SEBMOOI
Shop Manual
007
D31E,P,Pl,l’ll=~o D31 D31 &ho BOA
D37E=!i,D37p=sr
BULLDOZERS
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or disciosed except in accordance with written authorization from Komatsu America lntemational Company. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time wlthout Incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision.
May 1997
Copyright 1997 Komatsu America International Company
oo&
CONTENTS No. of page
01
GENERAL . . . . ..~.................................................................
01-l
10
STRUCTURE
10-I
20
TESTING AND ADJUSTING
30
DISASSEMBLY
40
MAINTENANCE
AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. ... ... ... .. . ... .. .. .. . .. .. ... .. .. ... . ... .
20-I
AND ASSEMBLY . . . . . . . . . . . . ..*.........*m.......
30-I
STANDARD . . . . . . . . . . . . . . . . . . ..n....m.........m..... 40-I % :
90
OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
90-I
0
SAFETY NOTICE
SAFETY
SAFETY SAFETY
NOTICE
IMPORTANT
SAFETY
Proper
and
service
NOTICE
repair
is extremely
service and repair techniques are both effective designed
manual.
for safe
by Komatsu
and safe. Some of these techniques
by Komatsu
To prevent
important
recommended
for the specific
injury to workers,
The cautions
fully. If any dangerous take the necessary
situation
operation.
require the use of tools specially
is used to mark safety precautions
these symbols
should
always
arises or may possibly arise, first consider
in operation
carefully
6. Decide
are extremely
BEFORE operating
a place
in the
repair
Always
or repairs,
Smoke
workshop
parts. Always
and parts in their correct
to keep
places.
keep the work area clean and make
sure that there is no dirt or oil on the floor.
given on the decals
only in the areas provided
ing. Never smoke while
for smok-
working.
are fixed to the machine.
2. When
carrying
out any operation,
wear safety shoes and helmet. loose work clothes,
always
. Always
wear
safety glasses when
trained,
adding
hitting
oil or making
wear
safety glasses
welder
always carry
work. When
carrying
out welding
ways
welding
gloves,
wear
grind-
etc.
repairs are needed, experienced
when
have a out the
work,
apron,
al-
hand
shield, cap and other clothes suited for welding work.
or tracks
out any operation
or more workers, ating procedure
with two
always agree on the operbefore
starting.
Always
in-
form your fellow workers before starting any step of the operation.
Before starting
work,
REPAIR signs on the controls
in the operator’s
compartment.
5. Keep all tools in good condition the correct way to use them.
and learn
repairs,
to prevent
and the
from moving. blade,
ripper,
bucket or any other work equipment
starting
to the
ground.
If this
work,
lower
is not possible,
insert
the
safety pin or use blocks to prevent the work equipment
from falling.
to lock all the control
In addition,
be sure
levers and hang warn-
ing signs on them. 9. When disassembling
carrying
hang UNDER
%. Before
any
on hard, level ground,
block the wheels machine
ing parts with a grinder, 3. If welding
7. Before
park the machine
parts with a hammer. . Always
PREPARATIONS FOR WORK
Do not wear
or clothes with buttons
missing.
4. When
the tools
Manual
the machine.
out any greasing
read all the precautions which
dangerous.
and Maintenance
1. Before carrying
care-
safety, and
keep tools and removed Mistakes
in this
be followed
actions to deal with the situation.
GENERAL PRECAUTIONS
Read the Operation
The
in this manual
purpose.
the symbol A
accompanying
machine
and described
the
machine
with
before starting IO. Remove
or assembling, blocks,
jacks
support or stands
work.
all mud and oil from
the steps or
other places used to get on and off the machine. Always
use the handrails,
ladders
steps when
getting
Never
on or off the machine.
jump
impossible
or
on or off the machine.
to use the handrails,
steps, use a stand to provide
If it is
ladders
or
safe footing.
00-3
SAFETY NOTICE
SAFETY
PRECAUTIONS DURING WORK
19. Be sure to assemble original
11 When removing or
hydraulic
pressure
loosen them spurting
the oil filler cap, drain plug
slowly to prevent
plugs,
the oil from
disconnecting
or removing
of the oil, water
remove
the
pressure
compo-
or air circuits, completely
first
from
the
circuit. 12. The
and
oil in the circuits
the engine
is stopped,
are hot
so be careful
for the oil and water
carrying
out any work
to cool
before
on the oil or water
circuits.
the battery.
Always
the negative
(-1 terminal
remove
the lead from
20. When sure
installing that
high pressure
they
are
ful when circuits.
installing Also,
use a hoist
21 When
assembling
vibrate
aligning
fingers
caught
lifting
ample
capacity.
Install
the lifting
equipment
Use a hoist to prevent
ting any other
23. When
equipment
which
has
or crane
and operate
the component
hit-
part. Do not work with
any
ternal
pressure
or under
always
leave two
bolts in position
sides. Slowly
release the pres-
covers which
are under in-
pressure
from
a
sure, then slowly loosen the bolts to remove.
wiring 17. When
components,
or damage
removing
be careful not
the wiring.
may cause electrical piping,
Damaged
fires.
stop the fuel or oil
from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. on the floor
Fuel or oil
can cause you to slip, or can
even start fires. 18. As a general
rule, do not use gasoline
to
wash parts. In particular,
use only the mini-
mum
washing
parts.
00-4
of gasoline
when
When
or rotate at
careful
to check
correctly.
Be careful
not to get your
in a hole.
measuring
hydraulic
pressure,
tool is correctly
bled before taking
any measurements.
electrical
removing
tracks of track-type When
removing
rates suddenly,
removing
to break
violently
that the measuring
24. Take care when
from
15. When
16. When removing
torques.
check assem-
at the correct
part still raised by the hoist or crane.
on opposite
parts, always
two holes, never insert your
Check that the wire rope, chains and hooks use
parts
parts such as guards,
be particularly
or hand.
are free from damage.
care-
connecting
tightening
protective
or parts which
22. When
Damaged
so be extremely
or installing
use the specified
high speed,
hoses, make
tubes for high pressure
check that
fingers
Always
is be-
installed.
or crane.
spring,
by contact
not twisted.
that they are installed
first.
14. When raising heavy components,
places.
be sure
ing operated.
installing
13. Before starting work, remove the leads from
slowly
parts with new parts.
hoses and wires,
that they will not be damaged
are correctly
not to get burned. Wait
installing
tubes are dangerous,
water
when
Replace any damaged . When
with other parts when the machine
out.
Before nents
measuring
all parts again in their
places.
or installing
the
machines.
the track,
the track
sepa-
so never let anyone stand at
either end of the track.
DISASSEMBLY
STARTING
AND ASSEMBLY
MOTOR
REMOVAL OF STARTING MOTOR ASSEMBLY D31E-20 D31P, PL-20 D31PLL-20 D31S, Q-20 D31P-20A D37E-5 D37P-5A
No.: No.: No.: No.: No.: No.: No.:
Serial Serial Serial Serial Serial Serial Serial
ADisconnect
the
cable
42001 45001 45001 41001 45001 3001 3001 from
-
42713 47616 47652 41183 47616 3730 3660
the
negative
(-)
terminal
of the battery. 1.
Remove
2.
Disconnect
3.
cover
of engine
fuel control
Disconnect
engine
with
(3). a
bracket
4.
Disconnect
5.
Remove
cable
stop
starting
starting
left side.
motor
motor
(1). m
motor
wiring
cable
(2)
together
(4) and (5).
assembly
(6).
INSTALLATION OF STARTING MOTOR ASSEMBLY D3 1 E-20 D3lP, PL-20 D31PLL-20 D3lS, Q-20 D31P-20A D37E-5 D37P-5A
l
No.: No.: No.: No.: No.: No.: No.:
Serial Serial Serial Serial Serial Serial Serial
Carrv out installation
p?iJ *
Adjust ING
the AND
42001 - 42713 45001 - 47616 45001 - 47652 41001 - 41183 45001 - 47616 3001 - 3730 3001 - 3660
in the reverse
control
cable.
ADJUSTING,
order
to removal.
For details,
see
TEST-
FUEL
CON-
see TESTING
AND
ADJUSTING
TROL LEVER.
m *
Adjust
the
ADJUSTING, CABLE.
30-6 a
cable.
For details,
ADJUSTING
ENGINE
STOP
MOTOR
-4
/
Il4FO2105
DISASSEMBLY
STARTING
AND ASSEMBLY
MOTOR
REMOVAL OF STARTING MOTOR ASSEMBLY D31E-20 D31P, PL-20 D31PLL-20 D31S, Q-20 D31P-20A D37E-5 D37P-5A
$ rr
5
0
Serial Serial Serial Serial Serial Serial Serial
No.: No.: No.: No.: No.: No.: No.:
42714 47617 47653 41184 47617 3731 3661
and up and up and up and up and up and up and up
A
Disconnect the cable from the negative minal of the battery.
1.
Remove
right engine
2.
Remove
adiabatic
3.
Disconnect terminal B (STB) (2) and terminal 0 (l-pin connector) (3).
4.
Remove
starting
(-) ter-
side cover.
plate (I).
motor
assembly
C
m
(4).
INSTALLATION OF STARTING MOTOR ASSEMBLY D31E-20 D31P, PL-20 D31PLL-20 D31S, Q-20 D31P-20A D37E-5 D37P-5A
.
Serial Serial Serial Serial Serial Serial Serial
No.: No.: No.: No.: No.: No.: No.:
42714 47617 47653 41184 47617 3731 3661
Carry out installation removal.
and up and up and up and up and up and up and up
in the
reverse
order
to CLPO2024
w
Terminal
B mounting nut: 17.64 2 1.96 Nm Il.8
+ 0.2 kgmj
w
Starting motor assembly mounting bolt: 42.95 t 5.98 Nm {4.38 f 0.61 kgm)
*
Coat the whole circumference with 1.0 mm of gasket sealant (LG-4) at a point 4 mm from the inside of the starting motor gasket.
30-7 a
DISASSEMBLY
AND ASSEMBLY
ALTERNATOR
REMOVAL OF ALTERNATOR ASSEMBLY D31 E-20 D31P. PL-20 D31PLL-20 D31S, Q-20 D31P-20A D37E-5 D37P-5A
Serial Serial Serial Serial Serial Serial Serial
ADisconnect
No.: No.: No.: No.: No.: No.: No.:
42001 45001 45001 41001 45001 3001 3001 -
-
42713 47616 47652 41183 47616 3730 3660
the cable from the negative
(-)
terminal
of
the battery. Remove cover of engine right side. Disconnect Remove
wiring (1) from alternator.
mounting
loosen mounting
bolt (2) of adjustment
plate,
bolt (3) and nut, and remove
then
fan belt
(4). j Remove
mounting
tor assembly
bolt and nut, then remove
alterna-
(5).
% 6
INSTALLATION OF ALTERNATOR ASSEMBLY D31E-20 D31P, PL-20 D31PLL-20 D31S, Q-20 D31P-20A D37E-5 D37P-5A l
Serial Serial Serial Serial Serial Serial Serial
No.: No.: No.: No.: No.: No.: No.:
Carry out installation
*
Adjust
the
STANDARD
fan
-
42713 47616 47652 41183 47616 3730 3660
in the reverse order to removal.
belt
VALUE
LATED PARTS.
30-7-l 0
42001 45001 45001 41001 45001 3001 3001 -
tension. TABLE
For FOR
details,
see
ENGINE
RE-
DISASSEMBLY
AND ASSEMBLY
ALTERNATOR
REMOVAL OF ALTERNATOR ASSEMBLY ~2 D31 E-20 D31P, PL-20 D31PLL-20 D31S, Q-20 D31P-20A D37E-5 D37P-5A
Serial Serial Serial Serial Serial Serial Serial
No.: No.: No.: No.: No.: No.: No.:
42714 47617 47653 41184 47617 3731 3661
and up and up and up and up and up and up and up
I’
a
Disconnect the cable from the negative minal of the battery.
1. 2.
Remove right engine side cover. Loosen locknut (I) and remove bolt (2). (Reversible fan specification) m
3.
Using ratchet handle @(insertion angle: 9.5 mm), raise tensioner (3) and remove fan belt (4). g Be extremely careful not to get your fingers caught between the tensioner and pulley when removing the fan belt.
4.
Remove terminal (6). * The wiring
% z
R (AIR) (5) and terminal
at the R terminal
(-) ter-
B (ALB)
is yellow.
I
'
CEO02251
0
5.
Remove alternator assembly (7). a * There are spacers installed to the mounting bolts, so be careful not to lose them.
INSTALLATION OF ALTERNATOR ASSEMBLY D31E-20 D31P. PL-20 D31PLL-20 D31S, Q-20 D31P-20A D37E-5 D37P-5A
.
Serial Serial Serial Serial Serial Serial Serial
No.: No.: No.: No.: No.: No.: No.:
42714 47617 47653 41184 47617 3731 3661
Carry out installation removal.
and up and up and up and up and up and up and up
in the
reverse
--u-Ji -
order
J
/
CEtl02252
to
Put the fan belt under tension from tensioner (31, adjust bolt (2) so that clearance a between bolt (2) and tensioner (3) is 0, then secure with locknut (I). m w *
Alternator assembly mounting bolt: 42.95 + 5.98 Nm I4.38 + 0.61 kgm} Use a straight edge and check that the end face of the alternator pulley is level with the end face of the other pulleys.
30-7-2 a
DISASSEMBLY
ENGINE
AND ASSEMBLY
REMOVAL OF ENGINE OIL COOLER CORE ASSEMBLY D31E-20 D31P, PL-20 D31PLL-20 D31S, Q-20 D31P-20A D37E-5 D37P-5A 1.
Serial Serial Serial Serial Serial Serial Serial
No.: No.: No.: No.: No.: No.: No.:
42714 47617 47653 41184 47617 3731 3661
and up and up and up and up and up and up and up
Remove alternator assembly. For details, see REMOVAL OF ALTERNATOR SEMBLY.
AS-
2.
Disconnect turbocharger lubrication hose (I). Ir Disconnect at the engine oil cooler end.
3.
Remove
oil filter (2).
4.
Remove
cooler cover assembly
5.
Remove cooler assembly.
a
core (4) from
a
(3). oil cooler
cover
INSTALLATION OF ENGINE OIL COOLER CORE ASSEMBLY D31E-20 D31P, PL-20 D31PLL-20 D31S, Q-20 D31P-20A D37E-5 D37P-5A l
Serial Serial Serial Serial Serial Serial Serial
No.: No.: No.: No.: No.: No.: No.:
42714 47617 47653 41184 47617 3731 3661
Carry out installation removal.
w
w
30-7-3 a
and up and up and up and up and up and up and up
in the
reverse
Oil filter: 13.04 z 1.96 Nm {I.33
order
to
2 0.2 kgm}
Oil cooler assembly mounting bolt: 24.03 f 4.02 Nm (2.45 = 0.41 kgm}
OIL COOLER CORE
DISASSEMBLY
AND ASSEMBLY
FUEL INJECTION
PUMP
REMOVAL OF FUEL INJECTION PUMP ASSEMBLY D31E-20 D31P, PL-20 D31PLL-20 D31S, Q-20 D31P-20A D37E-5 D37P-5A
Serial Serial Serial Serial Serial Serial Serial
1.
Remove
2.
Disconnect
No.: No.: No.: No.: No.: No.: No.:
42001 - 42713 45001 - 47616 45001 - 47652 41001 - 41183 45001 - 47616 3001 - 3730 3001 - 3660
cover of engine left side. fuel
control
cable
(1)
and
engine
stop
motor cable (2). m 3.
Disconnect *
fuel supply hose (3) and fuel hoses (4).
Fit a blind
plug
in supply
hose
(3) to
prevent
fuel
injection
fuel from leaking out. 4.
Remove
5.
Disconnect
6.
Remove
lubrication
tube (5).
6 fuel injection pipes (6). bracket
pump assembly
(7),
then
m
remove
(8). m
I
30-8 0
Il4FO2108
DISASSEMBLY
AND ASSEMBLY
FUEL INJECTION
PUMP
INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY D31 E-20 D31 P, PL-20 D31PLL-20 D31S. Q-20 D31 P-20A D37E-5 D37P-5A
.
Serial Serial Serial Serial Serial Serial Serial
No.: No.: No.: No.: No.: No.: No.:
Carry out installation
42001 45001 45001 41001 45001 3001 3001 -
-
42713 47616 47652 41183 47616 3730 3660
in the reverse
order to removal.
m *
Adjust
the cables.
ADJUSTING,
and ADJUSTING
m
Sleeve
For details,
ADJUSTING ENGINE
see TESTING
FUEL CONTROL STOP
MOTOR
AND LEVER
CABLE.
nut: 22.06 z 2.45 Nm (2.25 = 0.25 kgm)
m .
Install the fuel injection 1)
pump
as follows.
Set No. 1 cylinder at compression +
Rotate the crankshaft and align
the pointer
on the crankshaft
with
pulley.
2)
Replace
with
the
direction
1.6 TOP
If the match
on the idler gear cannot crankshaft
top dead center.
in the normal
be seen,
line
014OF107
mark
rotate the
one more turn. bolt @ and fix drive
gear
(11)
in
position. 3)
Injection +
pump
assembly
Insert pin @ (0 4.0 - 4.5 mm, length = approx. 100 mm)
through
cover
mounting
bolt hole
a, and check that the pin enters the casting hole in the drive gear smoothly. 4)
Remove
bolt 0,
and
replace
it with
a standard
bolt. .
Adjust the fuel injection
timing
and bleed the air from
the fuel system. For details,
see TESTING
AND
I I4FO2
109
il4FO21
IO
ADJUSTING.
DISASSEMBLY
FUEL INJECTION
AND ASSEMBLY
REMOVAL OF FUEL INJECTION PUMP ASSEMBLY D3 1 E-20 D31P, PL-20 D31PLL-20 D31S, Q-20 D31P-20A D37E-5 D37P-5A
Serial Serial Serial Serial Serial Serial Serial
No.: No.: No.: No.: No.: No.: No.:
42714 47617 47653 41184 47617 3731 3661
and up and up and up and up and up and up and up
1.
Drain fuel from fuel tank.
2.
Remove
3.
Remove hydraulic pump assembly. For details, see REMOVAL OF HYDRAULIC ASSEMBLY.
engine
left cover.
PUMP
4.
Disconnect rod (1) of engine stop solenoid. * Disconnect at the fuel injection pump end.
5.
Disconnect 2 wires (2) and remove engine stop a solenoid (3). * Be careful not to drop the spacer.
6.
Remove
7.
Disconnect fuel tubes (5), (61, and (7), fuel hose a (8), and lubrication tube (9).
30-9- 1 0
delivery
tubes (4).
PUMP
DISASSEMBLY
8.
9.
AND ASSEMBLY
Remove cap (IO). * Use a filter wrench
FUEL INJECTION
PUMP
a to remove.
Remove nut (11) and washer (12). m * Be careful not to drop the nut or washer inside the case.
CED02259
10. Using tool AZ, disconnect of fuel injection pump.
shaft and drive gear
CED02260
11. Remove
sound absorbing
12. Remove fuel injection
material
(13).
pump mount bracket (14). m
13. Remove 4 nuts (151, then remove pump assembly (16).
fuel injection m
CED02262
30-9-2 a
DISASSEMBLY
AND ASSEMBLY
FUEL INJECTION
INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY D31E-20 D31P, PL-20 D31PLL-20 D31S, Q-20 D31P-20A D37E-5 D37P-5A
l
Serial Serial Serial Serial Serial Serial Serial
No.: No.: No.: No.: No.: No.: No.:
42714 and up 47617 and up 47653 and up 41184 and up 47617 and up 3731 and up 3661 and up
Carry out installation removal.
*
in the
reverse
order
to
Adjust the engine stop solenoid. For details, see TESTING AND ADJUSTING, Adjusting engine stop solenoid linkage.
Delivery
tube sleeve nut: 24 + 4 Nm 12.45 + 0.41 kgm}
Fuel tube l-joint: 24 f 4 Nm 12.45 + 0.41 kgm} Lubrication tube l-joint: 12 + 2 Nm Il.2 + 0.2 kgm}
Ir
Turn the cap 180� to tighten
Ifmm .
Install the fuel injection pump assembly as follows. Loosen bolt, move plate (22) to the side, then remove cap (23).
1)
2)
it.
Using tool Al, crank the engine slowly in the normal direction, and push No. 1 cylinder compression top dead center positioning pin (17) into the gear.
30-9-3 a
PUMP
DISASSEMBLY
*
*
AND ASSEMBLY
FUEL INJECTION PUMP
Refer to the following and push positioning pin (17) securely into the gear. . Dimension a when free: 24 mm . Dimension b when there is gear contact: 20 mm . Dimension c when pushed into gear hole:16 mm When the positioning pin is pushed in, stop barring the engine immediately (otherwise, the positioning pin will break).
ET-l
CED02263
3)
Remove plug (19), then remove timing (20).
pin
4)
Reverse the position of timing pin (19) 180�, align the timing pin groove with pointer (21) inside the pump, then temporarily tighten plug (19). * If the tooth of pointer (21) cannot be aligned with the timing pin hole, rotate the shaft of the fuel injection pump to align the pointer tooth.
CEP05301
5)
Align fuel injection pump shaft with drive gear and install fuel injection pump assembly (16).
6)
Tighten nut (15). m Nut: 43 c 6 Nm (4.38 + 0.61 kgm}
ii CEP05302
DISASSEMBLY
FUEL INJECTION
AND ASSEMBLY
7)
Install washer (121, and tighten nut (II). -k Be extremely careful not to drop the nut or washer inside the case when installing. w Nut: 12.5 t 2.5 Nm Il.27 + 0.25 kgm} * This is not the final torque value. * To prevent damage to the No. 1 cylinder compression top dead center positioning pin, be careful not to tighten the nut to more than the above tightening torque.
8)
Remove meshing of No. 1 cylinder compression top dead center positioning pin (17).
PUMP
CED02259
CLPO2075
9)
Remove plug (191, reverse mounting position of timing pin (20), then assemble and install plug to fuel injection pump. m Plug: 14.7 Nm (1.5 kgm}
IO) Tighten drive gear mounting
nut (I I) of fuel injection pump fully. w Nut: 95 + 10 Nm (9.7 + 1.02 kgm}
11) Carry out the rest of the installation reverse order to removal.
in the CEP0530
*
.
Adjust fuel injection timing. For details, see TESTING AND ADJUSTING, Adjusting fuel injection timing.
Bleeding air Sr Bleed the air from the fuel line. For details, see TESTING AND ADJUSTING, Bleeding air from fuel circuit.
30-9-5 a
DISASSEMBLY
AND ASSEMBLY
WATER PUMP
REMOVAL OF WATER PUMP ASSEMBLY D31 E-20 D31P, PL-20 D31PLL-20 D31S, Q-20 D31P-20A D37E-5 D37P-5A 1.
Loosen
2.
Remove side
No.: No.: No.: No.: No.: No.: No.:
Serial Serial Serial Serial Serial Serial Serial
radiator
drain valve
exhaust
covers
42001 - 42713 45001 - 47616 45001 - 47652 41001 - 41183 45001 - 47616 3001 - 3730 3001 - 3660
pipe
and drain
(1) and
(2), disconnect
engine
hood
& kg
Engine
hood assembly:
3.
Remove
fan guard
4.
Disconnect
5.
Loosen
bolt
hoses gauge
and
tank
engine
hose,
then
40 kg
(4) and shroud
mounting
mounting
water.
right
(3).
radiator
temperature
cooling and
reserve
remove
water
left
(5).
(6),
(7)
and
wire
(8)
of
sensor.
bolt
of
nut,
and
adjustment
plate,
remove
belt
fan
then (9) and
fan (IO). 6.
Remove
fan pulley
7.
Remove
water
(11). @J
pump
assembly
(12).
INSTALLATION OF WATER PUMP ASSEMBLY D31 E-20 D31P, PL-20 D31PLL-20 D31S, Q-20 D31P-20A D37E-5 D37P-5A
Serial Serial Serial Serial Serial Serial Serial
No.: No.: No.: No.: No.: No.: No.:
Carry out installation
l
42001 - 42713 45001 - 47616 45001 - 47652 41001 - 41183 45001 - 47616 3001 - 3730 3001 - 3660
in the reverse
order
% 6
to removal.
m *
Adjust
the
fan
STANDARD
belt
VALUE
tension.
For
TABLE
FOR
specified
level
details,
ENGINE
see RELA-
TED PARTS. l
Refilling *
with water
Add
water
and
run
through again.
30-10 0
to the the
the
engine
system.
to Then
from
circulate check
the
filler the water
port, water level
DISASSEMBLY
AND ASSEMBLY
WATER
PUMP
REMOVAL OF WATER PUMP ASSEMBLY D3 1 E-20 D31P. PL-20 D31PLL-20 D31S. Q-20 D31P-20A D37E-5 D37P-5A
Serial Serial Serial Serial Serial Serial Serial
No.: No.: No.: No.: No.: No.: No.:
42714 47617 47653 41184 47617 3731 3661
and up and up and up and up and up and up and up
1.
Drain coolant.
2.
Remove alternator assembly. For details, see REMOVAL OF ALTERNATOR SEMBLY.
3.
Remove
water
pump assembly
(I).
AS-
m
INSTALLATION OF WATER PUMP ASSEMBLY D31E-20 D31P, PL-20 D31PLL-20 D31S, Q-20 D31P-20A D37E-5 D37P-5A
.
No.: No.: No.: No.: No.: No.: No.:
42714 and up 47617 and up 47653 and up 41184 and up 47617 and up 3731 and up 3661 and up
Carry out installation removal.
w
.
Serial Serial Serial Serial Serial Serial Serial
Water
in the
reverse
order
to
pump assembly mounting bolt: 24.03 + 4.02 Nm 12.45 2 0.41 kgm}
Refilling with water Add water through the water filler to the specified level. Run the engine to circulate the water through the system. Then check the water level again.
30-l o-1 a
DISASSEMBLY
REMOVAL D31 E-20 D31P, PL-20 D31PLL-20 D31S, Q-20 D31P-20A D37E-5 D37P-5A
THERMOSTAT
AND ASSEMBLY
OF THERMOSTAT
Serial Serial Serial Serial Serial Serial Serial
No.: No.: No.: No.: No.: No.: No.:
42001 - 42713 45001 - 47616 45001 - 47652 41001 - 41183 45001 - 47616 3001 - 3730 3001 - 3660
1.
Loosen radiatqr drain valve and drain cooling water.
2.
Remove
3.
Disconnect
4.
Remove
cover of engine right side. hose (I), and remove
thermostat
l
l
Serial Serial Serial Serial Serial Serial Serial
OF
No.: No.: No.: No.: No.: No.: No.:
Carry out installation
(2).
(3).
INSTALLATION THERMOSTAT D31E-20 D31P. PL-20 D31PLL-20 D31S, Q-20 D31P-20A D37E-5 D37P-5A
connector
42001 - 42713 45001 - 47616 45001 - 47652 41001 - 41183 45001 - 47616 3001 - 3730 3001 - 3660
in the reverse order to removal.
Refilling with water *
Add
water
and
run
through again.
30- 1o-2 a
to the specified the
engine
the system.
to
Then
level from circulate check
filler the
the water
port, water level
DISASSEMBLY
THERMOSTAT
AND ASSEMBLY
REMOVAL OF THERMOSTAT ASSEMBLY D3 1 E-20 D31 P, PL-20 D31 PLL-20 D31S, Q-20 D31 P-20A D37E-5 D37P-5A
Serial No.: 42714 and up Serial No.: 47617 and up Serial No.: 47653 and up Serial No.: 41184 and up Serial No.: 47617 and up Serial No.: 3731 and up Serial No.: 3661 and up
1.
Drain coolant.
2.
Remove alternator assembly. For details, see REMOVAL OF ALTERNATOR ASSEMBLY.
7.
Disconnect
hose (I I.
Disconnect
radiator
inlet port hose (2).
Remove
alternator
bracket (3).
Remove
thermostat
housing
Remove
thermostat
(5).
(4).
% z 0
INSTALLATION THERMOSTAT D3 1 E-20 D31P, PL-20 D31PLL-20 D31S. Q-20 D31P-20A D37E-5 D37P-5A l
.
Serial Serial Serial Serial Serial Serial Serial
No.: No.: No.: No.: No.: No.: No.:
OF ASSEMBLY 42714 47617 47653 41184 47617 3731 3661
Carry out installation removal.
and up and up and up and up and up and up and up
in the
reverse
order
to
m
Alternator bracket mounting bolt: 24.03 2 4.02 Nm I2.45 + 0.41 kgm}
w
Thermostat housing mounting bolt: 24.03 f 4.02 Nm I2.45 = 0.41 kgm}
CEDO2280
Refilling with water * Add water through the water filler to the specified level. Run the engine to circulate the water through the system. Then check the water level again.
30-l 1 a
DISASSEMBLY
NOZZLE HOLDER
AND ASSEMBLY
REMOVAL OF NOZZLE HOLDER ASSEMBLY D31 E-20 D31P, PL-20 D31PLL-20 D31S, Q-20 D31P-20A D37E-5 D37P-5A
Serial Serial Serial Serial Serial Serial Serial
No.: No.: No.: No.: No.: No.: No.:
42001 - 42713 45001 - 47616 45001 - 47652 41001 - 41183 45001 - 47616 3001 - 3730 3001 - 3660
1.
Remove clamp (l), then disconnet (2). m
fuel injection
pipe
2.
Disconnect spill hose (3).
3.
Remove the bolt, then remove nozzle holder assembly (4). 133f * When removing the nozzle holder assembly, clean around the nozzle holder assembly and fit a blind plug to prevent dust or dirt from entering.
INSTALLATION OF NOZZLE HOLDER ASSEMBLY D31 E-20 D31P, PL-20 D31PLL-20 D31S, Q-20 D31P-20A D37E-5 D37P-5A .
Serial Serial Serial Serial Serial Serial Serial
No.: No.: No.: No.: No.: No.: No.:
Carry out installation
42001 - 42713 45001 - 47616 45001 - 47652 41001 - 41183 45001 - 47616 3001 - 3730 3001 - 3660 in the reverse order to removal.
/I w
Sleeve nut: 22.06 t 2.45 Nm i2.25 + 0.25 kgml
*
When installing the nozzle holder assembly, check the nozzle holder mount, and clean before installing.
/izJ
w
30-12 0
Nozzle holder mounting bolt: 44.13 + 4.90 Nm (4.5 + 0.5 kgm}
F07
I27
DISASSEMBLY
NOZZLE
AND ASSEMBLY
HOLDER
REMOVAL OF NOZZLE HOLDER ASSEMBLY D31 E-20 D31P. PL-20 D31PLL-20 D31S, Q-20 D31P-20A D37E-5 D37P-5A
Serial Serial Serial Serial Serial Serial Serial
No.: No.: No.: No.: No.: No.: No.:
1.
Remove
left engine
2.
Remove air cleaner mounting bolts (2) and (3). * Support the air cleaner with block 0.
3.
Disconnect
4.
Loosen 2 clamps (5), remove air duct (6) at air cleaner end, then remove air cleaner assembly.
5.
Remove air supply connector (8). + When removing the No. 3 nozzle holder assem bly
6.
Remove muffler bracket (9). * When removing the No. 4 nozzle holder assem bly
7.
Remove
4 delivery
8.
Remove
spill tube (II).
wiring
42714 47617 47653 41184 47617 3731 3661
and up and up and up and up and up and up and up
side cover.
(AS1 and AS2) (4).
tubes (IO).
m m
-
CED02270
Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING
NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
DISASSEMBLY
9.
AND
ASSEMBLY
NOZZLE
Loosen nut (12) and remove nozzle holder assembly (13). m * If it is difficult to remove the nozzle holder assembly, use tool J to remove it. * Be careful not to let dirt or dust get into the nozzle holder assembly mount.
INSTALLATION OF NOZZLE HOLDER ASSEMBLY D3 1 E-20 D31P, PL-20 D31PLL-20 D31S, Q-20 D31P-20A D37E-5 D37P-5A l
Serial Serial Serial Serial Serial Serial Serial
No.: No.: No.: No.: No.: No.: No.:
42714 and up 47617 and up 47653 and up 41184 and up 47617 and up 3731 and up 3661 and up
Carry out installation removal.
w
in the
reverse
order
to
Fuel injection tube sleeve nut (nozzle holder end): 30.01 +. 5.00 Nm I3.06 z 0.51 kgm} Fuel injection tube sleeve nut (fuel injection pump end): 24.03 z 4.02 Nm 12.45 + 0.41 kgm) Mounting bolt of fuel injection tube intermediate clamp: 24.03 2 4.02 Nm 12.45 +. 0.41 kgm}
w
m
w
Spill tube joint bolt: 8.04 Nm IO.82 kgm}
w
Nozzle holder mounting bolt: 60.02 + 8.92 Nm 16.12 + 0.91 kgm} When assembling the nozzle holder, clean the nozzle holder mount, and check that there is no dirt or dust inside the sleeve before assembling.
*
30-l 3-l a
HOLDER
DISASSEMBLY
AND ASSEMBLY
REMOVAL OF TURBOCHARGER Serial Serial Serial Serial Serial Serial Serial
1.
Remove
left and right engine
2.
Remove
exhaust
3.
Remove
air cleaner
4.
Lift off engine
Disconnect
and up and up and up and up and up and up and up side covers.
pipe (I). mounting
the air cleaner
Engine
5.
42714 47617 47653 41184 47617 3731 3661
ASSEMBLY
D31E-20 D31P, PL-20 D31PLL-20 D31S, Q-20 D31P-20A D37E-5 D37P-5A
(3). * Support
No.: No.: No.: No.: No.: No.: No.:
TURBOCHARGER
bolts (2) and
with block 0.
hood (4). hood: 30 kg
wiring
(AS1 and AS2) (5).
30- 13-2 a
DISASSEMBLY
AND ASSEMBLY
TURBOCHARGER
6. Remove clamps (6) and (71, then remove air cleaner assembly (8) together with intake hose.
7. Remove adiabatic
8. Sling muffler
plate (9).
assembly
(IO).
9. Loosen clamp (II).
IO. Remove muffler assembly together connector (12). &I kg
Muffler
assembly:
with exhaust
35 kg
11. Loosen clamp and move hose (13) towards intake connector. a 12. Disconnect
lubrication
inlet hose (14).
a
13. Disconnect
lubrication
outlet tube (15).
113
30-13-3 0