2]
Removal 6. Remove radiator lower hose clamp (6) and dis-

k If the radiator coolant temperature is high, connect lower hose (7). [*3]
wait until it decreases and then drain the a Disconnect the hose while moving the
coolant so that you will not be scalded. lower part of radiator assembly (8) and
k Stop the engine, and then loosen the bracket (9) together toward this side.
hydraulic tank cap gradually to release the
remaining pressure in the hydraulic tank. 7. Remove 4 radiator upper mounting bolts (10).
k Disconnect the cable from the negative (–) [*4]
8. Remove radiator assembly (8) by pulling out it
1. Remove the oil cooler assembly. For details, and bracket (9) together toward this side. [*5]
see "Removal and installation of hydraulic oil
cooler assembly".
2. Drain the coolant through coolant drain port

(1). [*1]
3. Remove stay (2).
4. Remove 2 radiator lower bracket mounting

bolts (3).
50-200 26 D31/37-22
Removal and installation of radiator assembly SEN04725-01
Installation

removal.
[*1]
[*2]
3 Radiator upper hose clamp mounting bolt:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*3]
a Before installing the radiator assembly, align
the radiator lower hose with the outlet hole at
the radiator bottom and then insert the hose
while pressing the radiator assembly.
3 Radiator lower hose mounting bolt:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*4]
3 Radiator upper mounting bolt:
30 – 44 Nm {3.0 – 4.5 kgm}
[*5]
k When aligning the radiator lower mounting
holes with the holes on the bracket and
machine, never insert your finger in a hole.
Use a wood or steel bar to check the hole
alignment.
D31/37-22 50-200 27
SEN04725-01 Removal and installation of hydraulic oil cooler assembly
Removal and installation of 5. Remove cover (5).

hydraulic oil cooler assembly 1
6. Remove undercover (6).
Removal
k Stop the engine, and then loosen the
remaining pressure in the hydraulic tank.
1. Drain the hydraulic oil in the hydraulic oil

cooler. [*1]
2. Remove the cooling fan and motor assembly.

cooling fan and motor assembly". 7. Remove 4 mounting bolts (7) and valve
assembly (8). [*4]
3. Remove rubber mount mounting bolt (1). [*2]
a Remove the bolts on the radiator side and
aftercooler side, too.
4. Remove bracket mounting bolts (2) and

remove rubber mount (3) and bracket (4)
together. [*3]
a Remove these parts on the radiator side
and aftercooler side, too.
8. Remove 2 oil cooler lower mounting bolts (9).

[*5]
50-200 28 D31/37-22
Removal and installation of hydraulic oil cooler assembly SEN04725-01
9. Remove 4 oil cooler upper mounting bolts (10). Installation

[*6]
a Fully loosen 4 radiator mounting bolts (11) q Carry out installation in the reverse order to
and 2 aftercooler mounting bolts (12). [*7] removal.
[*1]
a Add hydraulic oil, run the engine to circulate
the oil through the piping, and then check the
oil level again.
[*2]
3 Rubber mount mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}
[*3]
3 Bracket mounting bolt:
10. Remove oil cooler assembly (13) by pulling out 98 – 123 Nm {10 – 12.5 kgm}
it and bracket (14) together toward this side.
[*8] [*4]
3 Valve assembly mounting bolt:
39 ± 5 Nm {4 ± 0.5 kgm}
[*5]
3 Oil cooler lower mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}
[*6], [*7]
3 Each cooler upper mounting bolt:
30 – 44 Nm {3.0 – 4.5 kgm}
[*8]
k When aligning the oil cooler lower mount-
ing holes with the holes on the bracket and
alignment.
D31/37-22 50-200 29
SEN04725-01 Removal and installation of aftercooler assembly
Removal and installation of 4. Remove aftercooler upper hose clamp (3) and
aftercooler assembly 1
disconnect upper hose (4). [*1]
Removal 5. Remove aftercooler lower hose clamp (5) and

k Stop the engine, and then loosen the disconnect lower hose (6). [*2]
hydraulic tank cap gradually to release the a Disconnect the hose while moving the
remaining pressure in the hydraulic tank. lower part of aftercooler assembly (7) and
k Disconnect the cable from the negative (–) bracket together toward this side.
1. Remove the oil cooler assembly. For details,

see "Removal and installation of hydraulic oil
cooler assembly".
2. Remove stay (1).
6. Remove 4 aftercooler upper mounting bolts

(9). [*3]
7. Remove aftercooler assembly (7) by pulling

out it and bracket (8) together toward this side.
[*4]
3. Remove 2 aftercooler lower bracket mounting

bolts (2).
50-200 30 D31/37-22
Removal and installation of aftercooler assembly SEN04725-01
Installation

removal.
[*1]
3 Aftercooler upper hose clamp mounting bolt:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*2]
a Before installing the aftercooler assembly,
align the aftercooler lower hose with the outlet
hole at the radiator bottom and then insert the
hose while pressing the radiator assembly.
3 Aftercooler lower hose clamp mounting bolt:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*3]
3 Aftercooler upper hose clamp mounting bolt:
30 – 44 Nm {3.0 – 4.5 kgm}
[*4]
k When aligning the aftercooler lower mount-
ing holes with the holes on the bracket and
alignment.
D31/37-22 50-200 31
SEN04725-01 Removal and installation of cooling fan and motor assembly
Removal and installation of 4. Remove net (5).

cooling fan and motor assembly 1
5. Remove 3 bolts (6) and cover (7).
Removal
1. Remove cover (1).
6. Disconnect 3 hoses (8). [*1]

a Remove hose fixing clamps (9), too.
7. Disconnect wiring connector (10).

a Remove wiring fixing clamp (11), too.
8. Loosen cooling fan and motor assembly

mounting bolts (12) on the right and left sides.
2. Disconnect connector (2). [*2]
a Record the right, left, upper and lower
3. Remove mask (3) and buzzer (4) together. installed positions of brackets (13).
4 Mask: 35 kg
50-200 32 D31/37-22
Removal and installation of cooling fan and motor assembly SEN04725-01
9. Remove the 4 fixing bolts at the bottom of cool- Installation

ing fan and motor assembly (14), open cooling
fan and motor assembly (14) upward, and then q Carry out installation in the reverse order to
sling it. removal.
10. Remove right and left covers (15) and (16). [*1]
a Add oil through the oil filler to the specified
11. Disconnect right and left springs (17). level. Run the engine to circulate the oil
through the piping. Then, check the oil level
12. Pull lock plate (18) toward this side to unlock. again.
[*2]
a When installing the cooling fan and motor
assembly, install the brackets to their original
positions.
3 Cooling fan and motor assembly mounting
bolt: 235 – 285 Nm {23.5 – 29.5 kgm}
13. Remove mounting bolt (19) to disconnect

bracket (20).
14. Remove the mounting bolts at the top of cool-

ing fan and motor assembly (21) and lift off
cooling fan and motor assembly (21).
4 Cooling fan and motor assembly: 85 kg
D31/37-22 50-200 33
SEN04725-01 Removal and installation of cooling fan drive motor assembly
Removal and installation of 5. Using puller [1], remove fan (5). [*4]
cooling fan drive motor assembly1
Removal
1. Remove the cooling fan and motor assembly.

cooling fan and motor assembly".
2. Remove net (1). [*1]

a Before removing the net, check its top and 6. Reverse and set the cooling fan and motor
bottom positions. assembly.
3. Remove lock bolt (2) and lock plate (3). [*2]
4. Remove nut (4). [*3] 8. Disconnect wiring connectors (7) and (8).
9. Remove 4 mounting bolts (9) and motor

assembly (10). [*5]
50-200 34 D31/37-22
Removal and installation of cooling fan drive motor assembly SEN04725-01
Installation [*5]
3 Motor assembly mounting bolt:
q Carry out installation in the reverse order to 59 – 74 Nm {6 – 7.5 kgm}
removal.
[*1] q Refilling with oil

a Install the net closed with the 2 corners having a Add oil through the oil filler to the specified
the triangular plates up. level. Run the engine to circulate the oil
through the piping. Then, check the oil
[*2], [*3], [*4] level again.
q Install fan assembly (5) according to the follow-
ing procedure.
1) Degrease tapered faces (a) at the hose
portions of shaft (11) and fan (5) before
installing.
a If fan assembly (5) was disassembled
and the fan unit is removed, install the
fan unit so that the stamp "FL" of the
fan mounting portion will be directed
toward the front of the machine.
2) Tighten fan mounting nut (4) to 117.6 Nm
{12 kgm}.
3) Align the holes of lock plates (3) on the
front side and rear side and tighten by the
least quantity of adjustment in the tighten-
ing direction and then install lock bolt (2).
3 Fan mounting nut (4):
98 – 127.5 Nm {10 – 13 kgm}
2 Lock bolt (2): Adhesive (LT-2)
3 Lock bolt (2):
59 – 74 Nm {6 – 7.5 kgm}
4) After installing fan assembly (5), adjust the
fan speed sensor. For detail, see “Adjust-
ment of fan speed sensor”.
D31/37-22 50-200 35
SEN04725-01 Removal and installation of fuel tank assembly
Removal and installation of fuel 8. Disconnect fuel level sensor connector (5) CN-
tank assembly 1
13.
Removal 9. Disconnect intermediate connector (6) CN-

k Disconnect the cable from the negative (–) FM1.
10. Disconnect ground cable (7) CN-TG1.
1. Close the fuel stop valve.
11. Disconnect accumulator (8).
2. Drain the hydraulic oil.
6
12. Disconnect fuel return hose (9).
Hydraulic tank: Approx. 60 l
13. Disconnect HST charge filter hoses (10) and
3. Remove the ROPS canopy and operator seat (11).
cation)

tion)
5. Open up cooling fan and motor assembly (1)

and sling it.
6. Disconnect spring (2) and disconnect lock plate

(3) of the cooling fan and motor assembly.
a Do not disconnect the hydraulic tank side.
7. Lower cooling fan and motor assembly (1).
50-200 36 D31/37-22
Removal and installation of fuel tank assembly SEN04725-01
14. Disconnect the 12 control valve hoses. 17. Lift off fuel tank assembly (26).
4
q (12): To tank (Hose color band: Red)
Fuel tank assembly: 200 kg
q (13): Lift lower (Hose color band: Yellow)
q (14): Lift raise (Hose color band: Green)
q (15): To angle cylinder bottom
(Hose color band: 2 red bands)
q (16): To angle cylinder head
(Hose color band: 2 orange bands)
q (17): To tilt cylinder bottom
(Hose color band: 2 blue bands)
q (18): To tilt cylinder head
(Hose color band: 2 white bands)
q (19): To lift cylinder bottom
(Hose color band: Yellow)
q (20): To lift cylinder head
(Hose color band: Green)
q (21): To fan pump
q (22): To tank
q (23): From work equipment pump Installation
15. Disconnect fuel supply hose (24). q Carry out installation in the reverse order to
removal.
[*1]
3 Fuel tank mounting bolt:
455 – 565 Nm {46.5 – 58 kgm}
3 Fuel tank lower mounting bolt:
235 – 285 Nm {23.5 – 29.5 kgm}
q Refilling with oil (Hydraulic tank)

level. Run the engine to circulate the oil
level again.
16. Remove fuel tank mounting bolts (25) and 4
lower mounting bolts. [*1]
q Bleeding air (HST circuit)
a Bleed air from the HST circuit. For details,
see Testing and adjusting, "Bleeding air
from hydraulic circuit".
D31/37-22 50-200 37
SEN04725-01
D31/37-22 Bulldozer
©2009 KOMATSU
All Rights Reserved
50-200 38
SEN04726-01
D31EX-22
D31PX-22
D37EX-22
D37PX-22
D31EX-22 60001 and up
D31PX-22 60001 and up
D37EX-22 60001 and up
D37PX-22 60001 and up
300 Power train

Removal and installation of HST pump assembly .......................................................................................... 2
Removal and installation of HST motor and final drive assembly ................................................................... 4
Disassembly and assembly of final drive assembly........................................................................................ 6
D31/37-22 50-300 1
300 Power train
SEN04726-01 Removal and installation of HST pump assembly
Removal and installation of HST 5. Disconnect the following 7 wiring connectors.

pump assembly 1
q (2) HST pump right pressure sensor con-
nector: CN-RP
Removal q (3) HST pump left pressure sensor con-
k Lower the work equipment to the ground nector: CN-LP
and stop the engine. Then, loosen the q (4) HST pump EPC solenoid valve (left
hydraulic tank oil filler cap gradually to rear) connector: CN-LR
release the pressure inside the hydraulic q (5) HST pump EPC solenoid valve (left
tank. front) connector: CN-LF
k Disconnect the cable from the negative (–) q (6) HST pump EPC solenoid valve (right
terminal of the battery. front) connector: CN-RF
a Plug the disconnected hoses to prevent foreign q (7) HST pump EPC solenoid valve (right
matter from entering them. rear) connector: CN-RR
a Record each piping to prevent a mistake in re- q (8) HST oil temperature sensor connector:
connecting it. CN-12

6 Hydraulic tank: Approx. 60 l

cation)

seat frame assembly". (ROPS cab specifica- 6. Disconnect drain hoses (9) and (10).
tion)
7. Disconnect air hoses (11) and (12).
4. Remove right and left ROPS cab mounting
brackets (1). (Cab specification only) 8. Disconnect charge port CPR hose (13).
11. Disconnect work equipment pump suction port

PS hose (16).
12. Disconnect work equipment pump discharge

port hose (17).
13. Disconnect suction hose (18).
14. Disconnect hoses (19) and (20).

q Hose (19) color band: Red/Green
q Hose (20) color band: Red/Yellow
15. Disconnect load pressure input port PLS hose

(21).
16. Disconnect right reverse PB2 hose (22). [*1]
50-300 2 D31/37-22
300 Power train
Removal and installation of HST pump assembly SEN04726-01
17. Disconnect left forward PA1 hose (23). [*1] 22. Sling HST pump assembly (28) and remove
the 6 mounting bolts. [*2]
18. Disconnect right forward PA2 hose (24). [*1]
23. Lift off HST pump assembly (28).
4
19. Disconnect left reverse PB1 hose (25). [*1]
HST pump assembly: 200 kg
20. Disconnect hose bracket (26).
21. Remove the mounting bolts and move out EPC

solenoid valve and bracket assembly (27).
a Do not disconnect the connector.
Installation

removal.
a When installing each hose, take extreme care
not to twist it.
[*1]
3 Flange mounting bolt of hoses (22) – (25):
98 – 123 Nm {10 – 12.5 kgm}
[*2]
2 Threaded part of mounting bolt:
Gasket sealant (LG-5)

level again.

a If the HST pump assembly was replaced,

adjust the new assembly. For details, see Test-
ing and adjusting, "Special functions of monitor
panel (EMMS), 11. Tuning mode (TUNING)".
D31/37-22 50-300 3
300 Power train
SEN04726-01 Removal and installation of HST motor and final drive assembly
Removal and installation of HST 4. Disconnect speed sensor connector (4).

motor and final drive assembly 1
5. Disconnect main hoses (5) and (6). [*1]
Removal
k Lower the work equipment to the ground 6. Disconnect pilot hose (7).
and stop the engine. Then, loosen the (Hose color band)
hydraulic oil filler cap slowly to release the Left HST motor: Brown – blue
internal pressure of the hydraulic tank. Right HST motor: Red – blue
terminal of the battery. 7. Disconnect drain hose (8).
1. Spread the track shoe. For details, see 8. Disconnect parking brake hose (9).
“Spreading and installation of track shoe
assembly”.
2. Using hydraulic jacks, lift up the machine body

and set stand [1] under the steering case.
9. Remove the mounting bolts and guard (10).

[*2]
3. Remove covers (1), (2), and (3).
50-300 4 D31/37-22
300 Power train
Removal and installation of HST motor and final drive assembly SEN04726-01
10. Sling HST motor and final drive assembly (11) Installation
temporarily.
• Carry out installation in the reverse order to
11. Remove the 24 mounting bolts and HST motor removal.
and final drive assembly (11). a Take extreme care that each hose will not
a If shims are inserted, check their quantity be twisted when connected.
and positions.
4
[*1]
3
HST motor and final drive assembly
Hose flange mounting bolt:
(Each side): 340 kg
98 – 123 Nm {10 – 12.5 kgm}
[*2]
2 Guard mounting bolt: Adhesive (LT-2)
• Refilling with oil (Hydraulic tank)

through the system. Then, check the oil
level again.
• Bleeding air (HST circuit)

a Bleed air from the HST pump circuit. For
details, see Testing adjusting, Part 2
"Bleeding air from hydraulic circuit".
D31/37-22 50-300 5
300 Power train
SEN04726-01 Disassembly and assembly of final drive assembly
Disassembly and assembly of 2) Using 2 forcing screws [1], remove cover

final drive assembly 1
(2).
Special tools
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
791-830-1320 Rod t 1
01580-01613 Nut t 1
01643-31645 Washer t 1
1 790-101-2540 Washer t 1
790-101-2102 Puller assembly t 1
790-201-2830 Spacer t 1
3. Ring gear
J 790-101-1102 Hydraulic pump t 1
1) Remove 18 mounting bolts (3).
2 791-427-1410 Wrench t 1
3 791-545-1510 Installer t 1
4 797T-427-1120 Push tool t 1 Q
5 791T-627-1360 Sleeve t 1 Q
79A-264-0091
6 or commercially Push-pull scale t 1
available
Disassembly
1. Draining oil
Remove the drain plug to drain the oil from the
final drive case.
6 Final drive case: Approx. 3.5 l
2) Using 2 forcing screws [2], remove ring
gear (4).
2. Cover
1) Remove 12 mounting bolts (1).
50-300 6 D31/37-22
300 Power train
Disassembly and assembly of final drive assembly SEN04726-01
4. No. 1 planetary carrier assembly 5. No. 1 sun gear

1) Remove thrust washer (5). Remove No. 1 sun gear (12).
2) Remove No. 1 planetary carrier assembly
(6).
6. No. 2 sun gear

1) Remove thrust washer (13).
3) Disassemble No. 1 planetary carrier 2) Remove No. 2 sun gear (14).
assembly according to the following pro-
cedure.
1] Drive pin (7) into shaft (8).
a 3 sets
2] Remove shaft (8) from No. 1 plane-
tary carrier assembly.
a After removing the shaft, remove
pin (7) from shaft (8).
a 3 sets
3] Remove 2 thrust washers (9), gear
(10), and bearing (11).
a 3 sets.
7. No. 2 planetary carrier assembly (HST

motor case)
1) Remove mounting bolts (15).
a 3 sets
D31/37-22 50-300 7
300 Power train
2) Using tools J1, pull shaft (16) out of No. 2 7) Remove thrust washer (21).
planetary carrier assembly.
a 3 sets
8. Hub assembly
1) Remove lock plate (22).
3) Remove ball (17).
a 3 sets
4) Remove gear (18) from No. 2 planetary
carrier assembly.
a 3 sets
5) Remove 2 inner race bearings (19) from
gear (18).
a 3 sets
2) Using tool J2, remove nut (23).
6) Remove 2 outer race bearings (20) from

the gear.
a 3 sets
50-300 8 D31/37-22
300 Power train
3) Using 2 eyebolts [3], remove hub assem- Assembly

bly (24) from No. 2 planetary carrier (HST a Clean the all parts and check them for dirt or
motor case). damage. Coat their sliding surfaces with
engine oil before installing.
a Adjust the pre-load at the normal temperature
while the temperature difference between the
No. 2 planetary carrier, bearing, hub, and nut is
3°C or less.
1. No. 2 planetary carrier (HST motor case)

Using tool J3, install floating seals (25) and
(27).
a Remove all oil and grease from the O-ring
and O-ring contact surface, and dry them
before installing the floating seal.
a Insert the O-ring by pushing it with tool J3.
a After installing the floating seal, check that
4) Disassemble the hub assembly according its slant is within 1 mm.
to the following procedure. a After installing the floating seal, thinly
1] Remove floating seal (25). apply power train oil (TO30) to the sliding
2] Remove 2 bearings (26). parts.
9. No. 2 planetary carrier (HST motor case) 2. Assembly of hub assembly

Remove floating seal (27) from No. 2 planetary 1) Using tool J4, press fit 2 bearings (26).
carrier (28). a Press fit each bearing until its outer
race end comes in full contact with
the hub.
a After press fitting each bearing, check
that a thickness gauge of 0.03 mm
cannot go through the clearance
between the outer race end and hub.
D31/37-22 50-300 9
300 Power train
2) Using tool J3, install floating seals (25) 4) Using push tool J5, press the inner race
and (27) to the hub assembly. on the bearing on the nut side with a
a For the installation procedure, see press.
step 1. a Pressing force on inner race:
8.8 – 12.7 kN {0.9 – 1.3 tons}
a After installing hub assembly, revolve
the hub by 2 – 3 turns against the
No. 2 planetary carrier.
3) Using eyebolts [3], set hub assembly (24)

to No. 2 planetary carrier assembly (HST
motor case).
a When inserting the hub assembly in
the No. 2 planetary carrier (HST 5) Tighten the nut and adjust the pre-load on
motor case), check that the bearing the bearing according to the following pro-
and No. 2 planetary carrier insertion cedure.
surface are free from flaws, burrs and a If nut (23) is not tightened sufficiently
dirt and take care that the bearing will (bearings (26) slant and do not go all
not slant. the way), the contact surfaces of
floating seals (25) and (27) may be
damaged. Accordingly, tighten nut
(23) securely according to the shown
procedure.
50-300 10 D31/37-22
300 Power train
1] Using tool J2, tighten nut (23) at 490 5] Tighten nut (23) to the range of 245 –
Nm {50 kgm}. Rotate hub (24) to the 490 Nm {25 – 50 kgm}. Using tool J6,
right by 3 revolutions, left by 3 revolu- adjust the pre-load on the bearing
tions. And tighten the nut (23) at 490 (the tangential force of the hub at a
Nm {50 kgm} again. bolt hole on its periphery). Both of the
a Tighten the nut at 490 Nm {50 following must be satisfied.
kgm} to prevent the bearing from (1) Tangential force at bolt hole on
slanting. periphery of hub:
2 Nut (Contact surface of bear- 127 – 206 N {13 – 21 kg}
ing): Molybdenum disulfide
lubricant (LM-P)
2] Loosen the nut at below 196 Nm {20
kgm}.
a Do not loosen at 0 Nm {0 kgm}.
If it is loosened at 0 Nm {0 kgm},
do step 1] again.
3] Tighten nut (23) at 245 Nm {25 kgm}.
Rotate hub assembly (24) to the right
by 3 revolutions and then to the left by
3 revolutions, and then tighten nut
(23) again at 245 Nm {25 kgm}.
(2) When tightening the nut, check

that tightening angle of the nut is
0.5 – 1 adjustment notch of the
nut by the deviation of the nut
from the match marks made in
step 4].
4] Make match marks (a) between nut

(23) and No. 2 planetary carrier (28).
6) Install lock plate (22).
D31/37-22 50-300 11
300 Power train
aIf the lock plate is turned over, it devi- 3) Install 2 inner race bearings (19) to gear
ates by 1/2 notch. Accordingly, install (18).
it so that its claw will be fitted to a a 3 sets
notch of the nut. 4) Install gear (18) to No. 2 planetary carrier
2 Threads of mounting bolt: assembly.
Adhesive (LT-2) a 3 sets
3 Mounting bolt: 5) Install shaft (16) and ball (17) to No. 2
58.8 – 73.5 Nm {6 – 7.5 kgm} planetary carrier assembly.
a Install the shaft by expansion fit.
a Match the hole of the shaft to that of
the carrier and install the shaft by hit-
ting it lightly with a plastic hammer,
etc.
a When installing the shaft, take care
that ball (17) will not come off. (If
grease is applied, the shaft can be
installed easily.)
a 3 sets
6) Tighten mounting bolt (15).
3 Mounting bolt:
98 – 122.5 Nm {10 – 12.5 kgm}
a After assembling No. 2 planetary car-
3. No. 2 planetary carrier assembly rier assembly, check that gear (18)
1) Install thrust washer (21). rotates smoothly.
a 3 sets
2) Install 2 outer race bearings (20) to the

gear.
a 3 sets
50-300 12 D31/37-22
300 Power train
4. No. 2 sun gear a After inserting the pin, bend pins "a"
Install sun gear (14) and thrust washer (13) to of the carrier.
No. 2 planetary carrier assembly. a After assembling No. 1 planetary car-
rier assembly, check that gear (10)
rotates smoothly.
5. No. 1 sun gear

Install No. 1 sun gear (12).
6. No. 1 planetary carrier assembly 2) Install No. 1 planetary carrier assembly

1) Assemble No. 1 planetary carrier assem- (6).
bly according to the following procedure. 3) Install thrust washer (5).
a Replace the thrust washers and pin
with new ones.
1] Install bearing (11) to gear (10) and fit
upper and lower thrust washers (9),
then set gear (10) to No. 1 planetary
carrier assembly.
2] Match the pin hole of shaft (8) to that
of the carrier and install shaft (8) by
hitting it lightly with a plastic hammer,
etc.
a Take care not to damage the
thrust washers.
3] Insert pin (7).
D31/37-22 50-300 13
300 Power train
7. Ring gear 8. Cover

1) Fit the O-ring to the hub side. Using eye- 1) Using 2 through bolts, install cover.
bolts [2] and matching the bolt holes of 2) Install cover to the ring gear with 12
ring gear (4) to those of the hub, install mounting bolts (1).
ring gear (4). 2 Cover mating face:
a Degrease the mating faces of the ring Gasket sealant (1207B)
gear and hub. 3 Mounting bolt:
98 – 122.5 Nm {10 – 12.5 kgm}
2) Tighten ring gear with 18 mounting bolts

(3). 9. Refilling with oil
3 Mounting bolt: Tighten the plug and add power train oil
245 – 308.7 Nm {25 – 31.5 kgm} through the oil filler.
3 Plug: 58.8 – 78.4 Nm {6.0 – 8.0 kgm}
5 Final drive case: Approx. 3.5 l (TO30)

a Check the oil level after installing the HST
motor and final drive assembly to the
machine body.
50-300 14 D31/37-22
300 Power train
D31/37-22 50-300 15
SEN04726-01
D31/37-22 Bulldozer
©2009 KOMATSU
All Rights Reserved
50-300 16
SEN04727-01
D31EX-22
D31PX-22
D37EX-22
D37PX-22
D31EX-22 60001 and up
D31PX-22 60001 and up
D37EX-22 60001 and up
D37PX-22 60001 and up

Spreading and installation of track shoe assembly ......................................................................................... 2
Removal and installation of idler and recoil spring assembly ......................................................................... 4
Disassembly and assembly of idler assembly ................................................................................................ 5
Disassembly and assembly of recoil spring assembly.................................................................................... 8
Disassembly and assembly of track roller assembly .................................................................................... 12
Disassembly and assembly of carrier roller assembly .................................................................................. 16
D31/37-22 50-400 1
SEN04727-01 Spreading and installation of track shoe assembly
Spreading and installation of 4. Remove the track shoe of master link (3). [*2]
track shoe assembly 1
a Pull both sides of the master link with
wires and chain blocks and remove the
Spreading master link bolts to disconnect the master
1. Position the master link properly. link.
a Start the engine and position each master
link in front of the idler.
a Set a block, jack, etc. under the track shoe
in front of each idler.
2. Remove mounting bolts and cover (1).
5. Guiding the track link end with a crane, move

the machine slowly in reverse to spread the
track shoe assembly (4).
3. Loosen lubricator (2) to lower the tension of the

track shoe. [*1]
k Since the pressure in the recoil spring
cylinder is very high, do not loosen the
lubricator more than one turn. If the
track tension is not lowered, move the
machine forward and in reverse.
50-400 2 D31/37-22
Spreading and installation of track shoe assembly SEN04727-01
Installation
removal.
[*1]
a Adjust the tension of the track shoe. For
details, see Testing and adjusting, “Testing and
adjusting track shoe tension”.
[*2]
a When winding the track shoe, use a bar, etc. to
prevent the link from parting from the sprocket.
a Take proper measures so that the mating faces
and threads of the master link will not be
rusted, bruised, or deformed. In addition,
check that the mating faces and threads are
free from dirt.
a Tighten the master link bolts in the order of [1]
– [4] in 2 steps.
2 Master link bolt:
Seizure prevention compound
(MARUZEN MOLYMAX No. 2 or
equivalent)
3 Master link bolt:
Initial torque:
150 ± 40 Nm {15 ± 4 kgm}
Retightening angle: 180 ± 10°
D31/37-22 50-400 3
SEN04727-01 Removal and installation of idler and recoil spring assembly
Removal and installation of idler Installation

and recoil spring assembly 1
removal.
Removal
1. Spread the track shoe. For details, see
“Spreading and installation of track shoe".
2. Pull out idler and recoil spring assembly (1)

and sling it by the rod to remove it.
4 Idler and recoil spring assembly: 250 kg
3. Remove bolt (2) and separate idler (3) and

recoil spring assembly (4) from each other.
4 Idler: 145 kg
4 Recoil spring assembly: 105 kg
50-400 4 D31/37-22
Disassembly and assembly of idler assembly SEN04727-01
Disassembly and assembly of

idler assembly 1
Special tools
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
791T-430-
1 Push tool t 1 Q
L 3210
2 791-675-1510 Installer t 1
Disassembly 5. Pull idler (7) out of the shaft and support

assembly.
a Oil of 160 cc is filled in. Drain it at this time
or spread cloths so that the floor will not
be stained with it.
6. Remove floating seals (9) from idler (7) and

shaft and support assembly.
7. Remove nut (11) and bolt (12).
8. Remove 2 bushings (13) from idler (7).
1. Remove mounting bolts, guide (1), and shims

(2).
a Check the quantity of the shims.
2. Remove nut (3) and bolt (4).
3. Remove support (5).
4. Remove floating seals (6) from support (5) and

idler (7).
D31/37-22 50-400 5
SEN04727-01 Disassembly and assembly of idler assembly
Assembly 4. Using tool L2, install floating seal (9) to idler

(7).
a When installing the floating seal, degrease

and dry the mating faces of the O-ring and
floating seal (indicated with thick line A)
completely. The contact surfaces of the
floating seal must be free from dirt.
its slant is within 1 mm and its projection
"a" is 7 – 11 mm.
1. Using tool L1, press fit 2 bushings (13) to idler

(7).
2. Fit the O-ring to shaft (8), then install them to

support (10).
3. Insert bolt (12) in support (10) and tighten nut

(11).
2 Bolt: Liquid adhesive (LT-2)
3 Nut: 89 – 123 Nm {9 – 12.5 kgm}
50-400 6 D31/37-22
Disassembly and assembly of idler assembly SEN04727-01
5. Using tool L2, install floating seal (9) to support 8. Using tool L2, install floating seal (6) to support
(10). (5).
a For precautions for installing the floating a For precautions for installing the floating
seal, see a in step 4 above. seal, see ain 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 tighten the plug.
5
(7).
Oil: Approx. 159 ± 10 cc (TO30)
3 Plug: 98 – 137 Nm {10 – 14 kgm}
a For precautions for installing the floating

seal, see a in step 4 above.
11. Install support (5).
12. Insert bolt (4) in support (5) and tighten nut (3).
3 Nut: 89 – 123 Nm {9 – 12.5 kgm}
13. Install shims (2) and guide (1).

D31/37-22 50-400 7
SEN04727-01 Disassembly and assembly of recoil spring assembly
Disassembly and assembly of recoil spring assembly 1
Special tools Disassembly

1. Remove the mounting bolts and lock plate (1).
New/remodel
Necessity
Symbol
Sketch
2. Remove valve (3).

Q'ty
Part No. Part Name
3. Remove rod assembly (5) from recoil spring

791-685-8006 Compressor (B) t 1 assembly (4).
790-201-2860 Spacer t 1
4. Disassembly of recoil spring assembly
791-635-3160 Extension t 1 1) Set recoil spring assembly (4) to tool M1.
1
Cylinder k Since the installed load of the
790-101-1600 t 1
(686 kN {70 tons}) spring is large and dangerous, set
790-101-1102 Pump t 1 it securely.
790-201-1702 Push tool kit 1 a Installed load of spring:
M 71.6 kN {7,305 kg}
790-201-1781 • Push tool t 1
2
790-101-5021 • Grip t 1
01010-50816 • Bolt t 1
790-201-1500 Push tool kit 1
790-201-1590 • Plate t 1
3
790-101-5021 • Grip t 1
01010-50816 • Bolt t 1
50-400 8 D31/37-22
Disassembly and assembly of recoil spring assembly SEN04727-01
2) Apply hydraulic pressure slowly to com-

press the spring and tighten nut (6).
3) Remove 2 lock plates (7) and nut (6).
a Compress the spring until the nut
becomes loose.
k Release the hydraulic pressure
slowly to lower the tension of the
spring to zero.
4) Remove pilot (9) and cylinder (10) from
spring (8).
5) Remove snap ring (11), spacer (12), dust
seal (13), and bushing (14) from cylinder
(10).
5. Disassembly of rod assembly

1) Remove wear ring (16) from rod assembly
(5).
2) Remove snap ring (17) and U-packing
(18).
D31/37-22 50-400 9
SEN04727-01 Disassembly and assembly of recoil spring assembly
Assembly
1. Assembly of rod assembly 3) Using push tool M3, install spacer (12)
1) Install U-packing (18) to rod assembly (5) and secure it with snap ring (11).
and secure it with snap ring (17).
2) Install wear ring (16).
2. Assembly of recoil spring assembly

1) Using push tool M2, press fit bushing (14)
to cylinder (10).
a Secure the cylinder with block [2].
4) Install cylinder (10) and pilot (9) to spring

(8), then set them to tool M1.
5) Apply hydraulic pressure slowly to com-
press the spring.
6) Set the installed length of the spring to "a".
a Installed length (a) of spring:
375.6 mm
2) Install seal (13) to cylinder (10). a Installed load of spring:
71.6 kN {7,305 kg}
7) Position the spring with nut (6) and secure
it with lock plate (7).
3 Nut: 147 Nm {15 kgm}
50-400 10 D31/37-22
Disassembly and assembly of recoil spring assembly SEN04727-01
8) Remove recoil spring assembly (4) from

the tool.
3. Supply at least 120 ml of grease to cylinder
(10), taking care not to leave any bubble in part
"A".
2 Inside of cylinder: Grease (G2-LI)
4. Install rod assembly (5) to recoil spring assem-

bly (4).
a Install the rod with valve (3) loosened,
then insert the rod assembly.
5. Secure valve (3) with lock plate (1).

a Install the valve with the fitting out.
3 Valve: 58.8 – 88.2 Nm {6 – 9 kgm}
D31/37-22 50-400 11
SEN04727-01 Disassembly and assembly of track roller assembly
Disassembly and assembly of 4. Remove floating seal (5) from collar (3).
track roller assembly 1
5. Pull out roller (6) from shaft.
Special tools
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
3 791T-430-3220 Push tool t 1 Q

L 4 791-651-1510 Installer t 1
5 790-601-1000 Oil pump t 1
Disassembly
1. Remove plug (1) and drain oil.
6 Track roller oil: Approx. 150 cc 6. Remove floating seals (7) and (8) from roller
(6).
7. Remove bushings (9) and (10) from roller (6).
2. Set roller assembly (2) to block [1].
3. Push collar (3) and pull out ring (4), then

8. Remove ring (11), then remove collar (12) from
remove collar (3).
shaft (13).
50-400 12 D31/37-22
Disassembly and assembly of track roller assembly SEN04727-01
9. Remove floating seal (14) from collar (12). Assembly

1. Fit O-rings (15) to shaft (13) and assemble col-
10. Remove O-rings (15) from shaft (13). lar (12), then install ring (11).
a After assembling, tighten plug (1) tempo-
rarily.
2. Using tool L4, install floating seal (14) to collar

(12).
a When installing the floating seal, degrease

and dry the mating faces of the O-ring and
floating seal (indicated with thick line A)
completely. The contact surfaces of the
floating seal must be free from dirt.
its slant is within 1mm and its projection
"a" is 7 – 11 mm.
D31/37-22 50-400 13
SEN04727-01 Disassembly and assembly of track roller assembly
3. Using tool L3, press fit bushings (9) and (10) to 6. Refilling with oil
roller (6). Pour oil through clearance between shaft (13)
a Bushing press-fitting force: and roller (6).
29.4 ± 3.92 kN {3.0 ± 0.4 ton} a When using tool L5 to add the oil, add the
oil after completing the total assembly.
5 Roller: Approx. 150 cc (GO140)
4. Install floating seal (8) to roller (6).

a For details of the precautions when install-
ing the floating seals, see Step 2, a Pre-
cautions when assembling floating seal. 7. Install floating seal (8).
a For details of the precautions when install-
ing the floating seals, see Step 2, a Pre-
cautions when assembling floating seal.
5. Set shaft (13) and collar (12) assembly on

block (1), then assemble roller (6).
a Coat the sliding surface of the floating seal
with engine oil, and make sure that no dirt 8. Install floating seal (5) to collar (3).
or dust sticks to the surface. a For details of the precautions when install-
a When assembling the roller, coat the shaft ing the floating seals, see Step 2, a Pre-
or bushing with engine oil. caution when assembling floating seal.
a Coat the sliding surface of the floating seal
with engine oil, and make sure that no dirt
or dust sticks to the surface.
50-400 14 D31/37-22
Disassembly and assembly of track roller assembly SEN04727-01
11. If oil was not added in Step 6, use tool L5 to fill

track roller assembly with oil.
5 Track roller oil:
Approx. 150 cc (GO140)
9. Fit roller (2) to collar (3), then install ring (4).
12. Tighten plug (12).

3 Plug: 98 – 137.2 Nm {10 – 14 kgm}
10. Using tool L5, apply basic pressure to roller oil

filler port, and check for leakage of air from
seal.
a Method of checking
The basic pressure shall be maintained for
10 seconds and the indicator of the gauge
shall not go down.
q Basic pressure: 0.1 MPa {1 kg/cm2}
D31/37-22 50-400 15
SEN04727-01 Disassembly and assembly of carrier roller assembly
Disassembly and assembly of 6. Disassembly of shaft assembly

carrier roller assembly 1
1) Remove collar (8) from shaft assembly
(6).
Special tools 2) Remove floating seal (9).
3) Remove floating seal (10) from collar (8).
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
6 791-430-3230 Installer t 1
7 791-415-5160 Sleeve t 1
L
8 790-445-3370 Push tool t 1
9 791T-B30-1110 Sleeve t 1 Q
Disassembly
1. Remove plug (1) to drain oil.
6 Carrier roller: Approx. 180 – 200 cc
4) Remove bearing (12) from shaft (11).
2. Remove snap ring (2) and cover (3). 7. Remove outer race (14) from roller (13).
3. Remove bolt (4) and spacer (5). 8. Turn over roller (13) and remove outer race
(15).
4. Set the carrier roller on block [1].
5. Using tool L7, pull out shaft assembly (6) with

a press and remove bearing (7).
50-400 16 D31/37-22
Disassembly and assembly of carrier roller assembly SEN04727-01
Assembly 3) Install floating seal (9) and press fit bear-

1. Press fit outer races (15) and (14) to roller (13). ing (12) with tool L9.
a For precautions for installing the float-
2. Assembly of shaft assembly ing seal, see ? in step 2 above.
1) Using tool L8, press fit ring (8) to shaft
(11).
a Press fitting force of ring:
65.7 – 99.0 kN {6.7 – 10.1 tons}
3. Set shaft assembly (6) on block [3] and install

roller (13).
4. Press fit bearing (7) with tool L9.

2) Using tool L6, install floating seal (10). a Press fit the bearing, rotating the roller,
a When installing the floating seal, and stop press fitting when the roller
degrease and dry the parts indicated becomes a little heavy to rotate.
with thick line A (O-ring and mating
face of the O-ring).
a After installing the floating seal, check
that its slant is within 1 mm and its
projection "a" is 4 – 8 mm.
D31/37-22 50-400 17
SEN04727-01 Disassembly and assembly of carrier roller assembly
5. Install spacer (5) with bolt (4).

3 Bolt: 245 – 309 Nm {25.0 – 31.5 kgm}
6. Supply oil to the carrier roller.

5 Carrier roller:
Approx. 180 – 200 cc (GO140)
7. Fit the O-ring to cover (3) and install them to

the roller, then install snap ring (2).
8. Check the oil level and tighten plug (1).
50-400 18 D31/37-22
Disassembly and assembly of carrier roller assembly SEN04727-01
D31/37-22 50-400 19
SEN04727-01
D31/37-22 Bulldozer
©2009 KOMATSU
All Rights Reserved
50-400 20
SEN04728-00
D31EX-22
D31PX-22
D37EX-22
D37PX-22
D31EX-22 60001 and up
D31PX-22 60001 and up
D37EX-22 60001 and up
D37PX-22 60001 and up
500 Hydraulic system

Removal and installation of hydraulic tank assembly...................................................................................... 2
Removal and installation of control valve assembly ....................................................................................... 4
Disassembly and assembly of control valve assembly ................................................................................... 5
Disassembly and assembly of hydraulic cylinder assembly ........................................................................... 7
D31/37-22 50-500 1
SEN04728-00 Removal and installation of hydraulic tank assembly
Removal and installation of 7. Remove 2 batteries (3).

hydraulic tank assembly 1
8. Disconnect hose clamps (4), (5) and (6).
Removal
k Lower the work equipment to the ground 9. Disconnect hoses (7), (8) and (9).
and stop the engine. Then, loosen the
hydraulic tank oil filler cap gradually to 10. Disconnect suction hoses (10) and (11).
release the pressure inside the hydraulic
tank. 11. Remove hydraulic tank mounting bolts (12)
k Disconnect the cable from the negative (–) and 4 lower mounting bolts. [*1]

5 Hydraulic tank: Approx. 60 l

cation)

and installation of ROPS cab and operator 12. Lift off hydraulic tank assembly (13).
4
Hydraulic tank assembly: 170 kg
tion)
4. Open cooling fan and motor assembly (1) and

sling it.
5. Disconnect spring (2).
6. Sling down the cooling fan and motor assem-

bly.
4 Cooling fan and motor assembly: 120 kg
50-500 2 D31/37-22
Removal and installation of hydraulic tank assembly SEN04728-00
Installation

removal.
[*1]
3 Hydraulic tank mounting bolt (12):
455 – 565 Nm {46.5 – 58 kgm}
3 Hydraulic tank lower mounting bolt:
235 – 285 Nm {23.5 – 29.5 kgm}

level again.

D31/37-22 50-500 3
SEN04728-00 Removal and installation of control valve assembly
Removal and installation of

control valve assembly 1
Removal
k Lower the work equipment to the ground
hydraulic tank oil filler cap gradually to
tank.
a Plug the disconnected hoses to prevent foreign
matter from entering them.
a Record each piping to prevent a mistake in re-
connecting it.
1. Drain the hydraulic oil. 5. Remove the 4 mounting bolts and lift off control
6
valve assembly (13).
Hydraulic tank: Approx. 60 l
4 Control valve assembly: 25 kg
cation)

tion)
4. Disconnect the 12 control valve hoses.

q (1): To tank (Hose color band: Red)
q (2): Lift lower (Hose color band: Yellow)
q (3): Lift raise (Hose color band: Green)
q (4): To angle cylinder bottom Installation
(Hose color band: 2 red bands)
q (5): To angle cylinder head q Carry out installation in the reverse order to
(Hose color band: 2 orange bands) removal.
q (6): To tilt cylinder bottom
(Hose color band: 2 blue bands) a When installing each hose, take extreme care
q (7): To tilt cylinder head not to twist it.
(Hose color band: 2 white bands)
q (8): To lift cylinder bottom
(Hose color band: Yellow) q Refilling with oil (Hydraulic tank)
q (9): To lift cylinder head a Add oil through the oil filler to the specified
(Hose color band: Green) level. Run the engine to circulate the oil
q (10): To fan pump through the piping. Then, check the oil
q (11): To tank level again.
q (12): From work equipment pump

50-500 4 D31/37-22
Disassembly and assembly of control valve assembly SEN04728-00
Disassembly and assembly of (For angle)

control valve assembly 1
a In this section, only precautions for assembling

the control valve assembly are explained.
Assembly of control valve assembly

q Coat the sliding surfaces of the parts with
engine oil before assembling.
q Use TB2706 (Threebond) or KANDEN
CLEANER (KANTO DENKA KOGYO) or
equivalent to clean the parts during assembly.
2 Mating face:
Gasket sealant (SEALEND 242
or equivalent)
q When tightening or loosening 3 bolts (1), be (For tilt)
sure to keep the spool in the valve body.
q For ripper (Ripper specification)
q For angle
q For tilt
q For lift
q For fan
3 Mounting bolt (1):
6.9 – 9.8 Nm {0.7 – 1.0 kgm}
(For lift)
q When tightening plugs (2), (3), (4) and (5),

apply 1 drop each of LOCTITE (No. 638) to
their threaded parts.
3 Plug: 14.7 – 19.6 Nm {1.5 – 2 kgm}
(For fan)
D31/37-22 50-500 5
SEN04728-00 Disassembly and assembly of control valve assembly
q Tighten the control valve upper and lower

cover mounting bolts in the order of A, B, C
and D in 3 times.
3 Cover mounting bolt:
1st time:
9.8 – 14.7 Nm {1.0 – 1.5 kgm}
2nd time:
19.2 – 24.5 Nm {2.0 – 2.5 kgm}
3rd time:
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
50-500 6 D31/37-22
Disassembly and assembly of hydraulic cylinder assembly SEN04728-00
Disassembly and assembly of 3) Pull out piston rod assembly (3).

hydraulic cylinder assembly 1
a Place an oil receiving pan, etc. under
the cylinder bottom to receive the oil.
Special tools
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
790-502-1003 Repair stand t 1

1
2 790-330-1100 Wrench t 1
790-302-1270 Socket t 1
3
790-302-1390 Socket t 1
4 790-720-1000 Expander t 1
796-720-1640 Rubber band q 1
2. Piston assembly and head assembly
07281-00909 Clamp q 1 1) Set piston rod assembly (3) to tool U1.
5
796-720-1650 Rubber band q 1 2) Using tool U3, remove nylon nut (4).
07281-01029 Clamp q 1 a Width across flats: 50 mm (Tilt cylinder)
U 46 mm (Lift, angle cylinder)
790-201-1702 Push tool kit 1
3) Remove piston assembly (5) and head
790-201-1741 • Push tool t 1
assembly (6).
6 790-201-1751 • Push tool t 1
790-101-5021 • Grip t 1
01010-50816 • Bolt t 1
790-201-1500 Push tool kit 1
790-201-1550 • Plate t 1
7 790-201-1560 • Plate t 1
790-101-5021 • Grip t 1
01010-50816 • Bolt t 1
Disassembly
1. Piston rod assembly
1) Set cylinder assembly (1) to tool U1.
2) Using a hydraulic pump or a power 4) Disassembly of piston assembly
wrench and tool U2, disconnect head 1] Remove wear ring (7).
assembly (2). 2] Remove piston ring (8).
D31/37-22 50-500 7
SEN04728-00 Disassembly and assembly of hydraulic cylinder assembly
5) Disassembly of head assembly Assembly

1] Remove backup ring (9) and O-ring a Apply engine oil to the sliding surfaces of each
(10). part and take care not to damage the rod,
2] Remove O-ring (11). packing, dust seal, and O-ring.
3] Remove packing (12).
4] Remove buffer ring (13). 1. Head assembly and piston assembly
5] Remove snap ring (14) and dust seal 1) Assembly of head assembly
(15). 1] Press fit bushing (17) with tool U6.
6] Remove snap ring (16) and bushing
(17).
2] Using tool U7, install dust seal (15).
3] Install snap rings (14) and (16).

4] Install buffer ring (13).
5] Install packing (12).
6] Install O-ring (11).
7] Install backup ring (9) and O-ring
(10).
a Warm the backup ring in water at
50 – 60°C before installing it.
50-500 8 D31/37-22
2) Assembly of piston assembly 2. Piston rod assembly

1] Set piston ring (8) to tool U4. 1) Set the piston rod to tool U1.
2] Rotate the handle by 8 – 10 turns to 2) Install head assembly (6) and piston
expand the piston ring. assembly (5).
3] Remove piston ring (8) from tool U4. 3) Using tool U3, tighten nut (4).
4] Install piston ring (8) to piston assem- 3 Nut:
bly (5). Tilt cylinder (Width across flat: 50 mm):

5] Using tool U5, reduce piston ring (8). 1.25 ± 0.13 kNm {127 ± 12.7 kgm}
Lift, angle cylinder (Width across flat: 46
mm): 912 ± 91.0 Nm {93 ± 9.3 kgm}
a Before installing the nut, degrease
the threads of the piston rod thor-
oughly.
2 Threads of rod:
Adhesive (LOCTITE N262)
6] Install wear ring (7).
4) Set cylinder (1) to tool U1.

5) Install piston rod assembly (3) to the cylin-
der.
D31/37-22 50-500 9
SEN04728-00 Disassembly and assembly of hydraulic cylinder assembly
6) Using a hydraulic pump or a power

wrench and tool U2, tighten head assem-
bly (2).
3 Head assembly:
Tilt cylinder:
677 ± 67.5 Nm {69 ± 6.9 kgm}
Lift cylinder:
569 ± 57.0 Nm {58 ± 5.8 kgm}
Angle cylinder:
588 ± 59.0 Nm {60 ± 6.0 kgm}
50-500 10 D31/37-22
D31/37-22 50-500 11
SEN04728-00
D31/37-22 Bulldozer
©2008 KOMATSU
All Rights Reserved
50-500 12
SEN04729-00
D31EX-22
D31PX-22
D37EX-22
D37PX-22
D31EX-22 60001 and up
D31PX-22 60001 and up
D37EX-22 60001 and up
D37PX-22 60001 and up
600 Work equipment

Removal and installation of work equipment assembly .................................................................................. 2
D31/37-22 50-600 1
600 Work equipment
SEN04729-00 Removal and installation of work equipment assembly
Removal and installation of work 3. Remove mounting bolts (3) and (4) and plate.
equipment assembly 1
[*1]
Removal 4. Remove pitching rod (5). [*2]

and stop the engine. Then, loosen the 5. Disconnect 2 tilt cylinder hoses (6) and remove
hydraulic tank oil filler cap gradually to mounting pins (7) and (8) and tilt cylinder
release the pressure inside the hydraulic assembly (9).
tank.
6. Remove piston rod mounting pins (10) and (11)
1. Lower the blade to a level place and set block to disconnect angle cylinder assemblies (12)
[1] under the work equipment U-frame. and (13) from the blade.
a Set a block between each angle cylinder
and U-frame.
7. Sling blade (14) and remove the 10 mounting

bolts of trunnion (15) to disconnect the trun-
nion from the U-frame. [*3]
a Use chain blocks etc. for the rear wires to
balance the blade.
8. Move blade (14) forward to remove.

4 Blade
D31EX-22: 565 kg
D31PX-22: 650 kg
D37EX-22: 585 kg
D37PX-22: 655 kg
50-600 2 D31/37-22
600 Work equipment
Removal and installation of work equipment assembly SEN04729-00
9. Remove 8 mounting bolts (16) to remove trun- 11. Fix the head side of lift cylinder (20) to the
nion (15), caps (17), shim (18) and bearing engine hood grip with ropes etc.
(19). [*4] q Work on both right and left sides.
a Check the quantity and thickness of the
shims.
12. Disconnect the 6 cylinder hoses.

q (22): Tilt cylinder hose
(2 pieces on right side)
q (23): Angle cylinder hose
(2 pieces each on right and left sides)
10. Sling lift cylinder assembly (20) and remove

piston rod mounting pin (21).
q Work on both right and left sides.
D31/37-22 50-600 3
600 Work equipment
SEN04729-00 Removal and installation of work equipment assembly
13. Sling U-frame assembly (24). Installation

14. Remove U-frame mounting pins (25) on the removal.
right and left sides and move the U-frame for-
ward to remove. [*1]
3
4
Pitching rod fixing bolt:
U-frame assembly: 450 kg
98 – 123 Nm {10 – 12.5 kgm}
[*2]
a Install the pitching rod to following dimension
(a).
Pitching rod standard dimension (a):
368.5 mm
[*3]
3 Trunnion mounting bolt:
455 – 565 Nm {46.5 – 58 kgm}
[*4]
a Adjust the center ball shim. For details, see
Testing and adjusting, "Adjusting play of blade
center ball".
15. Sling angle cylinder assemblies (12) and (13) k When aligning the pin holes, never insert
and remove its bottom mounting pin to remove your fingers in the pin holes.
it.
16. Remove 2 tilt cylinder hoses (6). q Refilling with oil (Hydraulic tank)
level again.
q Greasing
a After installing, grease the removed and
installed mounting pins securely.
50-600 4 D31/37-22
600 Work equipment
Removal and installation of work equipment assembly SEN04729-00
D31/37-22 50-600 5
SEN04729-00
D31/37-22 Bulldozer
©2008 KOMATSU
All Rights Reserved
50-600 6
SEN04730-00
D31EX-22
D31PX-22
D37EX-22
D37PX-22
D31EX-22 60001 and up
D31PX-22 60001 and up
D37EX-22 60001 and up
D37PX-22 60001 and up

Removal and installation of ROPS canopy and operator seat frame assembly ............................................. 2
Removal and installation of ROPS cab and operator seat frame assembly ................................................... 5
Removal and installation of operator’s cab glass (Stuck glass) ...................................................................... 9
D31/37-22 50-700 1
SEN04730-00 Removal and installation of ROPS canopy and operator seat frame assembly
Removal and installation of ROPS 4. Remove 2 brackets (4).

canopy and operator seat frame
5. Remove floor mat (5).
assembly 1
(ROPS canopy specification)

Removal
tank.
k Close the heater hose valve.
1. Remove right and left steps (1).

6. Remove cover (6) and floor plate (7).
2. Remove right and left covers (2).
3. After removing the left cover, disconnect

ground cable (3). 8. Disconnect wiring connectors (10) CN-104,
(11) CN-2 and (12) CN-3.
9. Disconnect heater hoses (13) and (14).
10. Disconnect bracket (15).
50-700 2 D31/37-22
Removal and installation of ROPS canopy and operator seat frame assembly SEN04730-00
11. Remove battery cable clamp (16) and discon- 14. Disconnect wiring connectors (20) CN-102 and
nect battery cable (17). (21) CN-RS.
15. Disconnect the 6 work equipment PPC hoses.

q (22): Angle right
q (23): Tilt right (Hose color band: Red)
q (24): Lift lower (Hose color band: Orange)
q (25): Angle left (Hose color band: Blue)
q (26): Tilt left (Hose color band: White)
q (27): Lift raise (Hose color band: Red)
12. Remove right engine side covers (18).
13. Disconnect starting motor cable (19).
17. Remove 4 each of mounting bolts (29) on the

front and rear sides of the ROPS canopy.
D31/37-22 50-700 3
SEN04730-00 Removal and installation of ROPS canopy and operator seat frame assembly
18. Lift off ROPS canopy and operator seat frame Installation
assembly (30). q Carry out installation in the reverse order to
a Check that all the wirings and pipings are removal.
disconnected.
4
[*1]
3
ROPS canopy and operator seat frame
ROPS canopy and operator seat frame
assembly: 700 kg
mounting bolt:
785 – 980 Nm {80 – 100 kgm}
q Refilling with coolant

a Add coolant through the coolant filler to
the specified level. Run the engine to
increase the coolant temperature. Then,
check the coolant level again.

level again.

50-700 4 D31/37-22
Removal and installation of ROPS cab and operator seat frame assembly SEN04730-00
Removal and installation of ROPS 3. Open the left side cover and disconnect
cab and operator seat frame ground cable (3).
assembly 1
(ROPS cab specification)

Removal
tank.
k Collect the air conditioner refrigerant
(R134a) from air conditioner circuit in
advance. (Machine with air conditioner) 4. Remove brackets (4).
a Ask professional traders for collecting and fill-
ing operation of refrigerant (R134a). 5. Remove floor mat (5).
a Never release the refrigerant (R134a) to the
atmosphere.
k If refrigerant gas (R134a) gets in your eyes,

you may lose your sight. Accordingly, put
on protective goggles while you are collect-
ing the refrigerant (R134a) or filling the air
conditioner circuit with the refrigerant
(R134a). Collecting and filling work must be
conducted by a qualified person. (Machine
with air conditioner)
k Close the heater hose valve.
1. Remove right and left steps (1).
2. Remove right and left covers (2). 6. Remove cover (6).
7. Remove floor plate (7).
D31/37-22 50-700 5
SEN04730-00 Removal and installation of ROPS cab and operator seat frame assembly
8. Disconnect wiring connectors (8) CN-104, (9) 14. Disconnect wiring connector (20) CN-B.
CN-2 and (10) CN-3.
15. Disconnect 4 washer hoses (21) and (22).
9. Disconnect heater hoses (11) and (12).
10. Disconnect bracket (13).
11. Disconnect air conditioner hoses (14) and (15).

[*1]
12. Disconnect wiring clamps (16) and (17).
16. Remove right engine side covers (23).
13. Remove battery cable clamp (18) and discon-

nect battery cable (19).
17. Disconnect starting motor cable (24).
50-700 6 D31/37-22
Removal and installation of ROPS cab and operator seat frame assembly SEN04730-00
18. Disconnect wiring connectors (25) CN-102 and 21. Replace all of the 4 front bolts on the cab roof
(26) CN-RS. with 16-mm eye bolts. Then, install the sling
chains to the 4 eye bolts at the front of the cab
19. Disconnect 6 work equipment PPC hoses. and to the 2 brackets at the rear.
q (27): Angle right
q (28): Tilt right (Hose color band: Red)
q (29): Lift lower (Hose color band: Orange)
q (30): Angle left (Hose color band: Blue)
q (31): Tilt left (Hose color band: White)
q (32): Lift raise (Hose color band: Red)
22. Remove mounting bolts (34) on the right and

left sides of the rear of the ROPS cab.
a Do not remove bolt (b).
23. Remove 1 ROPS stopper mounting bolt (34a)

on each of the right and left sides at the rear of
the ROPS cab. [*2]
24. Remove 2 ROPS stopper bolts (35) at the mid-

dle of the ROPS cab. [*3]
D31/37-22 50-700 7
SEN04730-00 Removal and installation of ROPS cab and operator seat frame assembly
25. Remove 8 mounting bolts (36) at the front of Installation

the ROPS cab. q Carry out installation in the reverse order to
removal.
[*1]
a When installing the air conditioner circuit hoses
and tubes, take care that dirt, dust, water, etc.
will not enter them.
a When connecting the air conditioner hoses and
tubes, check that O-rings are fitted to their
joints.
a Check that each O-ring is not damaged or
deteriorated.
a When connecting the refrigerant piping, apply
compressor oil for refrigerant (R134a)
(DENSO: ND-OIL8, VALEO THERMAL SYS-
26. Lift off ROPS cab and operator seat frame TEMS: ZXL100PG (equivalent to PAG46)) to
assembly (38). its O-rings.
a Check that all the wirings and pipings are 3 Hose (14) sleeve nut:
disconnected. 29 – 37 Nm {2.9 – 3.7 kgm}

3 Hose (15) sleeve nut:
4 ROPS cab and operator seat frame 21 – 28 Nm {2.1 – 2.8 kgm}
assembly: 1,200 kg
[*2]
3 ROPS stopper mounting bolt at the rear of
the ROPS cab:
785 – 980 Nm {80 – 100 kgm}
[*3]
3 ROPS stopper bolts at the middle of the
ROPS cab: 785 – 980 Nm {80 – 100 kgm}
q Charging air conditioner with refrigerant

Charge the air conditioner circuit with refriger-
ant (R134a).
q Refilling with coolant

a Add coolant through the coolant filler to
the specified level. Run the engine to cir-
culate the coolant through the system.
Then, check the coolant level again.

level again.

50-700 8 D31/37-22
Removal and installation of operator’s cab glass (Stuck glass) SEN04730-00
Removal and installation of operator’s cab glass (Stuck glass) 1
a Among the panes of window glass of the oper- (1): Front window glass
ator’s cab, the 4 panes of (1), (2) on both sides (2): Left door window glass
and (4) are stuck. : Right door window glass
In this section, the procedure for replacing the (3): Adhesive tape
stuck glass is explained. (4): Rear window glass
D31/37-22 50-700 9
SEN04730-00 Removal and installation of operator’s cab glass (Stuck glass)
Special tools a If the window glass is broken finely, it may be

removed with knife [4] and a screwdriver.
New/remodel
a Widening the cut with a screwdriver, cut the
Necessity
Symbol
Sketch
adhesive and both-sided adhesive tape with
Q’ty
Part No. Part name
knife [4].
(The following figure shows the operator’s cab
of a wheel loader.)
X1 793-498-1210 Lifter (Suction cup) t 2
Removal
a Remove the window glass to be replaced
1. Using seal cutter [1], cut the adhesive between

broken window glass (6) and operator’s cab
(metal sheet) (7).
2. Remove the window glass.
a If a seal cutter is not available, make holes on

the adhesive and both-sided adhesive tape
with a drill and pass a fine wire (piano wire,
etc.) [2] through the holes. Grip the both ends
of the wire with pliers [3], etc. (or hold them by
winding them onto something) and move the
wire to the right and left to cut the adhesive
and both-sided adhesive tape.
Since the wire may be broken by the frictional
heat, apply lubricant to it.
(The following figure shows the operator’s cab
of a wheel loader.)
50-700 10 D31/37-22
Installation 3. Stick both-sided adhesive tape (3) along the

1. Using a knife and scraper [5], remove the inside edges of the front window glass sticking
remaining adhesive and both-sided adhesive section and both door window glass sticking
tape from the metal sheets (glass sticking sur- sections.
faces) of the operator’s cab. a Do not remove the release tape of the
a Remove the adhesive and both-sided both-sided adhesive tape on the glass
adhesive tape to a degree that they will sticking side before sticking the glass.
not affect adhesion of the new adhesive. a When sticking the both-sided adhesive
Take care not to scratch the painted sur- tape, do not touch the cleaned surface as
faces. long as possible.
(If the painted surfaces are scratched, a Take care that the both-sided adhesive
adhesion will be lowered.) tape will not float at each corner of the
(The following figure shows the operator’s window frame.
cab of a wheel loader.) a Do not lap the finishing end of both-sided
adhesive tape (3) over the starting end but
make clearance (a) of about 5 mm
between them.
2. Remove oil, dust, dirt, etc. from the sticking

surfaces of cab (7) and window glass (8) with
white gasoline.
a If the sticking surfaces are not cleaned
well, the glass may not be stuck perfectly.
a Clean the all black part on the back side of
the window glass.
a After cleaning the sticking surfaces, leave
them for at least 5 minutes to dry.
D31/37-22 50-700 11
4. Position the new window glass. 5. Apply adhesive.

1) Using tool X1, set the window glass to the 2 Adhesive:
sticking position. Check the clearance Sikaflex 256HV manufactured by Sika
between the window glass and the opera- Japan
tor’s cab on the right, left, upper, and lower a Do not use primer.
sides, and then adjust it evenly. a The using limit of the adhesive is 6 months
a Position front window glass (1) from after the date of manufacture. Do not use
inside of operator’s cab (7). Adjust it the adhesive after this limit.
so that the difference between black a Keep the adhesive in a dark place where
coated part and the metal sheet of the temperature is below 25ºC.
operator’s cab (7) will be even on the a Never heat the adhesive higher than 30ºC.
right, left, upper, and lower sides. a When reusing the adhesive, remove the
a When positioning each door window all hardened part from the nozzle tip.
glass (2), adjust the door window
glass so that the positional relation- 1) Break aluminum seal (11) of the outlet of
ship between it and door metal sheet adhesive cartridge (10) and install the
will be even all around the window. nozzle.
2) After positioning the glasses, stick tapes
[6] between front window glass (1) and
operator’s cab (7) and the right, left, and
lower parts of each door window glass (2)
and each door (9), and then draw position-
ing line (e).
3) Cut the tapes between window glasses (1)
and (2) and operator’s cab (7) with a knife,
and then remove the window glasses.
a Do not remove the tapes left on the
window glasses and operator’s cab
before installing the window glasses.
2) Cut the tip of the adhesive nozzle (12) so

that dimensions (f) and (g) will be as fol-
lows.
q Dimension (f): 10 mm
q Dimension (g): 15 mm
50-700 12 D31/37-22
3) Set adhesive cartridge (10) to caulking

gun [7].
a An electric caulking gun is more effi-
cient.
a Apply adhesive (13) to dimensions (h) and (j)

of both-sided adhesive tape (3) of operator’s
cab (7).
q Dimension (h): 10 mm
4) Remove release tape of the both-sided q Dimension (j): 15 mm
adhesive tape (3a) on the glass side. a Apply adhesive (13) higher than both-sided
adhesive tape (3).
a Apply the adhesive evenly.
5) Apply adhesive (13) to the outside of both-

sided adhesive tape (3) of the operator’s
cab.
D31/37-22 50-700 13
6. Install the front window glass. 8. Fix the window glasses.

1) Using tool X1, match front window glass 1) Using styrene foam blocks [10] and rubber
(1) to line (e) on positioning tapes [6] bands [11], fix the front window glass to fit
drawn in step 5 and install it to operator’s it completely.
cab (7). a You may use sealing tapes to fix the
a Since the window glass cannot be front window glass.
removed and stuck again, stick it very (The figure shows the operator’s cab of a
carefully. hydraulic excavator.)
a Stick the glass within 5 minutes after
applying the adhesive.
2) After sticking the window glass, press all
around it until it is stuck to the both-sided
adhesive tape.
a Press the corners of the window glass
firmly.
9. After installing the window glasses, remove the

primer and adhesive from them and the opera-
tor’s cab.
a Using white gasoline, wipe off the adhe-
sive before it is dried up.
a When cleaning the glasses, do not give an
impact to them.
7. Install both door window glasses.
1) Using tool X1, match both door window 10. Protect the stuck window glasses.
glasses (2) to lines (e) on positioning 1) Keep the stopper rubbers, styrene foam
tapes [6] drawn in step 5 and install them blocks, and rubber bands installed for 10
to both doors (9). hours (at temperature of 20ºC and humid-
a Since the window glass cannot be
ity of 65%).
removed and stuck again, stick it very
2) After applying the adhesive, wait for at
carefully.
least 24 hours, before operating the
a Stick the glass within 5 minutes after
machine actually.
applying the adhesive.
2) After sticking each window glass, press all
around it until it is stuck to the both-sided
adhesive tape.
a Press the corners of each window
glass firmly.
50-700 14 D31/37-22
D31/37-22 50-700 15
SEN04730-00
D31/37-22 Bulldozer
©2008 KOMATSU
All Rights Reserved
50-700 16
SEN04731-00
D31EX-22
D31PX-22
D37EX-22
D37PX-22
D31EX-22 60001 and up
D31PX-22 60001 and up
D37EX-22 60001 and up
D37PX-22 60001 and up

Removal and installation of HST controller assembly..................................................................................... 2
Removal and installation of KOMTRAX terminal assembly ............................................................................ 3
D31/37-22 50-800 1
SEN04731-00 Removal and installation of HST controller assembly
Removal and installation of HST 5. Disconnect connectors CN-ST1 (8), CN-ST2

controller assembly 1
(9) and CN-ST3 (10) of HST controller (7).
Removal 6. Remove 4 mounting bolts (11) and HST con-

k Disconnect the cable from the negative (–) troller (7).
1. Pull out starting switch (1), remove 4 plastic

panel mounting bolts (2), and fold plastic panel
(3) toward the operator seat.
2. Disconnect 7 panel switches (4) and remove

plastic panel (3).
Installation
removal.
a If the HST controller assembly was replaced,

adjust the new assembly. For details, see Test-
3. Remove 6 mounting bolts (6) of monitor panel panel (EMMS), 11. Tuning mode (TUNING)".
mounting bracket (5) and fold the bracket
toward the operator seat.
4. Disconnect connectors CN-P1, CN-P2 and

CN-P3 and remove monitor panel mounting
bracket (5).
50-800 2 D31/37-22
Removal and installation of KOMTRAX terminal assembly SEN04731-00
Removal and installation of Installation

KOMTRAX terminal assembly 1
removal.
Removal
k Disconnect the cable from the negative (–) a If the HST controller assembly was replaced,
terminal of the battery. adjust the new assembly. For details, see Test-
1. Remove the operator seat. panel (EMMS), 11. Tuning mode (TUNING)".
4 Operator seat: 50 kg
3. Disconnect the 3 wiring connectors.

q (2): CN-G01
q (3): CN-KOM2
q (4): CN-KOM3
4. Remove KOMTRAX terminal (5).
D31/37-22 50-800 3
SEN04731-00
D31/37-22 Bulldozer
©2008 KOMATSU
All Rights Reserved
50-800 4
SEN04355-02
BULLDOZER
D31EX-22
D31PX-22
D37EX-22
D37PX-22
D31EX-22 60001 and up
D31PX-22 60001 and up
D37EX-22 60001 and up
D37PX-22 60001 and up
90 Diagrams and drawings 90
100 Hydraulic diagrams and drawings

Work equipment hydraulic circuit diagram ...................................................................................................... 3
D31/37-22 90-100 1
SEN04355-02
90-100 2 D31/37-22
Work equipment hydraulic circuit diagram
Work equipment hydraulic circuit diagram D31/37-22
1
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN04355-02
D31/37-22
90-100 3
D31PX-22 (Trimming specification)
1
Serial No.: 60001 - 61102
SEN04355-02
D31/37-22
90-100 5
1
Serial No.: 61103 and up
SEN04355-02
D31/37-22
90-100 7
SEN04355-02
D31/37-22 90-100 9
SEN04355-02
D31/37-22 Bulldozer
©2012 KOMATSU
All Rights Reserved
90-100 10
SEN04356-02
BULLDOZER
D31EX-22
D31PX-22
D37EX-22
D37PX-22
D31EX-22 60001 and up
D31PX-22 60001 and up
D37EX-22 60001 and up
D37PX-22 60001 and up
90 Diagrams and drawings 90
200 Electrical diagrams and drawings

Electrical circuit diagram ................................................................................................................................. 3
Cab electrical circuit diagram........................................................................................................................ 17
Air conditioner circuit diagram....................................................................................................................... 21
Connector list and stereogram...................................................................................................................... 23
D31/37-22 90-200 1
SEN04356-02
90-200 2 D31/37-22
Electrical circuit diagram (1/7)
Electrical circuit diagram (1/7) D31/37/39-22
1
D31/37/39-22
SEN04356-02
D31/37-22
90-200 3
1
D31/37/39-22
SEN04356-02
D31/37-22
90-200 5
Electrical circuit diagram (3/7) D39-22
1
D39-22
SEN04356-02
D31/37-22
90-200 7
Electrical circuit diagram (4/7) D31/37-22
1
D31/37-22
SEN04356-02
D31/37-22
90-200 9
1
D31/37/39-22
SEN04356-02
D31/37-22
90-200 11
1
D31/37/39-22
SEN04356-02
D31/37-22
90-200 13
1
D31/37/39-22
SEN04356-02
D31/37-22
90-200 15
Cab electrical circuit diagram SEN04356-02
Cab electrical circuit diagram 1
Cab specification
D31/37-22 90-200 17
Cab electrical circuit diagram SEN04356-02
Cab specification
Lamp circuit diagram
D31/37-22 90-200 19
SEN04356-02 Cab electrical circuit diagram
90-200 20 D31/37-22
Air conditioner circuit diagram SEN04356-02
Air conditioner circuit diagram 1
Cab specification
D31/37-22 90-200 21
Connector list and stereogram
Connector list and stereogram D31/37EX, PX-22 D31/37-22
Connector Number Address of Connector Number Address of

No. Model of pins Component name stereogram No. Model of pins Component name stereogram
CN-2 DT 8 Intermediate connector I-1 CN-FG #8 1 Intermediate connector E-5
CN-3 DT-T 12 Intermediate connector J-1 CN-MFG Terminal 1 Ground (floor) V-1
CN-4 DT 2 Intermediate connector F-1 CN-FM1 DT-T 8 Intermediate connector E-6
CN-11 Relay 5 Neutral safety relay AB-6 CN-FP DT-T 3 Fuel dial potentiometer Z-8
CN-11B Relay 5 Center brake relay AB-6 CN-FRS DT-T 2 Fan motor sensor M-5
CN-12 DT-T 2 HST oil temperature sensor I-1 CN-FWL SWP 6 Working lamp switch O-9
CN-13 DT-T 2 Fuel gauge sensor E-6 CN-G01 — 40 KOMTRAX terminal [ORBCOMM specification] AC-4
CN-17 #12 1 Spare power supply Y-1 CN-GND1 Terminal 1 Ground [Cab specification] H-9
CN-19 DT 6 Intermediate connector AE-1 CN-GND2 Terminal 1 Ground [Cab specification] H-9
CN-20 DT 3 Intermediate connector E-7 CN-GND3 Terminal 1 Ground [Cab specification] K-9
CN-21 Terminal 1 Horn C-4 CN-GND4 Terminal 1 Ground [Cab specification] M-7
CN-23 DT-T 2 Air conditioner compressor (if equipped) E-5 CN-GND5 Terminal 1 Ground [Cab specification] M-4
CN-26 DT-T 3 Neutral safety/Parking brake limit switch 1 AA-8 CN-GND6 Terminal 1 Ground [Cab specification] M-4
CN-26B DT-T 3 Neutral safety/Parking brake limit switch 2 AA-8 CN-GND7 Terminal 1 Ground [Cab specification] E-8
CN-27 DT-T 6 Intermediate connector Y-9 CN-GND8 Terminal 1 Ground [Cab specification] K-1
CN-38 C03 3 Travel speed shift switch W-9 CN-HEAT1 Yazaki 3 Foot heater (if equipped) AC-3
CN-39 C03 3 Travel speed shift switch X-9 CN-HEAT2 Yazaki 3 Foot heater (if equipped) AC-3
CN-45 DT-T 12 Intermediate connector R-2, AC-4 CN-HET SWP 6 Heater switch R-9
CN-54 Relay 6 Front lamp relay AA-1 CN-HRH Relay 5 Heater Hi relay Q-5
CN-54B Relay 6 Rear lamp relay Y-1 CN-HRL Relay 5 Heater Lo relay R-6
CN-92 DT 4 Intermediate connector (foot heater) V-1, AC-2 CN-KOM2 — 1 KOMTRAX terminal [ORBCOMM specification] AE-8
CN-102 DT-T 12 Intermediate connector E-7 CN-KOM3 — 1 KOMTRAX terminal [ORBCOMM specification] AE-9
CN-104 DT-T 12 Intermediate connector I-1 CN-KOM4 — 1 KOMTRAX antenna AH-8
CN-106 — — Fuse A-7 CN-LF DT-T 2 HST pump EPC solenoid valve (left front) H-1
CN-CE02 DRC 50 Engine controller B-3 CN-LME DT-T 2 Left motor EPC solenoid valve O-3
CN-116 DT 2 Dust indicator D-5 CN-LMP DT 4 Intermediate connector V-9
CN-CE03 DTP 4 Engine controller B-4 CN-LMP1 DT-T 2 Additional headlamp (left) [Cab specification] AD-8
CN-119 DT-T 3 CAN terminal resistor D-5 CN-LMP2 DT-T 2 Additional headlamp (right) [Cab specification] AC-7
CN-T126 Terminal 1 Ground (frame) E-1 CN-LMP3 DT-T 2 Additional rear lamp (left) [Cab specification] AG-9
CN-361 M 2 Washer motor (left) AG-1 CN-LMP4 DT-T 2 Additional rear lamp (right) [Cab specification] AF-9
CN-362 M 2 Washer motor (front) AG-1 CN-LMP5 DT-T 2 Additional headlamp (center) [Cab specification] AC-7
CN-363 M 2 Washer motor (right) AF-1 CN-LP AMP 3 HST pump left pressure sensor G-1
CN-364 M 2 Washer motor (rear) AF-1 CN-LR DT-T 2 HST pump EPC solenoid valve (left rear) H-1
CN-A DT-T 4 Right door wiper motor [Cab specification] E-6 CN-LRS2 DT-T 3 Left motor speed sensor M-2
CN-A DT-T 4 Left door wiper motor [Cab specification] M-2 CN-MC DT-T 12 Intermediate connector E-5
CN-A1 DT 2 Intermediate connector [Cab specification] I-9 CN-MTS SWP 6 Mode selector switch R-9
CN-A2 — 2 Rear speaker (left) [Cab specification] K-9 CN-P1 DT-T 12 Intermediate connector Q-3
CN-A4 — 2 Rear speaker (right) [Cab specification] H-9 CN-P2 DT-T 8 Intermediate connector Q-4
CN-A7 — 9 Radio [Cab specification] H-9 CN-P3 DT-T 12 Intermediate connector Q-4
CN-A8 DT 2 Accessory (12V) [Cab specification] G-9 CN-PB DT-T 3 Center brake proximity switch R-2
CN-A10 SWP 6 Additional light switch [Cab specification] G-9 CN-PSL DT-T 2 PPC lock solenoid valve P-3
CN-A11 SWP 6 Wiper intermittent switch [Cab specification] F-9 CN-PSW DT-T 3 PPC lock switch S-6
CN-A12 SWP 6 Rear wiper switch [Cab specification] F-9 CN-R23 Relay 5 Engine controller 1 relay X-1
CN-A13 SWP 6 Right wiper switch [Cab specification] F-9 CN-R24 Relay 5 Engine controller 2 relay X-1
CN-A14 SWP 6 Front wiper switch [Cab specification] F-9 CN-REV SWP 6 Reverse speed switch R-9
CN-A15 SWP 6 Left wiper switch [Cab specification] F-8 CN-RF DT-T 2 HST pump EPC solenoid valve (right front) H-1
CN-A16 — 2 Room lamp [Cab specification] E-8 CN-RH Terminal 1 Electrical intake air heater C-7
CN-A17 DT-T 4 Intermediate connector [Cab specification] E-8 CN-RHR Relay 5 Preheater relay AB-3
CN-A18 DT 2 Intermediate connector [Cab specification] E-7 CN-RME DT-T 2 Right motor EPC solenoid valve P-3
CN-A19 DT 6 Intermediate connector (washer motor) [Cab specification] L-1 CN-RP AMP 3 HST pump right pressure sensor H-1
CN-A23 DT-T 4 Front wiper motor [Cab specification] E-8 CN-RR DT-T 2 HST pump EPC solenoid valve (right rear) I-1
CN-A24 DT-T 4 Intermediate connector [Cab specification] M-4 CN-RRS2 DT-T 3 Right motor speed sensor M-3
CN-A25 Relay 5 Additional light relay [Cab specification] J-9 CN-RS DT-T 8 Intermediate connector E-7
CN-A26 Relay 6 Left wiper intermittent relay [Cab specification] J-9 CN-S03 070 20 Monitor panel R-8
CN-A27 Relay 5 Left wiper intermittent selector relay [Cab specification] J-9 CN-S04 070 12 Monitor panel R-8
CN-A28 Relay 5 Front wiper selector relay [Cab specification] J-9 CN-S3 DT-T 2 Slow brake solenoid valve O-2
CN-A30 Relay 6 Right wiper intermittent relay [Cab specification] K-9 CN-S4 DT-T 2 Parking brake solenoid valve O-2
CN-A31 Relay 5 Right wiper intermittent selector relay [Cab specification] L-8 CN-ST1 DRC 24 HST controller Q-4
CN-A32 Relay 5 Rear wiper intermittent selector relay [Cab specification] L-8 CN-ST2 DRC 40 HST controller Q-3
CN-A37 DT-T 4 Rear wiper motor [Cab specification] M-7 CN-ST3 DRC 40 HST controller Q-3
CN-A38 — — Capacitor [Cab specification] M-7 CN-T123 Terminal 1 Starting motor B terminal G-1
CN-AC DT 6 Intermediate connector W-9 CN-T2 Terminal 1 Starting motor C terminal G-1
CN-AC1 DT 6 Intermediate connector AD-8 CN-T3 Terminal 1 Safety relay B terminal F-1
CN-AC2 DT 4 Hot water valve AD-2 CN-T4 Terminal 1 Safety relay C terminal F-1
CN-AC3 DT 3 Temperature control switch AH-2 CN-T5 Terminal 1 Heater relay S terminal B-9
CN-AC4 DT 8 Blower selector switch AH-2 CN-T6 Terminal 1 Heater relay L terminal C-9
CN-AC5 DT 4 Mode selector switch AG-2 CN-T7 Terminal 1 Battery relay B terminal AB-2
CN-AC6 DT 12 Intermediate connector AH-8 CN-T8 Terminal 1 Battery relay M terminal AA-2
CN-AC7 DT 2 Foot heater Hi diode AD-2 CN-T9 Terminal 1 Battery relay (–) terminal AB-4
CN-AC8 DT 2 Foot heater Lo diode AD-2 CN-T12 Terminal 1 Heater relay B terminal B-9
CN-AC9 DT 2 A/C mode diode AE-1 CN-T13 Terminal 1 Battery relay (+) terminal AB-5
CN-ACC — 2 Accessory power outlet [Cab specification] M-4 CN-T15 Terminal 1 Alternator B terminal AN-3
CN-ACF DT-T 3 Check connector (KOMTRAX) AC-5 CN-T16 Terminal 1 Alternator R terminal AN-2
CN-ACM DT-T 3 Check connector (KOMTRAX) AC-5 CN-T17 Terminal 1 Alternator E terminal AN-2
CN-ASA DT-T 2 Intermediate connector (air suspension seat) S-1 CN-T1F DT-T 2 Check connector (KOMTRAX) AC-5
CN-ASB DT-T 2 Air suspension seat (if equipped) X-9 CN-T1M DT-T 2 Check connector (KOMTRAX) AC-5
CN-B DT-T 4 Intermediate connector [Cab specification] E-7 CN-T20 Terminal 1 Ground (engine) E-1
CN-B DT-T 4 Intermediate connector [Cab specification] M-3 CN-T20A Terminal 1 Ground (engine) E-1
CN-BP1 DT-T 3 Brake potentiometer R-2, AC-4 CN-T20B Terminal 1 Ground (engine) A-8
CN-BS — 3 Brake pressure sensor O-1 CN-T126A Terminal 1 Ground (engine controller) C-4
CN-BUZ SWP 6 Buzzer cancel switch O-8 CN-T250 Terminal 1 Starting switch B terminal P-5
CN-ENG1 DRC 60 Engine controller AI-6 CN-T255 Terminal 1 Starting switch R1 terminal P-4
CN-PFUEL BOSCH 3 Common rail pressure sensor (engine) AM-7 CN-T260 Terminal 1 Starting switch BR terminal O-4
CN-PTIM BOSCH 4 Boost pressure & temperature sensor (engine) AM-7 CN-T270 Terminal 1 Starting switch ACC terminal O-5
CN-PAMB AMP 3 Ambient pressure sensor (engine) AM-6 CN-T280 Terminal 1 Starting switch C terminal P-5
CN-CAM FRAMATOME 3 Cam sensor (engine) AI-7 CN-T35 Terminal 1 Ground O-2
CN-NE FRAMATOME 3 NE sensor (engine) AJ-5 CN-T36 Terminal 1 Ground (floor) S-1
CN-POIL FRAMATOME 1 Engine oil pressure switch (engine) AK-5 CN-T37 Terminal 1 Horn switch T-9
CN-TWTR DELPHI 2 Engine coolant temperature sensor (engine) AI-8 CN-T38 Terminal 1 Horn switch T-9
CN-CB M 2 Alarm buzzer R-8 CN-14 DT-T 2 Backup alarm M-6
CN-CFS DT-T 2 HST charge filter clogging switch E-6 CN-TG1 Terminal 1 Ground E-6
CN-CIG — 2 Cigarette lighter [Cab specification] M-5 CN-TSR Terminal 1 Ground F-1
CN-CLG DT 8 Intermediate connector M-6 CN-WLD SWP 2 Diode (working lamp) R-6
CN-CUR SWP 6 Cursor switch O8 CN-FUSE — — Fuse box [Cab specification] G-9
CN-CV1 DT 6 Converter [Cab specification] M-4 CN-ACD — 4 Capacitor AG-9
CN-D1 DT-T 2 Diode W-1 CN-ACP — 2 Pressure switch AF-9
CN-D2 DT 2 Diode W-1 CN-NM2 DT-T 12 Intermediate connector AN-1
CN-D4 SWP 8 Diode O-2 CN-NM3 DT 4 Intermediate connector ANM-1
CN-D10 DT-T 2 Diode W-1 CN-CN1 BOSCH 2 Injector #1 (engine) AJ-9
CN-D11 DT-T 2 Diode V-1 CN-CN2 BOSCH 2 Injector #2 (engine) AK-9
CN-D20 DT 2 Diode B-9 CN-CN3 BOSCH 2 Injector #3 (engine) AK-9
CN-DP1 DT-T 3 Deceleration potentiometer R-2 CN-CN4 BOSCH 2 Injector #4 (engine) AL-9
CN-DT12 DT-T 12 Service connector S-2 CN-PREG BOSCH 2 Supply pump regulator (engine) AK-5
CN-EL DT-T 8 Travel lever Y-9 (CN-CK0A) AMP070 18 KOMTRAX terminal [GPRS specification] AC-4
CN-F01 — — Fuse box Z-1 (CN-CK0B) AMP070 12 KOMTRAX terminal [GPRS specification] AC-4
CN-FAC DT-T 2 Fan EPC solenoid valve E-5 (CN-KOM2) — 1 KOMTRAX terminal [GPRS specification] AC-4
CN-FAN SWP 6 Fan reverse switch O-8 (CN-KOM5) — 1 KOMTRAX terminal [GPRS specification] AE-9
CN-FAR DT-T 2 Fan reverse solenoid M-5 (CN-WIF) DT-T 2 Water in fuel sensor (OPT) B-3
SEN04356-02
D31/37-22
90-200 23
SEN04356-02
D31/37-22 90-200 25
SEN04356-02
D31/37-22 Bulldozer
©2014 KOMATSU
All Rights Reserved
90-200 26

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SEN04343-09

BULLDOZER D31EX -22

00 Index and foreword 00

Composition of shop manual 1

Section Title Form Number

00 Index and foreword .................................................................................................................... SEN04344-09

01 General ...................................................................................................................................... SEN04345-00

10 Structure, function and maintenance standard........................................................................... SEN04346-01

20 Standard value table................................................................................................................... SEN04347-02

30 Testing and adjusting ................................................................................................................. SEN04348-03

50 Disassembly and assembly ........................................................................................................SEN04350-01

90 Diagrams and drawings..............................................................................................................SEN04351-04

00 Index and foreword

10 Structure, function and maintenance standard

20 Standard value table

30 Testing and adjusting

Check of engine piping for damage and looseness ...................................................................................... 32

Failure code [DV20KB] Back alarm buzzer: Short circuit .............................................................................. 7

500 Troubleshooting of hydraulic and mechanical system (H-mode) ...............................................SEN04513-00

50 Disassembly and assembly

Removal and installation of front guard assembly......................................................................................... 24

90 Diagrams and drawings

00 Index and foreword 00

200 Foreword and general information

Important safety notice

1. General precautions 7) If welding repairs are needed, always

2. Preparations for work

4. Precautions for sling work and making

6. Precautions for using overhead hoist crane

7. Selecting wire ropes 2) Connection

a The allowable load is one-sixth of the

8. Precautions for disconnecting and con-

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

2 Coat Places to be coated with adhesives, etc. during assembly.

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value or allow-

Handling of electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector

3. Removing, installing, and drying connec-

2] When removing from clips

q When removing a connector from a

3] Action to take after removing connec-

4) Drying wiring harness

5. Points to remember when troubleshooting