d31!37!39x21a Testing & Adjusting Procedure(Wm)

Customer Customer EX EX Date Date  _______________________________   _______________________________  SMR  SMR  Model Model

 D31/37/39X-21”A

 D31/37/39X-21”A” 

” 

_PXPX Serial Serial  ______________________________   ______________________________  Technician Technician

TESTING & ADJUSTING PROCEDURE 

TESTING & ADJUSTING PROCEDURE 

Use the following procedure as a

Use the following procedure as a  sequential 

 sequential supplement to the Shop Manual when testing & adjusting the

supplement to the Shop Manual when testing & adjusting the Komatsu

Komatsu

D31/37/39EX/PX-D31/37/39EX/PX-21”A”

21”A” KomStat

KomStat II

II Dozers.

Dozers. See

See also

also the

the HANDY CARD! Postures shown on last

 HANDY CARD! Postures shown on last page!

page!

Always ensure that a

Always ensure that all FLUIDS & FILTERS are as recommend

ll FLUIDS & FILTERS are as recommended for peak engine and

ed for peak engine and hydraulic performance.

hydraulic performance. Dirty

Dirty

oil and/or filters can affect a D39’s HST like no mechanical drive Dozer!

oil and/or filters can affect a D39’s HST like no mechanical drive Dozer! Follow this procedure in order because

Follow this procedure in order because

skipping one step may affect the measurements in the following steps.

skipping one step may affect the measurements in the following steps. FFOR fitting adapters may be needed if 

FFOR fitting adapters may be needed if 

any troubleshooting is being performed.

any troubleshooting is being performed. Also be sure BATTERY Voltage is

Also be sure BATTERY Voltage is normal (Monitor Mode 2).

normal (Monitor Mode 2).

See To

See Tools

ols List

List “C4"

“C4" *FFOR

*FFOR = Fl

= FlatFacedO-Ring”

atFacedO-Ring” TEST

TEST PORTS L

PORTS Listing

isting on

on last

last page.

page.

1)

1)

Begin with certainBegin with certain Machine Pre-C Machine Pre-Checks for Monithecks for Monitor & Controller or & Controller such as listed below, by such as listed below, by Monitor CodesMonitor Codes within the SERVICE MODE (Mode 8) then DUAL DISPLAY MODE (Mode 11):

within the SERVICE MODE (Mode 8) then DUAL DISPLAY MODE (Mode 11): MM=MonMode-Code

MM=MonMode-Code Key “ON” Engine “OFF” Key “ON” Engine “OFF”

Actual Actual Value Value After After Adjusting Adjusting Standard Value Standard Value D31xX-21 D31xX-21 Standard Value Standard Value D37xX-21 D37xX-21 Standard Value Standard Value D39xX-21 D39xX-21 MM=8-0001

MM=8-0001 Distr TEL Distr TEL InputInput Service Service Phone Phone No. No. Service Service Phone Phone No. No. Service Phone Service Phone No.No. MM=10-00200 Model Code

MM=10-00200 Model Code  No adj.##  No adj.## D31= ‘31’ D31= ‘31’ D37= ‘37’ D37= ‘37’ D39= ‘39’D39= ‘39’ MM=10-00200 Spec Code

MM=10-00200 Spec Code  No adj.##  No adj.## Ex=02 Ex=02 or or Px=01 Px=01 EX=02 EX=02 or or PX=01 PX=01 EX=02 EX=02 or or PX=01PX=01 MM=11-52500(R) Press. Sen.

MM=11-52500(R) Press. Sen.  No adj.  No adj. 300 – (500) – 700m300 – (500) – 700mV V 300 – (500) – 700m300 – (500) – 700mV V 300– (500) – 700m300– (500) – 700mVV MM=11-52502(L) Press. Sen.

MM=11-52502(L) Press. Sen.  No adj.  No adj. 300 – (500) – 700m300 – (500) – 700mV V 300 – (500) – 700m300 – (500) – 700mV V 300– (500) – 700m300– (500) – 700mVV MM=11-20215 HST Pgm Ver.

MM=11-20215 HST Pgm Ver.  No adj.  No adj. Ref Ref Ref Ref Ref Ref  MM=6

MM=6 Elec.Faults Elec.Faults (F.Name)(F.Name) F.Hours F.Hours F.Frequency F.Frequency F.Name F.Name F.Hours F.Hours F.FrequencyF.Frequency

MM=7

3)

Measure and record all of the Cycle Times listed below. See the Shop Manual for procedural details. Measurement

conditions High Idle

Actual Values After Adjusting Standard Value D31/37X-21

Standard Value D39X-21

Units Measured

Blade Raise 1.8 – 2.2 1.8 – 2.2 Seconds

Blade Down 1.2 – 1.6 1.5 – 1.9 ‘’

Blade Tilt Left 1.5 – 1.9 1.2 – 1.6 ‘’

Blade Tilt Right 1.5 – 1.9 1.2 – 1.6 ‘’

Blade ANGLE Left 2.1 – 3.1 2.2 – 3.2 ‘’

Blade ANGLE Right 2.1 – 3.1 2.2 – 3.2 ‘’

Ripper (opt) UP Option Option ‘’

Ripper DOWN Option Option Seconds

4) Measure, record Track Tension

Right Track Initial__________________ 

Right after ADJUSTMENT___________ 

Left Track Initial ___________________ 

Left after ADJUSTMENT ____________ 

STD VALUE = 20 – 30 mm

5)

Measure and record all of the Travel Speeds listed below. See the Shop Manual for p rocedural details.

*** OPTIONAL Measurement ~ use MM=11-52404+5 or 52406+7 to record Pump cc’s/Rev(ref).

Measurement conditions High Idle Actual Values F3 Actual Values R3 Standard Value D31/37EX/PX-21 Standard Value D39EX/PX-21 Units Measured

TOW Vlv

closed

! CAUTION!

Use Wire Tie or other secure means if pin (5) becomes

unavailable. Valve handle must be LOCKED or PINNED “OPEN” prior to releasing

D31/37/39x21A to work.

CAUTION!

 If Dozer moves during test(s) the KS2 HST  Controller will STOP BOTH TRACKS  while using the built-in HST Stall Check   Mode (MM=8-3016).

Use this Valve for TOWING Brake release “ONLY” 

!

 NOT REQUIRED when using KS2  Monitor Tests!!!

8)

Measure and record HST Stall pressures – 30 SECOND TIME LIMIT!

Keep HST temp at 50C. (MM=8-3016) NON ADJUSTABLE – Consult Troubleshooting if abnormal. HST Stall (MM=8-3016) Track -Direction Actual Pressure D31/37/39xx-21”A” Standard Value KS2, MPa

PCCS=Fwd Full fuel Right – Full F 40.2 – 44.1

PCCS=Fwd Full fuel Left – Full F 40.2 – 44.1

PCCS=Rev Full Fuel Right – R 40.2 – 44.1

PCCS=Rev Full fuel Left - R 40.2 – 44.1

**Note – MM code 8-3016 will ‘lock-in’ 3

rd

speed (@T/M) with Park Brake applied and will STOP

HST PUMP if any track movement is sensed (Brake Slippage). DO NOT use “Tow Valve”!

9)

Measure the Work Equipment  pressures at pump OR valve (under Operator’s seat). Compare with the standard values listed below, and adjust if necessary (work equipment relief only) This circuit not on MM.

Actual pressures compared to standard values MPa (kg/cm2)

Item Measurement conditions Actual D39EX/PX-21 Adjusted Value Blade Raise Cylinder relieved 20.6 – 30.3 (210 – 218)

Blade Down Cylinder relieved 20.6 – 30.3 (210 – 218) Blade Tilt Left Cylinder relieved 20.6 – 30.3 (210 – 218) Blade Tilt Right Cylinder relieved 20.6 – 30.3 (210 – 218) Blade ANGLE Left Cylinder relieved 20.6 – 30.3 (210 – 218) Blade ANGLE Right Cylinder relieved 20.6 – 30.3 (210 – 218) Ripper (opt) UP Cylinder relieved 20.6 – 30.3 (210 – 218) Ripper DOWN Cylinder relieved 20.6 – 30.3 (210 – 218)

D31.37.39ExPx21”A” KomStat II 4/18/2004

D31/37/39ExPx-21”A” Valves List

•  Note – ALL 10mm ports are Komatsu STD o-ring type 1.25 thread pitch. • Special NOTE – all PPC and Servo lines are Flat Face O-Ring “FFOR” #4 (9/16UNF) or #6 (11/16UNF) threads.

Valve NAME LOCATION FUNCTION Test PORT Type & Location

1. TVL PPC Valve

PCCS = Electrical Potentiometers

LH Operator’s Pedestal _{Direction & Steering command None}

2. Charge Safety HST Pump, LEFT SIDE center  _{Charge Pressure Limiter in “N”}

(neutral) = 31kg/cm2

Charge Port 10mm near solenoid valves

Or MM11 LOC”B” 3. Charge Relief(s)

…aka “Flushing Valves” 

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

“Vents” HST hot return oil from T/M to tank 

Same as above (#2) “B” Or MM11

4. HST AS Valve KS2 = Controller function

 None Engine RPM sensing (L=Off/M=ON/H=Off)

 None

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

HST Pump center case – low on LH side

Limits HST pump to 440kg/cm2 drive

MM=11-52501+52503

6. HST Safety Top & Sides of center case (2 each) Relieves HST 410-450kg/cm2 drive

 press. MM=11-52501+52503

7. Wk.Eq. RELIEF Lower WK.EQ.Valve Limits Wk.Eq. to 210kg/cm2 Top INNER 10mm at Wk.Eq.Valve LOC “E” 8. Wk. Eq. SAFETY Upper WK.EQ. Valve Protects Blade ANGLE to 240kg/cm2 Same as #6 “E”

9. Unloader Lower WK.EQ.Valve Dumps WK.EQ. 100% to cooler/Filter Same as #6 “E”

10. LS Selector Piston Inside Unloader Valve Cushions LS Pressure rise Top Outer 10mm Wk.Eq.V. port LOC “F” 11. Park Brake RELEASE

Solenoid

Solenoid Valve Manifold Assembly Releases park brake Outlet PPC line requires FFOR #4 Swivel run TEE LOC “G” 12. HST Brake Valve (EB)

KS2 = Slow Brake Solenoid

Solenoid Valve Manifold Assembly Delays Park Brake Apply to protect Outlet PPC line requires FFOR #4 Swivel run TEE LOC “H” 13. 2ndSpeed SELECT Solenoid Solenoid Valve Manifold Assembly Speed selection PPC signal to T/M Outlet PPC line requires FFOR #4

Swivel run TEE LOC “I” 14. 3rdSpeed SELECT Solenoid Solenoid Valve Manifold Assembly Speed selection PPC signal to T/M Outlet PPC line requires FFOR #4

D31.37.39ExPx21”A” KomStat II 4/18/2004

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

LOCATION

QTY

SIZE

A “Servo-In” KS2 = NOT REQ’D

4 NONE (was #6)

EPC Blocks are ported for “Servo-in” tests for troubleshooting Only.

Block ports = 10 x 1.25 B, C, D, E, F “See Valve List” 5 M10 x 1.25