Komatsu D31E-20 Dozer Bulldozer Service Repair Manual

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