Bulldozer D39ex, PX-21 (1501 and Up)

SEBM035005
MACHINE MODEL SERIAL NUMBER

D31EX-21 50501 and up
D31PX-21 50501 and up
D37EX-21 5501 and up
D37PX-21 5501 and up
D39EX-21 1501 and up
D39PX-21 1501 and up
• This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may
require. Materials and specifications are subject to change without notice.
• D31, D37, D39EX, PX-21 mount the SAA4D102E-2 engine.

For details of the engine, see the 102 Series Engine Shop Manual.
© 2007
All Rights Reserved 00-1
Printed in Japan 11-07 (01) (5)
GENERAL
CONTENTS
No. of page
01 GENERAL ................................................................................................................................ 01-1
10 STRUCTURE AND FUNCTION,

MAINTENANCE STANDARD ..................................................... 10-1
20 TESTING AND ADJUSTING ................................................................................... 20-1
30 DISASSEMBLY AND ASSEMBLY ................................................................... 30-1
90 OTHERS..................................................................................................................................... 90-1
00-2 D31/37/39EX, PX-21

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LIST OF REVISED PAGES
The affected pages are indicated by the use of the

following marks. It is requested that necessary
actions be taken to these pages according to the Mark Indication Action required
table below.
Q Page to be newly added Add
q Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are those previously revised

or made additions.

Time of Time of Time of Time of Time of
Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision
q 00-1 (5) Q 00-24 (5) 10-1 10-31 10-59
00-2 (1) Q 00-25 (5) 10-2 10-32 10-60
q 00-2-1 (5) Q 00-26 (5) 10-3 10-33 10-61
q 00-2-2 (5) Q 00-27 (5) 10-4 10-34 10-62
q 00-2-3 (5) Q 00-28 (5) 10-5 10-35 10-63
q 00-2-4 (5) Q 00-29 (5) 10-6 10-36 10-64
q 00-2-5 (5) 10-7 10-37 10-65
q 00-3 (5) 10-8 10-38 10-66
q 00-4 (5) 01-1 10-9 10-39 10-67
q 00-5 (5) 01-2 10-10 10-40 10-68
q 00-6 (5) 01-3 10-11 10-41 10-69
q 00-7 (5) 01-4 10-12 10-42 10-70
q 00-8 (5) 01-5 10-13 10-43 10-71 (4)
q 00-9 (5) 01-6 10-14 10-44 10-72
q 00-10 (5) 01-7 10-15 10-45 10-73
q 00-11 (5) 01-8 10-16 10-46 (2) 10-74
q 00-12 (5) 01-9 10-17 10-47 10-75
q 00-13 (5) 01-10 10-18 (4) 10-48 10-76
q 00-14 (5) 01-11 10-19 10-49 10-77
q 00-15 (5) 01-12 10-20 10-50 10-78
q 00-16 (5) 01-13 10-22 10-51 10-79
q 00-17 (5) 01-14 10-23 10-52 10-80
q 00-18 (5) 01-15 10-24 10-53 10-81
q 00-19 (5) 01-16 10-25 10-54 10-82
q 00-20 (5) 01-17 10-26 10-55 10-83
q 00-21 (5) 10-28 10-56 10-84
q 00-22 (5) 10-29 (4) 10-57 10-85
Q 00-23 (5) 10-30 (2) 10-58 10-86
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10-87 10-128 20-108 (1) 20-147 (4) 20-187 (1)
10-88 10-129 (2) 20-109 (4) 20-148 (4) 20-188 (1)
10-89 10-130 20-110 (1) 20-149 (4) 20-189 (1)
10-90 10-131 20-111 (1) 20-150 (1) 20-190 (1)
10-91 10-132 (2) 20-112 (1) 20-151 (1) 20-191 (1)
10-92 10-133 20-113 (1) 20-152 (1) 20-192 (1)
10-93 10-134 20-114 (4) 20-153 (1) 20-193 (1)
10-94 10-135 20-115 (4) 20-154 (1) 20-194 (1)
10-95 10-136 20-116 (1) 20-155 (1) 20-195 (1)
10-96 10-137 20-117 (1) 20-156 (1) 20-196 (1)
10-97 10-138 20-118 (4) 20-157 (1) 20-197 (1)
10-98 20-119 (1) 20-158 (1) 20-198 (1)
10-99 q 20-120 (5) 20-159 (1) 20-199 (1)
10-100 20-1 (1) Q 20-120-1 (5) 20-160 (1) 20-200 (1)
10-101 20-2 (1) 20-121 (4) 20-161 (1) 20-201 (1)
10-102 20-3 (1) 20-122 (4) 20-162 (1) 20-202 (1)
10-103 20-4 (1) 20-123 (4) 20-163 (3) 20-203 (1)
10-104 20-5 (1) q 20-124 (5) 20-164 (1) 20-204 (1)
10-105 20-6 (1) 20-125 (4) 20-165 (1) 20-205 (1)
10-106 20-7 (1) q 20-126 (5) 20-166 (3) 20-206 (1)
10-107 20-8 (1) 20-127 (1) 20-167 (1) 20-207 (1)
10-108 20-9 (1) q 20-128 (5) 20-168 (1) 20-208 (1)
10-109 20-10 (1) 20-129 (4) q 20-169 (5) 20-209 (1)
10-110 20-11 (1) 20-130 (4) q 20-170 (5) 20-210 (1)
10-111 20-12 (1) 20-131 (1) q 20-171 (5) 20-211 (1)
10-112 20-13 (1) 20-132 (1) 20-172 (1) 20-212 (1)
10-113 20-14 (1) 20-133 (1) 20-173 (1) 20-213 (1)
10-114 20-15 (1) 20-134 (1) 20-174 (1) 20-214 (1)
10-116 20-16 (1) 20-135 (4) 20-175 (1) 20-215 (1)
10-117 20-17 (1) 20-136 (1) 20-176 (1) 20-216 (1)
10-118 20-18 (1) q 20-137 (5) 20-177 (1) 20-217 (1)
10-119 20-138 (1) 20-178 (4) 20-218 (1)
10-120 q 20-101 (5) 20-139 (1) 20-179 (4) 20-219 (1)
10-121 q 20-102 (5) 20-140 (1) 20-180 (1) 20-220 (1)
10-122 q 20-103 (5) q 20-141 (5) 20-181 (1) 20-221 (1)
10-123 Q 20-103-1 (5) 20-142 (1) 20-182 (1) 20-222 (1)
10-124 20-104 (1) q 20-143 (5) 20-183 (1)
10-125 (4) 20-105 (4) 20-144 (1) 20-184 (1) q 20-301 (5)
10-126 (2) 20-106 (1) 20-145 (1) 20-185 (1) 20-302 (1)
10-127 20-107 (4) 20-146 (1) 20-186 (1) 20-303 (1)
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q 20-304 (5) q 20-344 (5) 20-417 (1) 20-458 (1) 20-500 (1)
q 20-305 (5) q 20-345 (5) 20-418 (1) 20-459 (1) 20-501 (1)
q 20-306 (5) q 20-346 (5) 20-419 (1) 20-460 (1) 20-502 (1)
q 20-307 (5) q 20-347 (5) 20-420 (1) 20-461 (1) 20-503 (1)
q 20-308 (5) q 20-348 (5) 20-421 (1) 20-462 (1) 20-504 (1)
q 20-309 (5) q 20-349 (5) 20-422 (1) 20-463 (1) 20-505 (1)
q 20-310 (5) q 20-350 (5) 20-423 (1) 20-464 (1) 20-506 (1)
q 20-311 (5) q 20-351 (5) 20-424 (1) 20-465 (1) 20-507 (1)
Q 20-311-1 (5) q 20-352 (5) 20-425 (1) 20-466 (1) 20-508 (1)
20-312 (1) q 20-353 (5) 20-426 (1) 20-467 (1) 20-510 (1)
20-313 (1) q 20-354 (5) 20-427 (1) 20-468 (1) 20-511 (1)
20-314 (1) Q 20-355 (5) 20-428 (1) 20-469 (1) 20-512 (1)
20-315 (1) Q 20-356 (5) 20-429 (1) 20-470 (1) 20-513 (1)
20-316 (1) Q 20-357 (5) 20-430 (1) 20-471 (1) 20-514 (1)
20-317 (1) Q 20-358 (5) 20-432 (1) 20-472 (1) 20-515 (1)
20-318 (1) Q 20-359 (5) 20-433 (1) 20-473 (1) 20-516 (1)
20-320 (1) Q 20-360 (5) 20-434 (1) 20-474 (1) 20-517 (1)
20-321 (1) Q 20-361 (5) 20-435 (1) 20-475 (1) 20-518 (1)
20-322 (1) Q 20-362 (5) 20-436 (1) 20-476 (1) 20-519 (1)
20-323 (1) Q 20-363 (5) 20-437 (1) 20-477 (1) 20-520 (1)
20-324 (1) Q 20-364 (5) 20-438 (1) 20-478 (1) 20-521 (1)
20-325 (1) Q 20-365 (5) 20-439 (1) 20-479 (1) 20-522 (1)
20-326 (1) Q 20-366 (5) 20-440 (1) 20-480 (1) 20-523 (1)
20-327 (1) Q 20-367 (5) 20-441 (1) 20-481 (1) 20-524 (1)
20-328 (1) Q 20-368 (5) 20-442 (1) 20-482 (1) 20-525 (1)
20-329 (1) 20-443 (1) 20-484 (1) 20-526 (1)
q 20-330 (5) 20-401 (1) 20-444 (1) 20-485 (1) 20-527 (1)
q 20-331 (5) 20-402 (1) 20-445 (1) 20-486 (1) 20-528 (1)
q 20-332 (5) 20-404 (1) 20-446 (1) 20-487 (1) 20-529 (1)
q 20-333 (5) 20-405 (1) 20-447 (1) 20-488 (1) 20-530 (1)
q 20-334 (5) 20-406 (1) 20-448 (1) 20-489 (1) 20-531 (1)
q 20-335 (5) 20-407 (1) 20-449 (1) 20-490 (1) 20-532 (1)
q 20-336 (5) 20-408 (1) 20-450 (1) 20-491 (1) 20-533 (1)
q 20-337 (5) 20-409 (1) 20-451 (1) 20-492 (1) 20-534 (1)
q 20-338 (5) 20-410 (1) 20-452 (1) 20-493 (1) 20-535 (1)
q 20-339 (5) 20-411 (1) 20-453 (1) 20-494 (1) 20-536 (1)
q 20-340 (5) 20-412 (1) 20-454 (1) 20-496 (1) 20-537 (1)
q 20-341 (5) 20-413 (1) 20-455 (1) 20-497 (1) 20-538 (1)
q 20-342 (5) 20-414 (1) 20-456 (1) 20-498 (1) 20-539 (1)
q 20-343 (5) 20-416 (1) 20-457 (1) 20-499 (1) 20-540 (1)
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20-541 (1) 20-621 (1) 20-703 (1) q 30-1 (5) 30-40 (1)
20-542 (1) 20-622 (1) 20-704 (1) q 30-2 (5) 30-41 (1)
20-543 (1) 20-624 (1) 20-705 (1) q 30-3 (5) 30-42 (1)
20-544 (1) 20-625 (1) 20-706 (1) q 30-4 (5) q 30-43 (5)
20-545 (1) 20-626 (1) 20-707 (1) q 30-5 (5) q 30-44 (5)
20-546 (1) 20-627 (1) 20-708 (1) Q 30-5-1 (5) q 30-45 (5)
20-547 (1) 20-628 (1) 20-709 (1) 30-6 (1) q 30-46 (5)
20-548 (1) 20-629 (1) 20-710 (1) 30-7 (1) q 30-47 (5)
20-549 (1) 20-630 (1) 20-711 (1) 30-8 (1) Q 30-47-1 (5)
20-550 (1) 20-631 (1) 20-712 (1) 30-9 (1) 30-48 (1)
20-551 (1) 20-632 (1) 20-713 (1) 30-10 (1) 30-49 (1)
20-552 (1) 20-633 (1) 20-714 (1) 30-11 (1) 30-50 (1)
20-553 (1) 20-634 (1) 20-715 (1) 30-12 (1) 30-51 (1)
20-554 (1) 20-635 (1) 20-716 (1) 30-13 (1) 30-52 (1)
20-555 (1) 20-636 (1) 30-14 (1) 30-53 (1)
20-556 (1) 20-638 (1) 20-801 (1) 30-15 (1) 30-54 (1)
20-557 (1) 20-639 (1) 20-802 (1) 30-16 (1) 30-55 (1)
20-558 (1) 20-640 (1) 20-803 (1) 30-17 (1) 30-56 (1)
20-559 (1) 20-641 (1) 20-804 (1) 30-18 (1) 30-57 (1)
20-642 (1) 20-805 (1) 30-19 (1) 30-58 (1)
20-601 (1) 20-643 (1) 20-806 (1) 30-20 (1) 30-59 (1)
20-602 (1) 20-644 (1) 20-807 (1) 30-21 (1) 30-60 (1)
20-603 (1) 20-646 (1) 20-808 (1) 30-22 (1) 30-61 (1)
20-604 (1) 20-647 (1) 20-809 (1) 30-23 (1) 30-62 (1)
20-605 (1) 20-648 (1) 20-810 (1) 30-24 (1) 30-63 (1)
20-606 (1) 20-649 (1) 20-811 (1) 30-25 (1) 30-64 (1)
20-607 (1) 20-650 (1) 20-812 (1) 30-26 (1) 30-66 (1)
20-608 (1) 20-651 (1) 20-813 (1) 30-27 (1) 30-67 (1)
20-609 (1) 20-652 (1) 20-814 (1) 30-28 (1) 30-68 (1)
20-610 (1) 20-653 (1) 20-815 (1) 30-29 (1) 30-69 (1)
20-611 (1) 20-654 (1) 20-816 (1) 30-30 (1) 30-70 (1)
20-612 (1) 20-655 (1) 20-817 (1) 30-31 (1) 30-71 (1)
20-613 (1) 20-656 (1) 20-818 (1) 30-32 (1) 30-72 (1)
20-614 (1) 20-657 (1) 20-819 (1) 30-33 (1) 30-73 (1)
20-615 (1) 20-658 (1) 20-820 (1) 30-34 (1) 30-74 (1)
20-616 (1) 20-659 (1) 20-821 (1) 30-35 (1) 30-75 (1)
20-617 (1) 20-660 (1) 20-822 (1) 30-36 (1) 30-76 (1)
20-618 (1) 20-823 (1) 30-37 (1) 30-77 (1)
20-619 (1) 20-701 (1) 30-38 (1) 30-78 (1)
20-620 (1) 20-702 (3) 30-39 (1) 30-79 (1)
00-2-4 D31/37/39EX, PX-21

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30-80 (1)
30-81 (1)
30-82 (1)
30-83 (1)
30-84 (1)
30-85 (1)
30-86 (1)
90-1
90-3
90-5
90-7
90-9
90-11
90-13
90-15
D31/37/39EX, PX-21 00-2-5

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FOREWORD SAFETY NOTICE
SAFETY NOTICE (Rev. 2007/03)

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 cau-
tions accompanying these symbols should always be followed carefully. If any dangerous situation
arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situa-
tion.
1. General precautions 8) Before starting work, warm up your body

k Mistakes in operation are extremely dan- thoroughly to start work under good condi-
gerous. Read the Operation and Mainte- tion.
nance Manual carefully before operating
the machine. Safety points
1) Before carrying out any greasing or repairs,
1 Good arrangement
read all the safety plates stuck to the
machine. For the locations of the safety 2 Correct work clothes
plates and detailed explanation of precau- 3 Following work standard
tions, see the Operation and Maintenance
4 Making and checking signs
Manual.
2) Decide a place in the repair workshop to Prohibition of operation and handling by
5
keep tools and removed parts. Always keep unlicensed workers
the tools and parts in their correct places. 6 Safety check before starting work
Always keep the work area clean and make Wearing protective goggles
sure that there is no dirt, water, or oil on the 7
(for cleaning or grinding work)
floor. Smoke only in the areas provided for
smoking. Never smoke while working. Wearing shielding goggles and protectors
8
(for welding work)
3) When carrying out any operation, always
wear safety shoes and helmet. Do not wear 9 Good physical condition and preparation
loose work clothes, or clothes with buttons Precautions against work which you are
missing. 10
not used to or you are used to too much
• Always wear safety glasses when hitting
parts with a hammer.
• Always wear safety glasses when grind- 2. Preparations for work
ing parts with a grinder, etc. 1) Before adding oil or making any repairs,
4) When carrying out any operation with 2 or park the machine on hard and level ground,
more workers, always agree on the operat- and apply the parking brake and block the
ing procedure before starting. Always inform wheels or tracks to prevent the machine
your fellow workers before starting any step from moving.
of the operation. Before starting work, hang 2) Before starting work, lower the work equip-
UNDER REPAIR warning signs in the oper- ment (blade, ripper, bucket, etc.) to the
ator's compartment. ground. If this is not possible, insert the lock
5) Only qualified workers must carry out work pin or use blocks to prevent the work equip-
and operation which require license or quali- ment from falling. In addition, be sure to lock
fication. all the control levers and hang warning
6) Keep all tools in good condition, learn the signs on them.
correct way to use them, and use the proper 3) When disassembling or assembling, support
ones of them. Before starting work, thor- the machine with blocks, jacks, or stands
oughly check the tools, machine, forklift, before starting work.
service car, etc. 4) Remove all mud and oil from the steps or
7) If welding repairs are needed, always have other places used to get on and off the
a trained and experienced welder carry out machine. Always use the handrails, ladders
the work. When carrying out welding work, or steps when getting on or off the machine.
always wear welding gloves, apron, shield- Never jump on or off the machine. If it is
ing goggles, cap and other clothes suited for impossible to use the handrails, ladders or
welding work. steps, use a stand to provide safe footing.
D31/37/39EX, PX-21 00-3

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3. Precautions during work 11) When installing high pressure hoses, make
1) Before disconnecting or removing compo- sure that they are not twisted. Damaged
nents of the oil, water, or air circuits, first tubes are dangerous, so be extremely care-
release the pressure completely from the ful when installing tubes for high pressure
circuit. When removing the oil filler cap, a circuits. In addition, check that connecting
drain plug, or an oil pressure pickup plug, parts are correctly installed.
loosen it slowly to prevent the oil from spurt- 12) When assembling or installing parts, always
ing out. tighten them to the specified torques. When
2) The coolant and oil in the circuits are hot installing protective parts such as guards, or
when the engine is stopped, so be careful parts which vibrate violently or rotate at high
not to get scalded. Wait for the oil and cool- speed, be particularly careful to check that
ant to cool before carrying out any work on they are installed correctly.
the oil or water circuits. 13) When aligning 2 holes, never insert your fin-
3) Before starting work, stop the engine. When gers or hand. Be careful not to get your fin-
working on or around a rotating part, in par- gers caught in a hole.
ticular, stop the engine. When checking the 14) When measuring hydraulic pressure, check
machine without stopping the engine (meas- that the measuring tools are correctly
uring oil pressure, revolving speed, temper- assembled.
ature, etc.), take extreme care not to get 15) Take care when removing or installing the
rolled or caught in rotating parts or moving tracks of track-type machines. When remov-
parts. ing the track, the track separates suddenly,
4) Before starting work, remove the leads from so never let anyone stand at either end of
the battery. Always remove the lead from the track.
the negative (–) terminal first. 16) If the engine is operated for a long time in a
5) When raising a heavy component (heavier place which is not ventilated well, you may
than 25 kg), use a hoist or crane. Before suffer from gas poisoning. Accordingly, open
starting work, check that the slings (wire the windows and doors to ventilate well.
ropes, chains, and hooks) are free from
damage. Always use slings which have
ample capacity and install them to proper
places. Operate the hoist or crane slowly to
prevent the component from hitting any
other part. Do not work with any part still
raised by the hoist or crane.
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually and
alternately to release the pressure, and then
remove the cover.
7) When removing components, be careful not
to break or damage the electrical wiring.
Damaged wiring may cause electrical fires.
8) When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips onto
the floor, wipe it up immediately. Fuel or oil
on the floor can cause you to slip and can
even start fires.
9) As a general rule, do not use gasoline to
wash parts. Do not use it to clean electrical
parts, in particular.
10) Be sure to assemble all parts again in their
original places. Replace any damaged parts
and parts which must not be reused with
new parts. When installing hoses and wires,
be sure that they will not be damaged by
contact with other parts when the machine is
operated.
00-4 D31/37/39EX, PX-21

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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 seen well from
the operator's seat and where he can see
the working condition easily. The sign maker
must always stand in front of the load and
guide the operator safely.
• Do not stand under the load.
• Do not step on the load.
2) Check the slings before starting sling work.
3) Keep putting on gloves during sling work.
(Put on leather gloves, if available.)
8) When installing wire ropes to an angular
4) Measure the weight of the load by the eye
load, apply pads to protect the wire ropes. If
and check its center of gravity.
the load is slippery, apply proper material to
5) Use proper sling according to the weight of
prevent the wire rope from slipping.
the load and method of slinging. If too thick
9) Use the specified eyebolts and fix wire
wire ropes are used to sling a light load, the
ropes, chains, etc. to them with shackles,
load may slip and fall.
etc.
6) Do not sling a load with 1 wire rope alone. If
10) Apply wire ropes to the middle portion of the
it is slung so, it may rotate and may slip out
hook.
of the rope. Install 2 or more wire ropes
• Slinging near the tip of the hook may
symmetrically.
k Slinging with 1 rope may cause turn-
cause the rope to slip off the hook during
hoisting. The hook has the maximum
ing of the load during hoisting, un-
strength at the middle portion.
twisting of the rope, or slipping of
the rope from its original winding po-
sition on the load, which can result
in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes forming
a wide hanging angle from the hook.
When hoisting a load with 2 or more ropes,
the force subjected to each rope will
increase with the hanging angle. The table
below shows the variation of allowable load
in kN {kg} when hoisting is made with 2
ropes, each of which is allowed to sling up
to 9.8 kN {1,000 kg} vertically, at various
hanging angles. When the 2 ropes sling a
load vertically, up to 19.6 kN {2,000 kg} of 11) Do not use twisted or kinked wire ropes.
total weight can be suspended. This weight 12) When lifting up a load, observe the follow-
is reduced to 9.8 kN {1,000 kg} when the 2 ing.
ropes make a hanging angle of 120°. If the 2 • Wind in the crane slowly until wire ropes
ropes sling a 19.6 kN {2,000 kg} load at a are stretched. When settling the wire
lifting angle of 150°, each of them is sub- ropes with the hand, do not grasp them
jected to a force as large as 39.2 kN {4,000 but press them from above. If you grasp
kg}. them, your fingers may be caught.
• After the wire ropes are stretched, stop
the crane and check the condition of the
slung load, wire ropes, and pads.
• If the load is unstable or the wire rope or
chains are twisted, lower the load and lift
it up again.
• Do not lift up the load slantingly.
D31/37/39EX, PX-21 00-5

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13) When lifting down a load, observe the fol- 15) After finishing the work, stop the hoist at the
lowing. specified position and raise the hook to at
• When lifting down a load, stop it tempo- least 2 m above the floor. Do not leave the
rarily at 30 cm above the floor, and then sling installed to the hook.
lower it slowly.
• Check that the load is stable, and then 7. Selecting wire ropes
remove the sling. 1) Select adequate ropes depending on the
• Remove kinks and dirt from the wire weight of parts to be hoisted, referring to the
ropes and chains used for the sling work, table below.
and put them in the specified place.
Wire ropes
5. Precautions for using mobile crane (Standard “Z” twist ropes without galvanizing)
★ Read the Operation and Maintenance Manu- (JIS G3525, No. 6, Type 6X37-A)
al of the crane carefully in advance and op- Nominal
Allowable load
erate the crane safely. diameter of rope
mm kN ton
6. Precautions for using overhead hoist crane 10 8.8 0.9
k When raising a heavy part (heavier than 12 12.7 1.3
25 kg), use a hoist, etc. In Disassembly 14 17.3 1.7
and assembly, the weight of a part heav-
16 22.6 2.3
ier than 25 kg is indicated after the mark
18 28.6 2.9
of 4.
20 35.3 3.6
1) Before starting work, inspect the wire ropes,
brake, clutch, controller, rails, over wind stop 25 55.3 5.6
device, electric shock prevention earth leak- 30 79.6 8.1
age breaker, crane collision prevention 40 141.6 14.4
device, and power application warning 50 221.6 22.6
lamp, and check safety. 60 318.3 32.4
2) Observe the signs for sling work.
3) Operate the hoist at a safe place. ★ The allowable load is one-sixth of the
4) Check the direction indicator plates (east, breaking strength of the rope used
west, south, and north) and the directions of (Safety coefficient: 6).
the control buttons without fail.
5) Do not sling a load slantingly. Do not move
the crane while the slung load is swinging.
6) Do not raise or lower a load while the crane
is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and lift
up a load to a safe height.
10) Place the control switch on a position where
it will not be an obstacle to work and pas-
sage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
13) If the hoist stops because of a power failure,
turn the power switch OFF. When turning on
a switch which was turned OFF by the elec-
tric shock prevention earth leakage breaker,
check that the devices related to that switch
are not in operation state.
14) If you find an obstacle around the hoist, stop
the operation.
00-6 D31/37/39EX, PX-21

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8. Precautions for disconnecting and connect-

ing hoses and tubes in air conditioner circuit
1) Disconnection
k Collect the air conditioner refrigerant
(R134a) from the air conditioner cir-
cuit in advance.
★ Ask professional traders for collecting
and filling operation of refrigerant
(R134a).
★ Never release the refrigerant (R134a) to
the atmosphere.
k If the refrigerant gas (R134a) gets in
your eyes, you may lose your sight.
Accordingly, when collecting or fill-
ing it, you must be qualified for han-
dling the refrigerant and put on
protective goggles.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings (1)
are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refrigerant
(R134a) (DENSO: ND-OIL8, ZEXEL:
ZXL100PG (equivalent to PAG46)) to
its O-rings.
★ Example of O-ring (Fitted to every joint of hoses

and tubes)
★ For tightening torque, see the precautions for in-

stallation in each section of “Disassembly and
assembly”.
D31/37/39EX, PX-21 00-7

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FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL

• 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.
• Materials and specifications are subject to change without notice.
• 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. FOREWORD
This section explains the safety and basic information.
01. GENERAL
This section explains the specifications of the machine.
10. STRUCTURE AND FUNCTION, 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 disas-
sembly and service.
20. TESTING AND ADJUSTING

Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjust-
ing, and troubleshooting. This standard value table is used to check the standard values in testing and
adjusting and to judge parts in troubleshooting.
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.
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.
30. 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 quan-
tity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. OTHERS (chassis volume)/Repair and replacement of parts (engine volume)

• Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
• 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.
00-8 D31/37/39EX, PX-21

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FOREWORD HOW TO READ THE SHOP MANUAL
3. Filing method
• See the page number on the bottom of the page. File the pages in correct order.
• Following examples show how to read the page number.
Example 1 (Chassis volume):
10 - 3
Item number (10. Structure and Function, Maintenance Standard)

Consecutive page number for each item.
Example 2 (Engine volume):
12 - 5
Unit number (1. Engine)

Item number (2. Testing and Adjusting)
Consecutive page number for each item.
• Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number.
File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
• Revised edition mark

When a manual is revised, an edition mark ((1) (2) (3)....) is recorded on the bottom of the pages.
• Revisions
Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.
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, conven-
tionally used Gravitational System of units is indicated in parentheses { }.
D31/37/39EX, PX-21 00-9

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FOREWORD EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD

The maintenance standard values necessary for judgment of products and parts are described by the following
terms.
1. Standard size and tolerance

• To be accurate, the finishing size of parts is
a little different from one to another.
• To specify a finishing size of a part, a tempo-
rary standard size is set and an allowable dif-
ference from that size is indicated.
• The above size set temporarily is called the
“standard size” and the range of difference
from the standard size is called the “toler-
ance”.
• The tolerance with the symbols of + or – is in-
dicated on the right side of the standard size.
Example:
Standard size Tolerance
–0.022
120
–0.126
★ 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)
• Usually, the size of a hole and the size of the

shaft to be fitted to that hole are indicated by
the same standard size and different toler-
ances of the hole and shaft. The tightness of
fit is decided by the tolerance.
• 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
00-10 D31/37/39EX, PX-21

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FOREWORD EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
2. Standard clearance and standard value 5. Clearance limit

• The clearance made when new parts are as- • Parts can be used until the clearance be-
sembled is called the “standard clearance“, tween them is increased to a certain limit.
which is indicated by the range from the min- The limit at which those parts cannot be used
imum clearance to the maximum clearance. is called the “clearance limit”.
• When some parts are repaired, the clear- • If the clearance between the parts exceeds
ance is generally adjusted to the standard the clearance limit, they must be replaced or
clearance. repaired.
• A value of performance and function of new
products or equivalent is called the “standard 6. Interference limit
value“, which is indicated by a range or a tar- • The allowable maximum interference be-
get value. tween the hole of a part and the shaft of an-
• When some parts are repaired, the value of other part to be assembled is called the
performance/function is set to the standard “interference limit”.
value. • The interference limit shows the repair limit
of the part of smaller tolerance.
3. Standard interference • If the interference between the parts ex-
• When the diameter of a hole of a part shown ceeds the interference limit, they must be re-
in the given standard size and tolerance ta- placed or repaired.
ble is smaller than that of the mating shaft,
the difference between those diameters is
called the “interference”.
• The range (A – B) from the difference (A) be-
tween 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”.
• 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

• 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”.
• If a part is worn to the repair limit must be re-
placed or repaired.
• The performance and function of a product
lowers while it is used. A value below which
the product can be used without causing a
problem is called the “allowable value”.
• If a product is worn to the allowable value, it
must be checked or repaired. Since the per-
missible value is estimated from various
tests or experiences in most cases, howev-
er, it must be judged after considering the
operating condition and customer's require-
ment.
D31/37/39EX, PX-21 00-11

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FOREWORD HOW TO READ ELECTRIC WIRE CODE
HOW TO READ ELECTRIC WIRE CODE

★ The information about the wires unique to each machine model is described in Troubleshooting section, Re-
lational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols.
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 thick-
ness 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
00-12 D31/37/39EX, PX-21

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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”.
D31/37/39EX, PX-21 00-13

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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 – – – – – – –
00-14 D31/37/39EX, PX-21

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FOREWORD PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general pre-
cautions given below when carrying out the operation.]
1.Precautions when carrying out removal work

• If the coolant contains antifreeze, dispose of it correctly.
• After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the necessary places
before removal to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when discon-
necting the connectors. Do not pull the wires.
• Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
• Check the number and thickness of the shims, and keep in a safe place.
• When raising components, be sure to use lifting equipment of ample strength.
• When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from enter-
ing after removal.
★ 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
D31/37/39EX, PX-21 00-15

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2. Precautions when carrying out installation work

• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins and lock plates securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion
with 2 – 3 drops of adhesive.
• 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.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press fitting parts, coat the surface with anti-friction compound (LM-P).
• After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
• When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the
direction of the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
★ When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hy-
draulic 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 cyl-
inder 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.
★ 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
• 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.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified lev-
el. Run the engine to circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment have been removed, always bleed the air from the system after
reassembling the parts.
★ For details, see Testing and adjusting, “Bleeding air”.
• 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.
• 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 suc-
tion 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.
00-16 D31/37/39EX, PX-21

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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 loose-
ness.
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”.
D31/37/39EX, PX-21 00-17

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FOREWORD METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL

TYPE COUPLER
k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to re-
lease 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)
★ The adapter can be pushed in about 3.5
mm.
★ 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)
★ Since some hydraulic oil flows out, pre-
pare 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)
★ 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)
★ When the hose is pulled back, the rubber
cap portion moves toward the hose
about 3.5 mm. This does not indicate ab-
normality, however.
00-18 D31/37/39EX, PX-21

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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 hexago-
nal 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 disconnect it.
(Fig. 8)
2. Connection
• Hold the tightening portion and push body
contacts contact surface (a) of the hexago-
D31/37/39EX, PX-21 00-19

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Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexago-
2) While holding the condition of Step 1), push
cover (10) straight until it contacts contact
surface (b) of the hexagonal portion at the
male end. (Fig. 11)
3) While holding the condition of Steps 1) and
2), pull out whole body (9) to disconnect it.
(Fig. 12)
2. Connection
• Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexago-
00-20 D31/37/39EX, PX-21

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FOREWORD STANDARD TIGHTENING TORQUE TABLE
STANDARD TIGHTENING TORQUE TABLE

1. Table of tightening torques for bolts and nuts
★ Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using
torque wrench)
★ The following table corresponds 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 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5
18 27 320 – 400 33.0 – 41.0
20 30 455 – 565 46.5 – 58.0
22 32 610 – 765 62.5 – 78.0
24 36 785 – 980 80.0 – 100.0
27 41 1,150 – 1,440 118 – 147
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
★ The following table corresponds 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
D31/37/39EX, PX-21 00-21

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2. Table of tightening torques for split flange bolts

★ 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

★ 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

★ 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}
00-22 D31/37/39EX, PX-21

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5. Table of tightening torques for hoses (taper seal type and face seal type)
★ Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the torque
below.
★ 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. -
Thread diame-
No. of across Thread size Number of
Range Target ter (mm) (Ref-
hose flats (mm) threads, type of
erence)
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 102, 107 and 114 engine series (Bolts and nuts)
★ 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 — —
7. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
★ 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
D31/37/39EX, PX-21 00-23

(5)
8. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
★ Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114 engine
series to the torque below.
Thread size Tightening torque

inch Nm kgm
1/16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.20
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
00-24 D31/37/39EX, PX-21

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FOREWORD CONVERSION TABLE
CONVERSION TABLE
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 horizontal
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 mil-
limeters 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
D31/37/39EX, PX-21 00-25

(5)
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
00-26 D31/37/39EX, PX-21

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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
D31/37/39EX, PX-21 00-27

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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
00-28 D31/37/39EX, PX-21

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Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade
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 Fahrenheit
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 Centigrade
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
D31/37/39EX, PX-21 00-29

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01 GENERAL
Specification drawing .......................................01- 2

Specifications ...................................................01- 4
Weight table .....................................................01-12
Table of fuel, coolant and lubricants .................01-16
D31/37/39EX, PX-21 01-1

GENERAL SPECIFICATION DRAWING
SPECIFICATION DRAWING
D31EX-21 Power angle, power tiltdozer with ROPS canopy

D31PX-21 Power angle, power tiltdozer with ROPS canopy
D31EX-21 D31PX-21
Item Unit 400 mm 600 mm 600 mm
Single shoe Single shoe Swamp shoe
7,650 7,630
Machine weight kg 7,130
(7,630) (7,610)
Engine model — Komatsu SAA4D102E-2-B diesel engine
Engine rated horsepower kW {HP} /rpm 56 {75} /2,000
A Overall length mm 4,015 3,995 3,975
Overall height (not including antenna) 2,700 2,720
B mm
(to tip of exhaust pipe) 2,645 2,665
3,200
C Overall width mm 2,435
(2,875)
FORWARD
km/h 4.3/5.6/8.5
Travel speed (1st/2nd/3rd)
(Quick shift mode) REVERSE
km/h 4.3/6.5/8.5
(1st/2nd/3rd)
Travel speed FORWARD km/h 0.8 – 8.5

(Variable shift mode) REVERSE km/h 0.8 – 8.5
Values in ( ) are for the machines equipped with narrow blade.
01-2 D31/37/39EX, PX-21

GENERAL SPECIFICATION DRAWING
D37EX-21 Power angle, power tiltdozer with ROPS canopy

D37PX-21 Power angle, power tiltdozer with ROPS canopy
D37EX-21 D37PX-21
7,770 7,750
(7,720) (7,700)
A Overall length mm 4,055 4,035 4,015
B mm
3,250
(2,875)
FORWARD
km/h 3.4/5.6/8.5
km/h 4.1/6.5/8.5
(1st/2nd/3rd)

D39EX-21 Power angle, power tiltdozer with ROPS cab

D39PX-21 Power angle, power tiltdozer with ROPS cab
D39EX-21 D39PX-21
9,200 9,180
(9,140) (9,120)
A Overall length mm 4,240 4,220
B mm
3,330
(2,980)
FORWARD
km/h 3.4/5.6/8.5
km/h 4.1/6.5/8.5
(1st/2nd/3rd)

D31/37/39EX, PX-21 01-3

GENERAL SPECIFICATIONS
SPECIFICATIONS
D31EX-21 D31PX-21
Machine model 400 mm 600 mm 600 mm
Serial No. 50501 and up 50501 and up
Operating weight
• Bare tractor kg 5,800 6,250 6,230
Weight
• With power angle tiltdozer + 7,650 7,630

kg 7,130
ROPS cab (7,630) (7,610)
• With power angle tiltdozer + 7,990 7,970
kg 7,470
ROPS canopy (7,970) (7,950)
Min. turning radius
m 1.7 1.8 1.8
(bare tractor,counter-rotation)
Gradeability deg 30 30 30
Stability (front, rear, left, right) deg 35 35 35
Quick shift mode
Forward (1st/2nd/3rd) km/h 3.4/5.6/8.5 3.4/5.6/8.5 3.4/5.6/8.5
Travel speed
Reverse (1st/2nd/3rd) km/h 4.1/6.5/8.5 4.1/6.5/8.5 4.1/6.5/8.5

Performance
Variable shift mode

Forward km/h 0.8 – 8.5 0.8 – 8.5 0.8 – 8.5
Reverse km/h 0.8 – 8.5 0.8 – 8.5 0.8 – 8.5
kPa 35.3 23.5 23.5
Ground pressure
Bare tractor
{kg/cm2} {0.36} {0.24} {0.24}
With power angle tiltdozer + kPa 43.1 28.4 28.4
ROPS canopy {kg/cm2} {0.44} {0.29} {0.29}
With power angle tiltdozer + kPa 45.1 29.4 29.4
ROPS cab {kg/cm2} {0.46} {0.30} {0.30}
Bare tractor mm 3,055 3,090 3,110

Overall
length
With power angle tiltdozer +

mm 4,015 3,995 3,975
ROPS canopy
With power angle tiltdozer +
mm 4,085 4,065 4,045
ROPS cab
Bare tractor mm 1,850 2,250 2,250

Overall
width
3,200 3,200
Power angle tiltdozer mm 2,435
(2,875) (2,875)
Dimensions
To tip of exhaust pipe mm 2,645 2,645 2,665

To top of operator's
Overall height
mm 2,015 2,015 2,035

compartment
With ROPS cab installed
mm 2,700 2,700 2,720
(not including antenna)
With ROPS canopy
mm 2,700 2,700 2,720
installed
Track gauge mm 1,450 1,650 1,650
Length of track on ground mm 2,010 2,185 2,185
Width of track
mm 400 600 600
(standard track shoe)
Min. ground clearance mm 315 315 385
01-4 D31/37/39EX, PX-21

D37EX-21 D37PX-21 D39EX-21 D39PX-21

400 mm 600 mm 600 mm 460 mm 635 mm 700 mm
Single shoe Single shoe Swamp shoe Single shoe Single shoe Swamp shoe
5501 and up 5501 and up 1501 and up 1501 and up
6,030 6,330 6,310 6,950 7,230 7,210

7,770 7,750 8,860 8,840
7,410 8,480
(7,720) (7,700) (8,800) (8,780)
8,110 8,090 9,200 9,180
7,750 8,820
(8,060) (8,040) (9,140) (9,120)
1.8 1.9 1.9 1.9 2.0 2.0
30 30 30 30 30 30
35 35 35 35 35 35
3.4/5.6/8.5 3.4/5.6/8.5 3.4/5.6/8.5 3.4/5.6/8.5 3.4/5.6/8.5 3.4/5.6/8.5

4.1/6.5/8.5 4.1/6.5/8.5 4.1/6.5/8.5 4.1/6.5/8.5 4.1/6.5/8.5 4.1/6.5/8.5
0.8 – 8.5 0.8 – 8.5 0.8 – 8.5 0.8 – 8.5 0.8 – 8.5 0.8 – 8.5
0.8 – 8.5 0.8 – 8.5 0.8 – 8.5 0.8 – 8.5 0.8 – 8.5 0.8 – 8.5
33.3 23.5 22.6 31.4 23.5 21.6
{0.34} {0.24} {0.23} {0.32} {0.24} {0.22}
40.2 28.4 28.4 38.2 29.4 26.5
{0.41} {0.29} {0.29} {0.39} {0.30} {0.27}
42.2 29.4 29.4 40.2 30.4 27.5
{0.43} {0.30} {0.30} {0.41} {0.31} {0.28}
3,090 3,090 3,095 3,235 3,235 3,255
4,055 4,035 4,015 4,240 4,240 4,220
4,085 4,065 4,045 4,240 4,240 4,220
1,850 2,250 2,250 2,110 2,425 2,490
3,250 3,250 3,330 3,330

2,720 2,740
(2,875) (2,875) (2,980) (2,980)
2,645 2,645 2,665 2,720 2,720 2,740
2,015 2,015 2,035 2,090 2,090 2,110
2,700 2,700 2,720 2,770 2,770 2,790
2,700 2,700 2,720 2,770 2,770 2,790
1,450 1,650 1,650 1,650 1,790 1,790

2,240 2,240 2,240 2,360 2,360 2,360
400 600 600 460 635 700
315 315 385 385 385 460
D31/37/39EX, PX-21 01-5

D31EX-21 D31PX-21
Serial No. 50501 and up
Model — SAA4D102E-2-B
4-cycle, water-cooled, in-line vertical type, 4 cylinders,
Type —
direct injection, with turbocharger, air-cooled after cooler
No. of cylinders – bore x stroke mm 4 – 102 x 120
Piston displacement l {cc} 3.92 {3,920}
kW {HP}
Rated horsepower 56 {75}/2,000
/rpm
Nm {kgm}
Performance
Max. torque 384 {39.2}/1,300

Engine
/rpm
High idling rpm 2,200
Low idling rpm 800
Min. fuel g/kWh
211 {157}
consumption ratio {g/HPh}
Starting motor — 24 V, 5.5 kW
Alternator — 24 V, 25 A
Battery (*1) — 12 V, 60 Ah x 2
Radiator core type — D-5
Variable displacement swash-plate piston type x 2
Type, number —
Fix displacement internal-gear type x 1
Discharge amount
HST pump
(variable pump) cm3/rev 63

(charge pump) 40
Power train system
Set pressure
MPa
(variable pump) 42.2 {430}
{kg/cm2}
(charge pump) 3.0 {31}
Variable displacement angled piston type
Type, number —
(3-stage selection, with parking brake) x 2
HST motor
Discharge amount
(Max.) 93
cm3/rev
(Medium) 61
(Min.) 46
Planetary gear, 2-stage reduction type,
Final drive —
splash type lubrication
Suspension — Rigid
Carrier roller — 1 on each side
Track roller — 5 on each side 6 on each side
Track shoe
Undercarriage
Width: 400 mm Width: 600 mm

Q'ty on each side: Q'ty on each side:
• Assembly-type single grouser —
38 pieces 40 pieces
Pitch: 154.3 mm Pitch: 154.3 mm
—
Width: 600 mm
Q'ty on each side:
• Assembly-type special swamp shoe — —
40 pieces
Pitch: 154.3 mm
*1: The battery capacity (Ah) is the 5-hour rate value.
01-6 D31/37/39EX, PX-21

D37EX-21 D37PX-21 D39EX-21 D39PX-21

400 mm 600 mm 600 mm 460 mm 635 mm 700 mm
5501 and up 1501 and up
SAA4D102E-2-B SAA4D102E-2-B
4-cycle, water-cooled, in-line vertical type, 4 cylinders, 4-cycle, water-cooled, in-line vertical type, 4 cylinders,
direct injection, with turbocharger, air-cooled after cooler direct injection, with turbocharger, air-cooled after cooler
4 – 102 x 120 4 – 102 x 120
3.92 {3,920} 3.92 {3,920}
63 {85}/2,000 71 {95}/2,200
412 {42.0}/1,300 431 {44.0}/1,300
2,200 2,400
800 825
211 {157} 211 {157}
24 V, 5.5 kW 24 V, 5.5 kW
24 V, 25 A 24 V, 25 A
12 V, 60 Ah x 2 12 V, 60 Ah x 2
D-5 D-7
Variable displacement swash-plate piston type x 2 Variable displacement swash-plate piston type x 2
Fix displacement internal-gear type x 1 Fix displacement internal-gear type x 1
63 63
40 40
42.2 {430} 42.2 {430}

3.0 {31} 3.0 {31}
Variable displacement angled piston type Variable displacement angled piston type
(3-stage selection, with parking brake) x 2 (3-stage selection, with parking brake) x 2
93 105
61 68
46 52
Planetary gear, 2-stage reduction type, Planetary gear, 2-stage reduction type,
splash type lubrication splash type lubrication
Rigid Rigid
1 on each side 1 on each side
6 on each side 6 on each side
Width: 400 mm Width: 600 mm Width: 460 mm Width: 635 mm

Q'ty on each side: Q'ty on each side: Q'ty on each side: Q'ty on each side:
— —
41 pieces 41 pieces 39 pieces 39 pieces
Pitch: 154.3 mm Pitch: 154.3 mm Pitch: 171.5 mm Pitch: 171.5 mm
Width: 600 mm Width: 700 mm
Q'ty on each side: Q'ty on each side:
— — — —
41 pieces 39 pieces
Pitch: 154.3 mm Pitch: 171.5 mm
*1: The battery capacity (Ah) is the 5-hour rate value.
D31/37/39EX, PX-21 01-7

D31EX-21 D31PX-21
Type, number — Fix displacement external-gear type x 1
Hydraulic
Theoretical discharge amount 3

cm /rev 40.2
pump
MPa
Max. discharge pressure 20.6 {210}
{kg/cm2}
control valve
Type, number — 3-spool valve x 1

Main
Operating method — Hydraulic pilot type
Type — Double-acting piston type

Cylinder bore mm ø85
Lift cylinder
Outside diameter of piston rod mm ø40

Piston stroke mm 365
Max. distance between pins mm 1,009
Min. distance between pins mm 644
Work equipment hydraulic system

Tilt cylinder

Max. distance between pins mm 598
Angle cylinder

Max. distance between pins mm 1,083
Double-acting
Type — —
piston type
Ripper cylinder
Cylinder bore mm ø90 —

Outside diameter of piston rod mm ø45 —
Piston stroke mm 433.5 —
Max. distance between pins mm 1,176.5 —
Min. distance between pins mm 743 —
Hydraulic tank — Box type (externally mounted control valve type)
Hydraulic filter — Tank return side
Oil cooler — Air-cooled type (SF-3)
01-8 D31/37/39EX, PX-21

D37EX-21 D37PX-21 D39EX-21 D39PX-21

400 mm 600 mm 600 mm 460 mm 635 mm 700 mm
Fix displacement external-gear type x 1 Fix displacement external-gear type x 1
40.2 43.7
20.6 {210} 20.6 {210}
3-spool valve x 1 3-spool valve x 1
Hydraulic pilot type Hydraulic pilot type
Double-acting piston type Double-acting piston type

ø85 ø90
ø40 ø45
365 393
1,009 1,109
644 716
ø90 ø90
ø45 ø45
139 145
598 634
459 489
ø75 ø85
ø40 ø45
393 393
1,083 1,109
690 716
Double-acting Double-acting
— —
piston type piston type
ø90 — ø90 —
ø45 — ø45 —
433.5 — 433.5 —
1,176.5 — 1,176.5 —
743 — 743 —
Box type (externally mounted control valve type) Box type (externally mounted control valve type)
Tank return side Tank return side
Air-cooled type (SF-3) Air-cooled type (SF-4)
D31/37/39EX, PX-21 01-9

D31EX-21 D31PX-21
Type — Hydraulic type angle tiltdozer
Blade support method — Hydraulic cylinder type
Max. lifting height (from ground) mm 860 855 920
Max. lowering depth
Performance
mm 385 380 315

(from ground)
Work equipment
435 435
Max. tilt mm 330
(395) (395)
Max. angle deg 25 25 25
3,200 3,200
Blade width mm 2,435
Dimensions
(2,875) (2,875)
750 750
Blade height mm 845
(790) (790)
Blade cutting angle deg 56 56 58
Type Tool bar type
Beam length mm 520
Number of shanks Standard 3 units (Wearing is possible 5 units)
Digging angle (at on the ground/
deg 74/37
Ripper
at max. digging depth)

Performance
Adjustment of digging depth Rigid for 1 level

Max. digging depth mm 310
Max. lift mm 435
Shank interval
mm 700/350
(at 3 units/at 5 units)
01-10 D31/37/39EX, PX-21

D37EX-21 D37PX-21 D39EX-21 D39PX-21

400 mm 600 mm 600 mm 460 mm 635 mm 700 mm
Hydraulic type angle tiltdozer Hydraulic type angle tiltdozer
Hydraulic cylinder type Hydraulic cylinder type
860 855 920 890 890 965
385 380 315 440 440 365
445 445 480 480

375 395
(395) (395) (430) (430)
25 25
25 25 25 25
(22) (22)
3,250 3,250 3,330 3,330
2,720 2,740
(2,875) (2,875) (2,980) (2,980)
865 830 830 980 910 910
56 56 58 57 57 59
Tool bar type Tool bar type
520 520
Standard 3 units (Wearing is possible 5 units) Standard 3 units (Wearing is possible 5 units)
74/37 67/37
Rigid for 1 level Rigid for 1 level

310 245
435 505
700/350 700/350
D31/37/39EX, PX-21 01-11

GENERAL WEIGHT TABLE
WEIGHT TABLE
a This Weight Table is for reference when handling components or when transporting the machine.
Unit: kg
Machine model D31EX-21 D31PX-21
Engine, damper assembly (not including water or oil) 485 485

• Engine assembly 400 400
• Damper assembly 27 27
• Engine related parts
58 58
(engine mount, air cleaner, muffler, etc.)
Cooling assembly 177 177
• Radiator 71 71
• Oil cooler 33 33
• Charge air cooler 15 15
Fuel tank (not including fuel) 106 106
HST pump 134 134
HST motor (each side) 133 133
Final drive (each side) 162 162
Sprocket (each side) 26 26
Frame assembly 1,765 1,870
• Main frame 1,100 1,150
• Front underguard 8 8
• Rear underguard (including inspection cover) 41 41
• Idler assembly (each side) 93 93
• Recoil spring assembly (each side) 64 64
• Track roller (each side) 27 x 5 27 x 6
• Carrier roller (each side) 16 16
Track shoe assembly
• Single grouser shoe (400 mm) 520 x 2 520 x 2
• Single grouser shoe (460 mm) — —
• Single grouser shoe (600 mm) — 690 x 2
• Single grouser shoe (635 mm) — —
• Swamp shoe (600 mm) — 680 x 2
• Swamp shoe (700 mm) — —
Hydraulic tank (not including hydraulic oil) 65 65
Hydraulic pump 6 6
Control valve
• 3-spool valve 16 16
• 4-spool valve (with ripper) 19 —
01-12 D31/37/39EX, PX-21

Unit: kg
D37EX-21 D37PX-21 D39EX-21 D39PX-21
485 485 485 485

400 400 400 400
27 27 27 27
58 58 58 58
177 177 207 207

71 71 96 96
33 33 42 42
15 15 15 15
106 106 106 106
134 134 134 134
133 133 133 133
162 162 162 162
26 26 38 38
1,850 1,890 2,335 2,355
1,130 1,170 1,342 1,362
8 8 8 8
41 41 41 41
93 93 144 144
64 64 102 102
27 x 6 27 x 6 35 x 6 35 x 6
16 16 15 15
560 x 2 560 x 2 — —
— — 760 x 2 760 x 2
— 710 x 2 — —
— — — 925 x 2
— 700 x 2 — —
— — — 915 x 2
65 65 65 65
6 6 6 6
16 16 16 16
19 — 19 —
D31/37/39EX, PX-21 01-13

Unit: kg
Machine model D31EX-21 D31PX-21
1,020
Power angle tiltdozer assembly 945
(1,005)
530
• Blade 460
(515)
• Dozer frame 380 380
• Tilt cylinder assembly 20 20
• Angle cylinder assembly 22 x 2 22 x 2
Lift cylinder assembly 23 x 2 23 x 2
Ripper 500 —
Ripper cylinder assembly 30 —
ROPS cab assembly 620 620
ROPS canopy assembly 310 310
Operator's seat 60 60
Floor frame assembly 150 150
Radiator guard assembly (including radiator mask) 175 175
Engine hood assembly 40 40
Engine side cover assembly
55 55
(including left, right, top, bottom)
Front bracket (engine dividing wall) 42 42
Fender (left) 107 107
Fender (right) 113 113
01-14 D31/37/39EX, PX-21

Unit: kg
D37EX-21 D37PX-21 D39EX-21 D39PX-21
1,035 1,195
975 1,120
(1,000) (1,140)
550 655
490 580
(505) (600)
380 380 400 400
20 20 20 20
22 x 2 22 x 2 25 x 2 25 x 2
23 x 2 23 x 2 28 x 2 28 x 2
500 — 500 —
30 — 30 —
620 620 620 620
310 310 310 310
60 60 60 60
150 150 150 150
180 180 190 190
40 40 40 40
55 55 55 55
42 42 42 42
107 107 107 107
113 113 113 113
D31/37/39EX, PX-21 01-15

GENERAL TABLE OF FUEL, COOLANT AND LUBRICANTS
TABLE OF FUEL, COOLANT AND LUBRICANTS
AMBIENT TEMPERATURE CAPACITY ( )

KIND OF
RESERVOIR 22 4 14 32 50 68 86 104
FLUID Specified Refill
30 20 10 0 10 20 30 40
SAE30
SAE10W
Engine oil pan 14 12.5
SAE10W-30
SAE15W-40
Idler (each) SAE30 0.16 0.16

Engine oil
SAE10W
Hydraulic system SAE10W-30 97 47
SAE15W-40
Final drive case

SAE30 3.5 3.5
(each)
ASTM D975 No.2

Fuel tank Diesel fuel 165
ASTM D975 No.1
Grease fitting Grease NLGI No.2
D31, 37:
Cooling system 27
Coolant Add antifreeze
(including sub-tank) D39:
32
01-16 D31/37/39EX, PX-21

GENERAL TABLE OF FUEL, COOLANT AND LUBRICANTS
NOTICE
Use only diesel fuel.
The engine mounted on this machine employs electronic control and a high-pressure fuel injection device to
obtain good fuel consumption and good exhaust gas characteristics. For this reason, it requires high precision
for the parts and good lubrication. If kerosene or other fuel with low lubricating ability is used, there will be a big
drop in durability.
REMARK
• When fuel sulphur content is less than 0.5%, change oil in the oil pan according to the periodic maintenance
hours described in this manual.
• Change oil according to the following table if fuel sulphur content is above 0.5%.
• When staring the engine with an atmospheric temperature of lower than 0°C (32°F), be sure to use engine
oil of SAE10W, SAE10W-30 and SAE15W-40, even though the atmospheric temperature goes up to 10°C
(50°F) more or less during the day.
• Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to
half.
• There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to add
single grade oil that matches the temperature range in the table.
• We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine
and hydraulic work equipment applications.
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Institute
Change interval of oil in

Fuel sulphur content
engine oil pan
0.5 to 1.0% 1/2 of regular interval
Above 1.0% 1/4 of regular interval
D31/37/39EX, PX-21 01-17

10 STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD
Cooling system ........................................ 10- 2 Track shoe................................................10- 64

Engine control.......................................... 10- 3 Arrangement of hydraulic equipment
Power train .............................................. 10- 4 for work equipment .............................10- 69
Power train system .................................. 10- 5 Work equipment control ...........................10- 70
Damper .................................................... 10- 6 Hydraulic tank, filter..................................10- 72
HST hydraulic equipment PPC lock valve .........................................10- 73
arrangement diagram......................... 10- 7 Accumulator .............................................10- 74
Steering, brake control ............................ 10- 8 Hydraulic pump ........................................10- 75
Solenoid valve ......................................... 10- 10 Work equipment cylinder..........................10- 76
Towing valve ............................................ 10- 12 Control valve ............................................10- 80
Final drive ................................................ 10- 13 CLSS ........................................................10- 88
HST pump ............................................... 10- 16 PPC valve.................................................10- 98
Safety-suction valve ................................ 10- 24 Work equipment .......................................10-108
Charge safety valve ................................. 10- 28 Cutting edge, end bit ................................10- 112
Charge pump ........................................... 10- 30 Ripper.......................................................10- 113
Towing valve ............................................ 10- 31 Cab related...............................................10- 114
HST motor ............................................... 10- 32 Engine control ..........................................10- 116
Electric lever (for steering)....................... 10- 44 HST control system ..................................10- 117
Frame assembly ...................................... 10- 47 Gear shift control system..........................10- 118
Track frame, recoil spring ........................ 10- 48 Parking brake control system ...................10-122
Idler.......................................................... 10- 50 Component equipment of system.............10-124
Track roller ............................................... 10- 54 Monitor system .........................................10-128
Carrier roller............................................. 10- 58 Monitor panel............................................10-130
Sprocket .................................................. 10- 60 Sensors ....................................................10-134
D31/37/39EX, PX-21 10-1

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD COOLING SYSTEM
COOLING SYSTEM
a The diagram shows D31EX/PX-21, D37EX/PX-21.
1. Radiator 8. After cooler outlet port

2. Radiator cap 9. Radiator inlet port hose
3. Oil cooler 10. Reservoir tank
4. After cooler 11. After cooler inlet port
5. Shroud 12. Radiator outlet port hose
6. Fan 13. Oil cooler inlet port hose
7. Drain valve 14. Oil cooler outlet port tube
Specifications
Radiator Oil cooler After cooler

Item Unit
D31/D37 D39 D31/D37 D39 D31/D37/D39
Core type — D-5 D-7 SF-3 SF-4 AL-CFT
Fin pitch mm 3.0 3.0 3.0 3.0 6.0/2
Total heat dissipation
m2 34.05 46.87 12.35 16.46 11.44
area
Pressure valve kPa 88.3 ± 14.7 88.3 ± 14.7
— — —
cracking pressure {kg/cm2} {0.9 ± 0.15} {0.9 ± 0.15}
Vacuum valve cracking kPa 0 – 4.9 0 – 4.9
— — —
pressure {kg/cm2} {0 – 0.05} {0 – 0.05}
10-2 D31/37/39EX, PX-21

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD ENGINE CONTROL
ENGINE CONTROL
1. Decelerator pedal Outline

2. Clutch • The control of the engine speed is carried out
3. Fuel control lever with fuel control lever (3) or decelerator pedal
4. Fuel control lever potentiometer (1).
5. Fuel control cable
6. Decelerator cable
7. Governor lever
D31/37/39EX, PX-21 10-3

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD POWER TRAIN
POWER TRAIN
Outline
• 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.
• 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).
• HST pump (3) changes the discharge direction
and discharge amount continuously in accor-
dance with the movement of the swash plate of
each pump to match the movement of the steer-
ing, direction, and speed lever. This changes
the direction of rotation and speed of the left
and right HST motors and controls the forward
and reverse travel and turning of the machine.
• The hydraulic power transmitted to HST motor
(5) is output from the motor output shaft as
mechanical power, and is transmitted to final
drive (6).
• Final drive (6) is a 2-stage planetary gear mech-
anism. It reduces the speed and rotates
sprocket (7) to drive track shoe (8).
10-4 D31/37/39EX, PX-21

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD POWER TRAIN SYSTEM
POWER TRAIN SYSTEM
1. Engine 6. HST motor

2. Damper 7. Final drive
3. HST pump 8. Sprocket
4. Charge pump 9. Track shoe
5. High-pressure hose
D31/37/39EX, PX-21 10-5

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD DAMPER
DAMPER
Unit: mm
No. Check item Criteria Remedy
Distance between HST pump Standard size Repair limit

1 mounting surface and tip of Adjust
boss 62.0 ±0.8
Wear of inner teeth of cou-

2 Repair limit: 1.0 Replace
pling (resin)
3. Coupling Outline
4. Boss • The damper reduces the torsional vibration
5. HST pump input shaft caused by variations in the engine torque, and
6. Cover acts to protect the engine and downstream drive
7. Flywheel system from the torsional vibration.
• The power from the engine is transmitted from
flywheel (7) to coupling (3). Coupling (3)
absorbs the torsional vibration and transmits the
power through boss (4) to the HST pump.
10-6 D31/37/39EX, PX-21

HST HYDRAULIC EQUIPMENT
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD ARRANGEMENT DIAGRAM
HST HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAM

a HST: Abbreviation for HydroStatic Transmission
1. HST pump
2. R.H. HST motor
3. HST charge filter
4. L.H. HST motor
5. 4-spool solenoid valve
6. Towing valve
D31/37/39EX, PX-21 10-7

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD STEERING, BRAKE CONTROL
STEERING, BRAKE CONTROL

a PCCS: Abbreviation for Palm Command Control System
10-8 D31/37/39EX, PX-21

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD STEERING, BRAKE CONTROL
1. Parking brake lever Outline

2. Joystick • Electric lever (3) sends electric signals to HST
(PCCS lever) controller (6) according to the stroke of joystick
3. Electric lever (PCCS lever) (2). Upon receiving these signals,
4. Parking brake limit switch 1 HST controller (6) sends signals to the EPC
5. Parking brake limit switch 2 valve of HST pump (7) to change the flow in
6. HST controller HST pump (7) and control the HST motor.
7. HST pump • If the joystick (PCCS lever)(2) is leaned to the
8. Center brake limit switch left a little while it is leaned to the forward posi-
9. Brake pedal potentiometer tion, the machine turns to the left gradually. If it
10. Brake pedal is leaned to the left stroke end, the machine
makes a counter-rotation.
• Brake pedal potentiometer (9) sends electric
signals to HST controller (6) according to the
stroke of brake pedal (10). Upon receiving
these signals, HST controller (6) sends signals
to the EPC valve of HST pump (7) to decelerate
the right and left HST motors simultaneously.
• If brake pedal (10) is pressed fully while parking
brake lever (1) is in the FREE position, the right
and left HST hydraulic brakes operate simulta-
neously. At the same time, the signal of center
brake limit switch (8) is sent to the slow brake
solenoid valve and parking brake solenoid
valve. As a result, the machine stops, and then
the parking brakes built in the right and left HST
motors operate.
• Parking brake limit switch 1 (4) is connected to
parking brake lever (1) and it sends electric sig-
nals to HST controller (6). Upon receiving these
signals, HST controller (6) sends signals to the
parking brake solenoid valve to operate the
parking brakes built in the right and left HST
motors.
D31/37/39EX, PX-21 10-9

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD SOLENOID VALVE
SOLENOID VALVE
4-spool solenoid valve
P : From HST pump CPA 1. Parking brake solenoid valve

T : To hydraulic tank 2. Slow brake solenoid valve
A1 : To towing valve 3. 3rd selector solenoid valve
A2 : To left-and-right HST motor PCMID 4. 2nd selector solenoid valve
A3 : To left-and-right HST motor PCMIN
A4 : Plug Solenoid valve
A5 : To PPC lock valve 5. Coil (ON-OFF type)
6. Push pin
7. Sleeve
8. Valve spool
9. Return spring
10. Block
10-10 D31/37/39EX, PX-21

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD SOLENOID VALVE
Outline
• Block (10) has 4 solenoid valves.
• Parking brake solenoid valve (1) transmits a sig-
nal generated by the potentiometer which oper-
ates when the brake pedal is pressed or a signal
of the limit switch connected to the parking
brake lever through the HST controller to drain
the changeover oil and operate the parking
brakes built in the HST motors.
• Upon receiving a signal generated by the limit
switch which operates when the brake pedal is
pressed fully or a signal from the limit switch
connected to the parking brake lever, slow brake
solenoid valve (2) drains the changeover oil
slowly through the orifice in it to operate the
parking brakes built in the HST motors.
• 3rd travel speed selector solenoid valve (3)
transmits the shift switch signals of the steering/
directional/gear shift lever through the HST con-
troller to output the changeover oil pressure and
change the HST motor capacity for the 3rd
travel speed.
• 2nd travel speed selector solenoid valve (4)
transmits the shift switch signals of the steering/
directional/gear shift lever through the HST con-
troller to output the changeover oil pressure and
change the HST motor capacity for the 2nd
travel speed.
Operation
When solenoid is "de-energized"

(When circuit is disconnected)
• While the signal current is not flowing in coil (1)
from outside, coil (1) is de-energized.
• Accordingly, spool (2) is pushed back to the left
by spring (3).
• As a result, ports P and A are disconnected and
the pilot pressure does not flow from port A to the
actuator.
At the same time, port T is opened and the oil
from the actuator flows in the hydraulic tank.
When solenoid is "energized"

(When circuit is connected)
• If the signal current flows in coil (1) from outside,
coil (1) is energized.
• Accordingly, spool (2) is pushed to the right by
push pin (4).
• As a result, ports P and A are connected and the
pilot pressure flows from port A to the actuator.
At the same time, port T is closed and the oil
from the actuator does not flow in the hydraulic
tank.
D31/37/39EX, PX-21 10-11

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD TOWING VALVE
TOWING VALVE
1. Lever
2. End cap
3. Ball
4. Seat
5. Body
Outline
• The towing valve is installed between the parking
brake solenoid valve and HST motor. When the
parking brake cannot be released because of an
engine trouble, etc., the parking brake can be re-
leased by setting lever (1) of this valve in the
"Close" position and applying parking brake re-
lease pressure from outside.
a For the procedure of releasing the parking brake,
see TESTING AND ADJUSTING, Procedure for
releasing parking brake.
10-12 D31/37/39EX, PX-21

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
a The diagram shows D31EX/PX-21, D37EX/PX-21.
1. Oil level plug

2. Drain plug
Outline
• The final drive is a planetary gear, 2-stage reduc-
tion type. It provides splash lubrication when the
gear rotates.
It is also possible to remove or install the final
drive as a single unit.
• A floating seal is installed to the rotating and slid-
ing portion of the sprocket to prevent the 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
D31/37/39EX, PX-21 10-13

3. No. 1 sun gear (No. of teeth: 14) 9. Floating seal

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

15
and No. 1 planetary pinion 0.13 – 0.35 1.00
Backlash of No. 1 planetary
16 0.17 – 0.54 1.10
pinion and ring gear
Backlash of No. 1 planetary Replace
17 0.27 – 0.46 1.00
carrier and No. 2 sun gear
Backlash of No. 2 sun gear
18 0.14 – 0.38 1.00
and No. 2 planetary pinion
Backlash of No. 2 planetary
19 0.18 – 0.54 1.10
pinion and ring gear
10-14 D31/37/39EX, PX-21

Path of power transmission
• The power from the HST motor goes from No. 1

sun gear (1) through No. 1 planetary pinion (2),
is reduced and rotates in the opposite direction
from the rotation of the HST motor, and is then
transmitted to ring gear (6).
When this happens, No. 1 planetary pinion (2)
forms one unit with No. 1 planetary carrier (3),
and the power from No. 1 planetary carrier (3) is
transmitted to No. 2 sun gear (4).
• The power transmitted to No. 2 sun gear (4)
passes through No. 2 planetary pinion (5), has its
speed reduced, and is transmitted to ring gear
(6).
• The rotating power undergoes two-stage reduc-
tion, is transmitted to ring gear (6), passes
through hub (7), and is transmitted to sprocket
(8).
D31/37/39EX, PX-21 10-15

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD HST PUMP
HST PUMP
a HST: Abbreviation for HydoroStatic Transmission
Type: HPV63 + 63
Structure
• This pump consists of a variable displacement
swash plate tandem piston pump, servo valve,
EPC valve, safety valve with suction, charge
safety valve and charge pump.
10-16 D31/37/39EX, PX-21

1. EPC valve
2. Piston pump
3. Servo valve
4. Safety valve with suction
5. Charge safety vavle
6. Charge pump
D31/37/39EX, PX-21 10-17

1. Shaft 9. End cap

2. Cradle bearing 10. Bearing
3. Rocker cam 11. Piston
4. Case 12. Spline
5. Servo piston 13. Shoe
6. Slider 14. Bearing
7. Cylinder block 15. Charge pump
8. Valve plate
Outline
• The rotation and torque transmitted to the pump • Rocker cam (3) has flat surface A, and shoe
shaft is converted into hydraulic energy, and (13) is always pressed against this surface while
pressurized oil is discharged according to the sliding in a circular movement. Rocker cam (3)
load. positions cradle bearing (2) between case (4)
• It is possible to change the discharge amount by and cylindrical surface B, and rocks.
changing the swash plate angle (normal io 0 • Piston (11) carries out relative movement in the
io reverse discharge). axial direction inside each cylinder chamber of
cylinder block (7).
Structure • Cylinder block (7) seals the pressure oil to valve
• Cylinder block (7) is supported to shaft (1) by plate (8) and carries out relative rotation. This
spline (12). Shaft (1) is supported by front and surface is designed so that the oil pressure bal-
rear bearings (14) and (10). ance is maintained at a suitable level. The oil
• The tip of piston (11) is a concave ball, and shoe inside each cylinder chamber of cylinder block
(13) is caulked to it to form one unit. Piston (11) (7) is sucked in and discharged through valve
and shoe (13) form a spherical bearing. plate (8).
10-18 D31/37/39EX, PX-21

(4)
Operation
1. Operation of pump
• Cylinder block (9) rotates together with shaft (1),

and shoe (7) slides on flat surface A. When this
happens, angle between center line X of
rocker cam (4) and the axial direction of cylinder
block (9) changes. (Angle is called the
swash plate angle.)
• Center line X of rocker cam (4) maintains swash
plate angle in relation to the axial direction of
cylinder block (9), and flat surface A moves as a
cam in relation to shoe (7).
• In this way, piston (8) slides on the inside of cyl-
inder block (9), so a difference between volumes
E and F is created inside cylinder block (9). The
suction and discharge is carried out by an
amount equal to this difference F – E.
• In other words, when cylinder block (9) rotates
and the volume of chamber F becomes smaller,
the oil is discharged during that stroke. On the
other hand, the volume of chamber E becomes
larger, and as the volume becomes larger, the
oil is sucked in.
• If center line X of rocker cam (4) is in line with
the axial direction of cylinder block (9) (swash
plate angle = 0), the difference between vol-
u mes E' and F ' i nsi de cy lin der bl ock ( 7)
becomes 0, so the pump does not carry out any
suction or discharge of oil.
• Piston (8) slides on the inside of cylinder block

(9), so a difference between volumes E" and F"
is created inside cylinder block (9). The suction
and discharge is carried out by an amount equal
to this difference E" – F".
• In other words, when cylinder block (9) rotates
a nd the v olum e of c hamber E" bec omes
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. When the angle of the swash plate
is reversed, the suction and discharge of ports
PA and PB are reversed.
D31/37/39EX, PX-21 10-19

2. Control of discharge amount
• If swash plate angle becomes larger, the dif-

ference between volumes E and F becomes
larger and discharge amount Q increases.
Swash plate angle is changed by servo piston
(5).
• Servo spool (7) moves according to the com-
mand of the EPC valve. Servo piston (5) is
reciprocated by the command pressure output
from servo spool (7).
• This straight line movement is transmitted
through slider (6) to rocker cam (4). Rocker cam
(4), which is supported by the cylindrical surface
to cradle bearing (3), then rocks on the cylindri-
cal surface.
• For the pump, swash plate angle is a maxi-
mum of ± 15.3°.
10-20 D31/37/39EX, PX-21

3. Operation of servo valve
10-22 D31/37/39EX, PX-21

(1) When lever is operated

1) Operation of servo spool
• The command current from the pump
controller flows in the EPC valve sole-
noids (ESA and ESB).
• This command current works on the
EPC valve to output signal pressure.
The signal pressure is applied through
port SA (SB) to chamber sa (sb) and
used to change the pressing force on
servo spool (1).
• The servo spool (1) stops at a point
where the pressing force on servo spool
(1) is balanced with the force of spring
(3).
• The strength 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
• 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 re-
sult, servo piston (2) moves to the left.
• If servo piston (2) moves to the left and
port CP is disconnected from port A, ser-
vo piston (2) stops.
• In short, servo spool (1) and servo piston
(2) move by the same distance.
• 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 piston (2) moves to the right
until port CP is disconnected from port
B.
(2) When lever is in neutral

• If oil does not flow from the EPC valve,
servo spool (1) does not move. Servo
piston (2) is kept at the neutral position
by the force of spring (4) and the main
pump is kept in neutral.
D31/37/39EX, PX-21 10-23

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD SAFETY-SUCTION VALVE
SAFETY-SUCTION VALVE
1. Charge pump 3C. Sleeve

2. Charge safety valve 3D. Spring
3. Safety-suction valve 3E. Spring
3A. Valve 3F. Plug
3B. Rod
10-24 D31/37/39EX, PX-21

1. When it is high-pressure relief valve
Function
• It restricts the maximum pressure inside the
HST circuit to protect the circuit.
Operation
(valve at piston pump discharge side)
• Port A is connected to the pump circuit and port
B is connected to the charge circuit. The pres-
sure oil passes through drill hole a in piston (3A)
and also fills port C.
• The oil at high-pressure port A passes through
passage groove b in the body and also fills port
D.
• Poppet (3A) is in tight contact with valve seat
(3C).
• If abnormal pressure is generated in the circuit
and the oil pressure at ports A and D reaches
the pressure set by spring (3D), poppet (3A) is
pushed to the right, and the oil at port A is
relieved to port B, so the oil pressure at port A
goes down.
2. When it is safety-suction valve
Function
• This ensures the oil flow in in the HST closed
circuit. It prevents the charge oil flow from flow-
ing to the pump high-pressure side (discharge
side).
Operation
(1) When HST pump discharge amount is 0
• The HST closed circuit is sealed, so the charge

pressure oil does not flow into the HST circuit.
• Therefore, the charge pressure oil from charge
pump (1) all passes through charge safety valve
(2) and is drained to the inside of the case.
D31/37/39EX, PX-21 10-25

(2) When HST pump discharge amount is being dis-

charged from port PA
1) Valve at piston pump discharge side
• If pressure oil is being discharged from port PA

of HST pump (4), port PA becomes the high-
pressure side.
• This pressure oil at port PA passes through pas-
sage b in the body and flows into port D.
• When this happens, sleeve (3C) is pushed fully
to the left because of the relationship of the dif-
ference in area (A1>A2).
• Therefore, the pressure oil from charge pump
(1) is prevented from flowing in.
3. Valve at piston pump suction side
Operation
• Port PB becomes the suction side, so it is at
low-pressure. Sleeve (3C) is pushed to the right
by the charge pressure oil from the relationship
of the difference in area (A1<A2), and the seat
of sleeve (3C) opens.
• As a result, the charge pressure oil at port B
passes through this gap, flows to port PB, and
carries out the charge action in the HST circuit.
10-26 D31/37/39EX, PX-21

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD CHARGE SAFETY VALVE
CHARGE SAFETY VALVE
1. Charge pump
2. Charge safety valve
2A. Valve
2B. Spring
2C. Valve seat
2D. Poppet
2E. Spring
2F. Adjustment screw
3. Safety-suction valve
Function
• The charge safety valve is installed to the HST
pump. It limits the maximum pressure in the
charge circuit and protects the charge circuit.
10-28 D31/37/39EX, PX-21

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD CHARGE SAFETY VALVE
Operation
• Port A is connected to the charge circuit, and
port B is connected through the HST pump case
to the tank drain circuit. The pressure oil passes
through orifice a in valve (2A) and fills chamber
C. Poppet (2D) is in tight contact with valve
seat (2C).
• If abnormal pressure is generated in the circuit

or the shuttle valve of the HST motor is at neu-
tral, and the pressure oil at port A and chamber
C rises to the pressure set by the spring (2E),
poppet (2D) is pushed to the right. The oil in
chamber C is relieved to port B, so the pressure
in chamber C goes down.
• When the pressure at port C goes down, a dif-

ference in pressure is generated between port A
and chamber C through orifice a of valve (2A).
Valve (2A) is pushed to the right by the oil pres-
sure at port A, and the oil at port A is relieved to
port B. In this way, the pressure in the charge
circuit is prevented from rising any further.
D31/37/39EX, PX-21 10-29

(4)
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD CHARGE PUMP
CHARGE PUMP
1. Side plate
2. Coupling
3. Shaft
4. Outer ring
5. Case
6. Inner rotor
7. Outer rotor
Outline
• The HST charge pump is built into the HST
pump and drives at the same time as the HST
pump.
• The HST charge pump supplies pilot-pressure
oil to the low-pressure side of the HST main cir-
cuit, charge safety valve, 4-spool solenoid valve,
and work equipment PPC valve.
• The charge pump sucks in the oil from the
hydraulic tank.
Specifications
Type: Trochoid pump
Theoretical discharge amount: 40 cc/rev
Operation
• The charge pump is connected to the HST
pump shaft by coupling (2) and rotates inner
rotor (6) and outer rotor (7).
• When inner rotor (6) and outer rotor (7) rotate,
the capacity of chamber A increases, oil is
sucked in, the capacity of chamber B
decreases, and the oil is discharged.
10-30 D31/37/39EX, PX-21

(2)
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD TOWING VALVE
TOWING VALVE
Function
• These valves are built into the top surface of the
pump. There are two valves: the F valve (for the
left track) and the R valve (for the right track).
• If there is a failure on the machine, it is possible
to tow the machine by connecting the HST cir-
cuit.
• However, it is necessary to cancel the shaft
brake of the motor at the same time.
Operation
• To actuate the towing valves, loosen the two
valves a maximum of 4.5 mm (3 turns).
D31/37/39EX, PX-21 10-31

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD HST MOTOR
HST MOTOR
a HST: Abbreviation for HydoroStatic Transmission
Model: KMV105
1. Left HST motor

Direction of rotation (as seen facing drive shaft)
Flows in from MA: Clockwise rotation
Flows in from MB: Counterclockwise rotation
1. Drive shaft A. T : Drain

2. 3rd variable bent axis piston B. MA : (High pressure when traveling forward) Discharge port
motor (L.H.) C. MB : (High pressure when traveling in reverse) Discharge port
3. 3rd valve D. PCMID : 3rd spool q mid signal port
4. Speed sensor E. PB : Parking brake cancel signal port
5. Charge relief valve F. PCMIN : 3rd spool q min signal port
10-32 D31/37/39EX, PX-21

2. Right HST motor

Direction of rotation (as seen facing drive shaft)
Flows in from MA: Counterclockwise rotation
Flows in from MB: Clockwise rotation
1. Drive shaft A. T : Drain

2. 3rd variable bent axis piston B. MA : (High pressure when traveling forward) Discharge port
motor (R.H.) C. MB : (High pressure when traveling in reverse) Discharge port
3. 3rd valve D. PCMID : 3rd spool q mid signal port
4. Speed sensor E. PB : Parking brake cancel signal port
5. Charge relief valve F. PCMIN : 3rd spool q min signal port
D31/37/39EX, PX-21 10-33

1. 3rd variable shaft piston motor Specifications

2. Angled main piston Model : KMV105
3. Angled sub piston Type : 3-speed variable displacement, bent axis
4. Shuttle valve type piston pump
5. Charge relief valve Charge relief valve set pressure:
6. 3rd selector valve 2.06 – 2.16 MPa {21 – 22 kg/cm2}
7. Parking brake Parking brake release pressure:
8. Speed sensor 0.78 – 1.27 MPa {8 – 13 kg/cm2}
9. Tank
Theoretical capacity (cm3/rev)
Model 1st 2nd 3rd

D31/D37 93 61 46
D39 105 68 52
a The above values are for 1 motor.
10-34 D31/37/39EX, PX-21

3. Operation of piston motor
Principle
• Let us assume that the shaft of a disc is sup-
ported to allow the disc to rotate freely. If force F
is applied to this disc at an angle, this force F
can be divided into force F1 applied at a right
angle to the face of the disc and force F2
applied in the direction of the circumference of
the disc. Force F1 pushes the disc in the axial
direction, and force F2 rotates the disc in a
clockwise direction.
• If force F' is applied to the disc instead of force
F, the force can be divided in the same way into
forces F'1 and F'2, and force F'2 will rotate the
disc in a counterclockwise direction.
Structure
• Seven pistons (2) are installed with a spherical
connection to the disc portion of output shaft (1).
Pistons (2) are at a certain angle to drive shaft
(1) and are fitted inside cylinder block (3).
• The angle of cylinder block (3) and pistons (2) is
decided by the ON-OFF signal of the control
pressure to PCMIN and PCMID of 3rd speed
valve (4). The combination is as shown in the
table.
PCMIN PCMID
Motor capacity MAX (1st) OFF OFF
Motor capacity MID (2nd) OFF ON
Motor capacity MIN (3rd) ON OFF
Operation
• The oil sent under pressure from the main piston
pump enters from the piston motor inlet port. Oil
pressure is formed at the rear face of piston (2),
and drive shaft (1) is rotated by angle Q of pis-
ton (2) and the cylinder block.
D31/37/39EX, PX-21 10-35

4. Changing capacity of 3rd speed motor
Motor capacity MAX (1st) Motor capacity MID (2nd) Motor capacity MIN (3rd)
Chamber A ON ON OFF
Chamber B ON OFF OFF
Chamber C ON ON ON
Function
• As shown in the diagram above, when the main • When the motor capacity is MAX (1st speed),
piston is at the lowest position, the motor capac- high pressure (self pressure) is being supplied
ity is MAX (1st speed). to all of chamber A, chamber B, and chamber C.
• When the main piston is at the highest position, However, the main piston is at the lowest posi-
the motor capacity is MIN (3rd speed). tion because the area on which the high pres-
• When it is at the midpoint position, the motor sure is acting in chamber B is larger than the
capacity is MID (2nd speed). A sub piston is area on which the high pressure is acting in
provided to produce the MID (2nd speed) motor chamber C. As a result, the combined force
capacity. generates a force in the downward direction.
• The area on which the self pressure is acting in
Operation chamber A and chamber B of the sub piston is
• The 3rd speed mechanism includes chamber A, the same. However, the high pressure (self
chamber B, and chamber C. Each of these pressure) acting on chamber A is greater than
chambers has its high pressure (self pressure) the high pressure acting on chamber B (the
turned ON (supplied) and OFF (drained) by the pressure is lower than the self pressure for
3rd speed valve, and the main piston and sub chamber A because the self pressure passes
piston are actuated. through a throttle), so the sub piston is pushed
down.
10-36 D31/37/39EX, PX-21

5. 3rd speed valve and shuttle valve
Function
• The pressure at the high-pressure side is
selected at HST main pressures MA and MB,
and is supplied to the 3rd speed spool.
• A shuttle valve is provided to select the pressure
from the low-pressure side and supply it to the
charge relief valve.
Operation
• With cross section D-D, HST main pressure MA
is taken to the left end face of the shuttle valve;
HST main pressure MB is taken to the right end
face of the shuttle valve.
• The position of the shuttle valve at cross section
D-D is the neutral position when the difference
in pressure between MA and MB is small. Pres-
sures MA and MB are both taken to the 3rd
speed spool.
• Because of the two check valves, a higher pres-
sure than MA and MB is taken to the spool of
the shuttle valve. In this case, the passage to
the charge relief valve is shut off.
• With the position of the shuttle valve at cross
section D-D, when MA>MB, the shuttle valve
moves to the right, MA is selected as the high
pressure, and is taken to the 3rd speed spool.
MB is selected as the low pressure and is taken
to the charge relief valve.
• When MA<MB, the shuttle valve moves to the
left, MB is selected as the high pressure, and is
taken to the 3rd speed spool. MA is selected as
the low pressure and is taken to the charge relief
valve.
a: Check valve
b: Shuttle valve
c: Charge relief valve
D31/37/39EX, PX-21 10-37

6. 3rd speed valve
1. 3rd speed spool

2. Flow control valve
3. PCMIN port
4. PCMID port
Function Operation
• The HST main pressure at the high-pressure • When both PCMIN (3) and PCMID (4) are OFF,
side is selected by the shuttle valve and is taken 3rd speed spool (1) is at neutral, and pressure P
to portion P. is supplied to all of A, B, and C.
• 3rd speed spool (1) is moved by pressures • However, the supply to A passes through the
PCMIN and PCMID, so this pressure is supplied groove on the outside circumference of the
to rounds A, B, and C, which are connected to spool. Compared with this, the supply to B and
chamber A, chamber B, and chamber C of the C passes through flow control valve (2) built into
3rd speed mechanism. 3rd speed spool (1).
• As a result, the pressure at A is the highest and
the pressure at B and C is slightly lower.
[q = MAX (1st speed)]
• When PCMIN (3) is OFF and PCMID (4) is ON,
3rd speed spool (1) moves to the left and pres-
sure P is supplied to A and C, while B is drained
to the tank. [q = MID (2nd speed)]
• When PCMIN (3) is ON and PCMID (4) is OFF,
3rd speed spool (1) moves to the right and pres-
sure P is supplied to C, while A and B are
drained to the tank.
10-38 D31/37/39EX, PX-21

7. Flow control valve (built into 3rd speed spool)
1. Spring
2. Spool
Function Operation
• The high pressure of the HST main pressure is • The oil inside spool (2) of the flow control valve
selected by the shuttle valve and is taken to por- flows W o X o Y. Portion X is a throttle.
tion P. • The position of the spool (area of opening at
• The pressure at this portion P changes from portion W) is determined by the differential pres-
approx. 2.45 MPa {25 kg/cm2} (charge pressure) sure between chamber Y and chamber Z and
to a maximum of 47.1 MPa {480 kg/cm2}. the force of spring (1).
• The flow control valve supplies an almost con-
stant oil flow to B and C, regardless of the (1) When oil does not flow W o X o Y
change in pressure at portion P. • There is no difference in pressure between
• This constant oil flow can be set as desired by chamber Y and chamber Z, so spool (2) is
the diameter of the throttle and spring (1). moved to the right end by the force of spring (1),
and the area of opening at portion W becomes
the maximum.
(2) When flow of oil is generated W o X o Y

• A difference in pressure between chamber Y
and chamber Z is generated by the throttle and
becomes PY<PZ. The spool moves to the left
and the area of opening at portion W is reduced.
• The position of the spool (area of opening at
portion W) is determined by the position where
the force of spring (1) is balanced with differen-
tial pressure P = PZ – PY.
• As a result, the flow from W o X o Y can be
controlled to an almost constant value, regard-
less of the pressure at portion P.
D31/37/39EX, PX-21 10-39

8. Charge relief valve
1. Valve 4. Poppet
2. Spring 5. Spring
3. Valve seat 6. Adjustment screw
Function
• The charge relief valve is installed inside the 3rd
speed valve. It prevents the pressure at the
HST main low-pressure side (charge pressure)
selected by the shuttle valve from going above
the set pressure. At the same time, it relieves
the determined oil flow inside the motor case
and prevents the motor from overheating.
• In addition, it discharges the dirtiest oil inside the
HST main circuit to the outside and acts to keep
the inside of the HST main circuit clean.
Operation
• Port A connects the pressure at the HST main
low-pressure side (charge circuit) selected by
the shuttle valve.
• In addition, ports B and D are connected to the
tank drain circuit through the HST motor case.
• The pressure oil passes through orifice g in
valve (1) and fills chamber C. Poppet (4) is fit-
ted tightly to valve seat (5).
10-40 D31/37/39EX, PX-21

• If abnormal pressure is generated inside the

circuit, and the oil pressure in port A and cham-
ber C rises to the pressure set by spring (5),
poppet (4) is pushed to the right, and the oil in
chamber C is relieved to port D, so the oil pres-
sure in chamber C goes down.
• When the oil pressure in chamber C goes down,

a difference in pressure between ports A and C
is generated by orifice g of valve (1).
• Valve (1) is pushed to the right by the oil pres-
sure at port A, and the oil at port A is relieved to
port B.
• As a result, the pressure in the charge circuit is
prevented from rising any further.
D31/37/39EX, PX-21 10-41

9. Actuation of parking brake
(1) When parking brake valve is de-energized
• If the parking brake valve is de-energized, the

pressure oil of the control pump is shut off and
port B is connected to the tank.
• As a result, brake piston (2) is pushed down by
brake spring (1), disc (3) and plate (4) are
pushed together, and the brake is applied.
(2) When parking brake valve is energized
• If the parking brake valve is energized, the valve

is switched, the pressure oil from the control
pump enters port B, and flows into brake cham-
ber A.
• The oil entering chamber A overcomes brake
spring (1) and pushes brake piston (2) up. As a
result, disc (3) and plate (4) separate, and the
brake is released.
10-42 D31/37/39EX, PX-21

10. Speed sensor
1. Hall IC (with magnet) Function

2. Housing • The speed sensor is installed to the end cover of
3. Wire the motor. It senses revolution pulses from the
4. O-ring drive shaft spline in the motor and transmits
5. Shrinkable tube electric signals to the HST controller.
6. Wire protection hose • This sensor is of Hall IC type. Unlike a common
7. Connector speed sensor of coil type, the specified gap and
angle between this sensor and spline are main-
tained.
a When adjusting the positions of the sensor and
spline, adjust the gap between them first, and
then adjust the angle between them.
a If either or both of the gap and angle are adjusted
wrongly, the revolution is not sensed accurately.
Therefore, adjust them carefully according to the
given procedure.
D31/37/39EX, PX-21 10-43

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD ELECTRIC LEVER (FOR STEERING)
ELECTRIC LEVER (FOR STEERING)

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 5. Screw
2. Bracket 6. Lever
3. Plate 7. Connector
4. Bolt
10-44 D31/37/39EX, PX-21

Function
1. Operating effort characteristics
(1) Operation for forward and reverse travel
• The control lever is held at 3 positions of
Forward, Neutral, and Reverse.
(2) Operation for steering

• Free return.
• The operating effort rises or falls when
the operator makes a counter-rotation.
D31/37/39EX, PX-21 10-45

2. Output voltage characteristics

• The control unit is installed to the left control
stand and the control lever is installed directly
onto it.
• The operating angle (stroke) of the control lever
is sensed with potentiometers and signal volt-
ages are output to the transmission, steering
controller.
• A potentiometer is installed in each of longitudi-
nal direction and lateral direction. Each potenti-
ometer outputs 2 signal voltages which are
opposite to each other as shown in the figure at
right.
10-46 D31/37/39EX, PX-21

(2)
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD FRAME ASSEMBLY
FRAME ASSEMBLY
a The diagram shows the D37PX-21.
1. Engine mount
2. Frame assembly
3. Rear underguard
4. Front underguard
Outline
• A hull frame structure with the main frame, track
frame, and underguard forming one unit is used.
D31/37/39EX, PX-21 10-47

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD TRACK FRAME, RECOIL SPRING
TRACK FRAME, RECOIL SPRING

a The diagram shows the D37PX-21.
1. Idler 9. Recoil spring

2. Carrier roller 10. Cylinder
3. Track frame 11. Wear ring
4. Sprocket 12. U-packing
5. Track roller guard 13. Pilot
6. Track roller 14. Nut
7. Rod 15. Lubricator
8. Dust seal, oil seal 16. Bushing
10-48 D31/37/39EX, PX-21

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD TRACK FRAME, RECOIL SPRING
Unit: mm
Item Repair limit
17 Deformation of track frame Curvature 7 (for length of 3,000) Correct

Twisting 3 (for length of 300)
Opening of idler portion 5
Standard size Repair limit
Free length Installed Installed Installed
Free length
x OD length load load
18 Recoil spring 71.6 kN 63.7 kN Replace
D31/D37 465 x ø159 375.6 454
{7,300 kg} {6,500 kg}
88.5 kN 78.8 kN
D39 557 x ø192 443 543
{9,028 kg} {8,035 kg}
Standard Tolerance Standard Clearance

size Shaft Hole clearance limit
Clearance
–0.030 +0.163 0.036 – Replace
19 between rod D31/D37 ø55 0.5
–0.076 +0.006 – 0.239 bushing
and bushing
–0.030 +0.163 0.036 –
D39 ø60 0.5
–0.076 +0.006 – 0.239
Outline Specifications
• Recoil spring (9) moves rod (7) to the front or
rear when grease is added or removed from Model D31/D37 D39
lubricator (15), and adjusts the track tension. Grease G2-LI (NLGI No.2)
Recoil spring (9) also acts to absorb any sudden
Amount of grease (cc) 160 270
shock applied to idler (1).
• Track roller
Q'ty on Flange type and

Model
each side arrangement
S, S, S, S, S
D31EX-21 5
(S, W, S, W, S)
D31PX-21
D37EX-21
S, S, S, S, S, S
D37PX-21 6
(S, W, S, S, W, S)
D39EX-21
D39PX-21
S : Single flange
W : Double flange
The arrangement inside ( ) indicates the arrange-
ment when the double flange roller (If equipped) is
installed.
D31/37/39EX, PX-21 10-49

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD IDLER
IDLER
D31EX/PX-21
D37EX/PX-21
10-50 D31/37/39EX, PX-21

Unit: mm

1 Outside diameter of projection
ø471 —
2 Outside diameter of tread ø440 ø424 Repair by
buildup
3 Depth of tread 15.5 23.5
welding or
4 Thickness of tread 17 9 replace
5 Width of tread 33 39
6 Overall width 118 —

Clearance between shaft and size Shaft Hole clearance limit
7
bushing
–0.250 +0.062 0.250 –
ø50 —
–0.350 +0.062 – 0.362
Replace
Clearance between shaft and –0.250 +0.062 0.250 –
8 ø49.7 —
support –0.350 +0.062 – 0.362
Standard clearance Clearance limit
9 Axial play of shaft
0.49 – 0.91 —
Repair by
Clearance between guide buildup
10 1.0 —
plate and support welding or
replace
Clearance between guide
11 0.5 —
plate and side plate Adjust shim or
Standard shim thickness at replace plate
12 5.0
side plate fitting part
D31/37/39EX, PX-21 10-51

D39EX/PX-21
10-52 D31/37/39EX, PX-21

Unit: mm

1 Outside diameter of projection
ø527 —
2 Outside diameter of tread ø489 ø471 Repair by
buildup
3 Depth of tread 19 10
welding or
5 Width of tread 34.5 39

7
bushing
–0.250 +0.074 0.250 –
ø54 —
–0.280 +0.074 – 0.354
Replace
Clearance between shaft and –0.250 –0.160 0.044 –
8 ø54 —
support –0.280 –0.206 – 0.120
9 Axial play of shaft
0.26 – 0.66 —
Repair by
Clearance between guide buildup
10 0.2 – 3.8 —
plate and support welding or
replace
Clearance between guide
11 1.0 —
plate and side plate Adjust shim or
Standard shim thickness at replace plate
12 4.0
side plate fitting part
D31/37/39EX, PX-21 10-53

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD TRACK ROLLER
TRACK ROLLER
D31EX/PX-21
D37EX/PX-21
SINGLE FLANGE TYPE
DOUBLE FLANGE TYPE (IF EQUIPPED)
10-54 D31/37/39EX, PX-21

Unit: mm
Outside diameter of flange Standard size Repair limit

1
(outside) ø198 —
Outside diameter of flange
2 ø190 —
(inside)
3 Outside diameter of tread ø170 ø156
4 Thickness of tread 56.5 49.5 Repair by
buildup
5 Width of flange (outside) 14 8 welding or
6 Width of flange (inside) 12 6 replace
Width of tread
7 34.5 —
(Single-flange type)
Width of tread
8 35.5 —
(Double-flange type)

10
bushing
–0.250 +0.062 0.250 –
ø50 —
–0.300 +0.062 – 0.362
Replace
Clearance between shaft and –0.250 +0.062 0.250 –
11 ø49.7 —
collar –0.300 +0.062 – 0.362
12 Axial play of roller
0.29 – 0.71 —
D31/37/39EX, PX-21 10-55

D39EX/PX-21
SINGLE FLANGE TYPE
DOUBLE FLANGE TYPE (IF EQUIPPED)
10-56 D31/37/39EX, PX-21

Unit: mm
Outside diameter of flange Standard size Repair limit

1
(outside) ø198 —
Outside diameter of flange
2 ø196 —
(inside)
3 Outside diameter of tread ø175 ø150
4 Thickness of tread 59 46.5 Repair by
buildup
5 Width of flange (outside) 18 13 welding or
6 Width of flange (inside) 15 10 replace
Width of tread
7 34.5 —
(Single-flange type)
Width of tread
8 35.5 —
(Double-flange type)

10
bushing
–0.250 +0.062 0.250 –
ø50 —
–0.350 +0.062 – 0.412
Replace
Clearance between shaft and –0.250 –0.100 0.100 –
11 ø49.7 —
collar –0.350 –0.150 – 0.250
12 Axial play of roller
0.27 – 0.73 —
D31/37/39EX, PX-21 10-57

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD CARRIER ROLLER
CARRIER ROLLER
D31EX/PX-21
D37EX/PX-21
Unit: mm

1 Outside diameter of flange
ø162 —
2 Outside diameter of tread ø142 ø128 Rebuild or
3 Thickness of tread 35.5 28.5 replace
5 Width of flange 52 42

6
support
–0.100 +0.250 0.100 –
ø41 —
–0.200 +0.025 – 0.450
Standard Tolerance Standard Interference

Replace
Interference between shaft size Shaft Hole interference limit
7
and seal guard
+0.170 +0.025 0.115 –
ø41.5 —
+0.140 +0.025 – 0.170
8 Play in axial direction of shaft
0.58 – 0.70 —
10-58 D31/37/39EX, PX-21

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD CARRIER ROLLER
D39EX/PX-21
Unit: mm

1 Outside diameter of flange
ø170 —
2 Outside diameter of tread ø150 ø126 Rebuild or
5 Width of flange 15 10

6
support
–0.100 +0.250 0.100 –
ø41 —
–0.200 +0.025 – 0.450
Standard Tolerance Standard Interference

Replace
Interference between shaft size Shaft Hole interference limit
7
and seal guard
+0.170 +0.025 0.115 –
ø41.5 —
+0.140 +0.025 – 0.170
8 Play in axial direction of shaft
0 – 0.50 —
D31/37/39EX, PX-21 10-59

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD SPROCKET
SPROCKET
D31EX/PX-21
D37EX/PX-21
Unit: mm
Standard size Tolerance Repair limit

Wear of diameter at root of
1 +1.0
tooth ø568.9 ø556.9
–2.0
Wear of diameter at tip of
2 ø628 ±2.0 ø616 Rebuild or
tooth
replace
3 Wear of width at tip of tooth 38 — 32
4 Wear of width at root of tooth 47.5 ±1.5 42
+1.5
5 Thickness of root of tooth 56.95 50.95
–2.0
10-60 D31/37/39EX, PX-21

DIMENSIONS OF SHAPE OF SPROCKET TOOTH (ACTUAL SIZE)
a Make the dimensions of the scale the actual size and copy on to an OHP sheet.
D31/37/39EX, PX-21 10-61

D39EX/PX-21
Unit: mm

Wear of diameter at root of
1 +1.0
tooth ø579.3 ø567.3
–2.0
Wear of diameter at tip of
2 ø652 ±2.0 ø640 Rebuild or
tooth
replace
3 Wear of width at tip of tooth 40.2 — 33.2
4 Wear of width at root of tooth 62 ±1.5 55
+0.5
5 Thickness of root of tooth 62.15 56.15
–1.0
10-62 D31/37/39EX, PX-21

DIMENSIONS OF SHAPE OF SPROCKET TOOTH (ACTUAL SIZE)
a Make the dimensions of the scale the actual size and copy on to an OHP sheet.
D31/37/39EX, PX-21 10-63

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD TRACK SHOE
TRACK SHOE
D31EX/PX-21
D37EX/PX-21
a Port P is the link on the bushing fitting side.
*1. Single shoe

*2. Swamp shoe
10-64 D31/37/39EX, PX-21

Unit: mm

1 Link pitch
154.3 157.3
Turning over Turn over or
Standard size
2 Outside diameter of bushing Light load Heavy load replace
47.2 39.7 41.2

3 Thickness of bushing 9.3 1.8 3.3
Standard size Repair limit Repair or
4 Height of link
87 80 replace
Thickness of link
5 23.5 16.5 Replace
(Bushing fitting part)
a. Tightening torque (Nm {kgm}) Retightening angle (deg.)

Shoe bolt Regular link 265 ± 30 {27 ± 3} —
6 (Single shoe) Retighten
(Swamp shoe) b. Tightening torque (Nm {kgm}) Retightening angle (deg.)
Master link 150 ± 40 {15 ± 4} 180 ± 10
Tolerance Standard
Standard size
Interference between bushing Shaft Hole interference
7
and link
+0.287 +0.062
ø47 0.185 – 0.287
+0.247 +0.062
Adjust or
Interference between regular +0.150 –0.148
8 ø28 0.148 – 0.350 replace
pin and link +0.150 –0.200
Standard clearance
9 Clearance of link mating face Each side Both sides
1.2 2.4
D31/37/39EX, PX-21 10-65

D39EX/PX-21
a Port P is the link on the bushing fitting side.
*1. Single shoe

*2. Swamp shoe
10-66 D31/37/39EX, PX-21

Unit: mm

1 Link pitch
171.7 174.7
Turning over Turn over or
Standard size
2 Outside diameter of bushing Light load Heavy load replace
56 47.5 50
3 Thickness of bushing 11 2.5 5
Standard size Repair limit Repair or
4 Height of link
98 89 replace
Thickness of link
5 27.2 18.2 Replace
(Bushing fitting part)
a. Tightening torque (Nm {kgm}) Retightening angle (deg.)

Shoe bolt Regular link 196 ± 19.6 {20 ± 2} 120 ± 10
6 (Single shoe) Retighten
(Swamp shoe) b. Tightening torque (Nm {kgm}) Retightening angle (deg.)
Master link 196 ± 19.6 {20 ± 2} 180 ± 10
Tolerance Standard
Standard size
Interference between bushing Shaft Hole interference
7
and link
+0.304 +0.074
ø55.7 0.190 – 0.304
+0.264 +0.074
Adjust or
Interference between regular +0.372 +0.062
8 ø33.2 0.210 – 0.372 replace
pin and link +0.272 +0.062
Standard clearance
9 Clearance of link mating face Each side Both sides
1.2 2.4
D31/37/39EX, PX-21 10-67

SINGLE SHOE
Unit:mm

Height of
1 D31/D37 47 20
grouser
Rebuild or
D39 53 25
replace
Thickness of D31/D37 56 29
2
grouser D39 46.5 36.5
SWAMP SHOE
Unit:mm

Height of
1 D31/D37 74.5 62.5
grouser
Rebuild or
D39 83 70
replace
Thickness of D31/D37 17 5
2
grouser D39 20 5
10-68 D31/37/39EX, PX-21

ARRANGEMENT OF HYDRAULIC
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD EQUIPMENT FOR WORK EQUIPMENT
ARRANGEMENT OF HYDRAULIC EQUIPMENT FOR WORK

EQUIPMENT
a The diagram shows D31EX/PX-21,D37EX/PX-21.
1. Tilt cylinder 8. Hydraulic tank

2. Angle cylinder 9. Oil filter
3. Oil cooler 10. Ripper cylinder
4. Lift cylinder (If equipped: D31EX/D37EX/D39EX-21)
5. Blade PPC valve 11. Control valve
6. PPC lock valve 12. Accumulator (If equipped)
7. Ripper PPC valve 13. Hydraulic pump
(If equipped: D31EX/D37EX/D39EX-21)
D31/37/39EX, PX-21 10-69

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD WORK EQUIPMENT CONTROL
WORK EQUIPMENT CONTROL
10-70 D31/37/39EX, PX-21

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD WORK EQUIPMENT CONTROL
1. Work equipment lock lever Outline

2. Blade PPC valve • The work equipment control system is a PPC
3. Blade control lever system, which moves each spool of the control
4. Ripper control lever valves through blade control lever (3) and blade
(If equipped:D31EX/D37EX/D39EX-21) PPC valve (2) and through ripper control lever
5. Ripper PPC valve (4) and ripper PPC valve (5).
(If equipped:D31EX/D37EX/D39EX-21) • If work equipment lock lever (1) is set in the
6. PPC lock valve LOCK position, it is connected to PPC lock valve
7. Accumulator (If equipped) (6) and the operator can move blade control
lever (3) and ripper control lever (4) but cannot
operate the work equipment.
• 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.
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 posi-
tion automatically.
• 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 automati-
cally.
D31/37/39EX, PX-21 10-71

(4)
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD HYDRAULIC TANK, FILTER
HYDRAULIC TANK, FILTER
1. Hydraulic tank Specifications

2. Hydraulic oil filter
3. Oil filler cap Tank capacity (l) 66.4
4. Sight gauge Quantity of oil in tank (l) 47
5. Strainer
Set pressure of bypass valve 0.15 ± 0.03
6. Drain plug
(MPa {kg/cm2}) {1.5 ± 0.3}
7. Bypass valve
Cracking pressure of pressure valve 38 ± 14
(kPa {kg/cm2}) {0.39 ± 0.15}
Actuating pressure of vacuum valve 0 – 4.5
(kPa {kg/cm2}) {0 – 0.046}
10-72 D31/37/39EX, PX-21

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD PPC LOCK VALVE
PPC LOCK VALVE

a PPC: Abbreviation for Proportional Pressure Control
1. Lever
2. End cap
3. Ball
4. Seat
5. Body
Outline
• The PPC lock valve is installed between the
HST pump and blade PPC valve. If the work
equipment lock lever is set in the LOCK position,
the lock valve connected to it shuts off the oil in
the PPC circuit, thus the operator cannot oper-
ate the work equipment.
D31/37/39EX, PX-21 10-73

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD ACCUMULATOR
ACCUMULATOR
For PPC circuit (If equipped)
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Outline
• The accumulator is installed between the HST
pump and blade PPC valve. Even if the engine
stops with the work equipment raised, the pres-
sure of the compressed nitrogen gas in the
accumulator sends the pilot oil pressure to the
work equipment control valve to operate the
valve so that the work equipment will lower by its
weight.
Specification
Gas used: Nitrogen gas
Quantity of gas: 300 cc
Charged gas pressure:
1.18 MPa {12 kg/cm2} (at 80°C)
Max. using pressure:6.68 MPa {70 kg/cm2}
10-74 D31/37/39EX, PX-21

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
SAR(2)040: D31EX/PX-21, D37EX/PX-21
SAR(2)045: D39EX/PX-21
Unit: mm

1 Side clearance
0.100 – 0.150 0.190
Clearance between inside
2 diameter of plain bearing and 0.060 – 0.125 0.200
Replace
outside diameter of gear shaft
3 Pin driving-in depth –0.5
12 —
–0.5
4 Spline shaft rotating torque 2.9 – 6.9 Nm {0.3 – 0.7 kgm}
Discharge Standard dis- Discharge
Speed
Discharge amount pressure charge amount amount limit
(rpm) —
Oil: SAE10WCD (MPa {kg/cm2}) (l/min) (l/min)
—
Oil temperature:
D31/D37 3,000 20.6 {210} 111 103
45 – 55°C
D39 3,000 20.6 {210} 121 111
D31/37/39EX, PX-21 10-75

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD WORK EQUIPMENT CYLINDER
WORK EQUIPMENT CYLINDER

D31EX/PX-21
D37EX/PX-21
Lift cylinder
Tilt cylinder
Angle cylinder
10-76 D31/37/39EX, PX-21

D31EX/D37EX-21
Ripper cylinder (If equipped)
Unit: mm
Name of Standard Tolerance Standard Clearance

cylinder size Shaft Hole clearance limit
–0.025 +0.132 0.031 –

Lift ø40 0.496
Clearance –0.064 +0.006 – 0.196
between –0.025 +0.141 0.021 –
1 Tilt ø45 0.505
piston rod and –0.064 –0.004 – 0.205
bushing
–0.025 +0.132 0.031 –
Angle ø40 0.496
–0.064 +0.006 – 0.196
–0.025 +0.141 0.021 –
Ripper ø45 0.505
–0.064 –0.004 – 0.205
–0.025 +0.142 0.105 –
Lift ø45 1.0
–0.064 +0.080 – 0.206
Clearance –0.025 +0.003 0.010 – Replace
between Tilt ø45 0.5 bushing
–0.064 –0.015 – 0.067
2 piston rod
support shaft –0.025 +0.003 0.010 –
Angle ø40 0.5
and bushing –0.087 –0.015 – 0.090
–0.025 +0.142 0.105 –
Ripper ø40 1.0
–0.064 +0.080 – 0.206
–0.025 +0.142 0.105 –
Lift ø45 1.0
–0.064 +0.080 – 0.206
Clearance
between –0.025 +0.003 0.010 –
Tilt ø45 0.5
cylinder –0.064 –0.015 – 0.067
3
bottom –0.025 +0.003 0.010 –
support shaft Angle ø40 0.5
–0.087 –0.015 – 0.090
and bushing
–0.025 +0.142 0.105 –
Ripper ø40 1.0
–0.064 +0.080 – 0.206
Lift 637 ± 63.5 Nm {65 ± 6.5 kgm}
Tightening Tilt 677 ± 67.5 Nm {69 ± 6.9 kgm}
4 torque of
cylinder head Angle 569 ± 57.0 Nm {58 ± 5.8 kgm}
Ripper 677 ± 67.5 Nm {69 ± 6.9 kgm}
Tighten
Lift 785 ± 78.5 Nm {80 ± 8 kgm} (Width across flats: 46 mm)
Tightening
torque of Tilt 1.08 ± 0.11 Nm {110 ± 11 kgm} (Width across flats: 50 mm)
5
cylinder piston Angle 785 ± 78.5 Nm {80 ± 8 kgm} (Width across flats: 46 mm)
lock nut
Ripper 1.08 ± 0.11 Nm {110 ± 11 kgm} (Width across flats: 50 mm)
D31/37/39EX, PX-21 10-77

D39EX/PX-21
Lift cylinder
Tilt cylinder
Angle cylinder
10-78 D31/37/39EX, PX-21

D39EX-21
Ripper cylinder (If equipped)
Unit: mm
Name of Standard Tolerance Standard Clearance

cylinder size Shaft Hole clearance limit
–0.025 +0.141 0.021 –

Lift ø45 0.505
Clearance –0.064 –0.004 – 0.205
between –0.025 +0.141 0.021 –
1 Tilt ø45 0.505
piston rod and –0.064 –0.004 – 0.205
bushing
–0.025 +0.141 0.021 –
Angle ø45 0.505
–0.064 –0.004 – 0.205
–0.025 +0.141 0.021 –
Ripper ø45 0.505
–0.064 –0.004 – 0.205
–0.025 +0.250 0.075 –
Lift ø50 1.0
–0.064 +0.050 – 0.314
Clearance –0.025 +0.003 0.010 – Replace
between Tilt ø45 0.5 bushing
–0.064 –0.015 – 0.067
2 piston rod
support shaft –0.025 +0.003 0.010 –
Angle ø45 0.5
and bushing –0.064 –0.015 – 0.067
–0.025 +0.142 0.105 –
Ripper ø40 1.0
–0.064 +0.080 – 0.206
–0.025 +0.250 0.075 –
Lift ø50 1.0
–0.064 +0.050 – 0.314
Clearance
between –0.025 +0.003 0.010 –
Tilt ø45 0.5
cylinder –0.064 –0.015 – 0.067
3
bottom –0.025 +0.003 0.010 –
support shaft Angle ø45 0.5
–0.064 –0.015 – 0.067
and bushing
–0.025 +0.142 0.105 –
Ripper ø40 1.0
–0.064 +0.080 – 0.206
Lift 677 ± 67.5 Nm {69 ± 6.9 kgm}
Tightening Tilt 677 ± 67.5 Nm {69 ± 6.9 kgm}
4 torque of
cylinder head Angle 637 ± 63.5 Nm {65 ± 6.5 kgm}
Ripper 677 ± 67.5 Nm {69 ± 6.9 kgm}
Tighten
Lift 1.08 ± 0.11 kNm {110 ± 11 kgm} (Width across flats: 50 mm)
Tightening
torque of Tilt 1.08 ± 0.11 kNm {110 ± 11 kgm} (Width across flats: 50 mm)
5
cylinder piston Angle 1.08 ± 0.11 kNm {110 ± 11 kgm} (Width across flats: 50 mm)
lock nut
Ripper 1.08 ± 0.11 kNm {110 ± 11 kgm} (Width across flats: 50 mm)
D31/37/39EX, PX-21 10-79

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD CONTROL VALVE
CONTROL VALVE
Outline
• This external view diagram shows the ripper

valve.
a The standard valve does not have the ripper

section.
P : Pump port
T : Tank port (to tank)
C : Cooler port (oil cooler)
A1: To lift cylinder head

B1: To lift cylinder bottom
A2: To tilt cylinder bottom
B2: To tilt cylinder head
A3: To L.H. angle cylinder bottom
To R.H. angle cylinder head
B3: To L.H. angle cylinder head
To R.H. angle cylinder bottom
A4: To ripper cylinder bottom
B4: To ripper cylinder head
10-80 D31/37/39EX, PX-21

D31/37/39EX, PX-21 10-81

1. Main relief valve 7. Suction valve (angle)

2. Suction valve (lift bottom) 8. Spool (lift)
3. Suction valve (angle) 9. Spool (tilt)
4. Suction valve (ripper head) 10. Spool (angle)
5. Safety valve 11. Spool (ripper)
6. Suction valve (ripper bottom)
10-82 D31/37/39EX, PX-21

Unit: mm

Installed Installed
Free length Installed
Spool return spring load Free length load
12 x OD length
(lift RAISE) (N {kg}) (N {kg})
34.0 26.9
19.34 x 17.2 18.57 —
{3.43} {2.74}
Spool return spring 34.0 26.9 Replace
13 11.28 x 12.6 8.73 —
(lift RAISE) {3.43} {2.74} spring if
55.9 44.7 damaged or
14 Spool return spring (tilt) 32.0 x 17.4 28.5 — deformed
{5.7} {4.56}
Spool return spring 24.5 19.6
15 29.3 x 17.6 28.5 —
(angle, ripper) {2.5} {2.0}
16 17.05 x 17.2 16.5 —
(lift LOWER) {1.4} {1.12}
17 40.73 x 17.4 28.5 —
(lift FLOAT) {19.25} {15.4}
D31/37/39EX, PX-21 10-83

1. Unload valve 7. Pressure compensation valve R (angle)

2. Pressure compensation valve F (lift) 8. Pressure compensation valve R (tilt)
3. Pressure compensation valve F (tilt) 9. Pressure compensation valve R (lift)
4. Pressure compensation valve F (angle) 10. LS selector piston
5. Pressure compensation valve F (ripper) 11. Cooler bypass valve
6. Pressure compensation valve R (ripper)
a The F and R in the above list indicate the follow-

ing valves.
F: Flow control valve
R: Pressure reducing valve
10-84 D31/37/39EX, PX-21

Unit: mm

Installed Installed
Free length Installed
Pressure compensation valve load Free length load
12 x OD length
spring (flow control valve end) (N{kg}) (N{kg})
7.45 5.96
15.4 x 6.0 8.0 —
{0.76} {0.61}
Replace
Pressure compensation valve
6.86 5.49 spring if
13 spring 23.0 x 8.4 15.0 —
{0.7} {0.56} damaged or
(reducing pressure valve end)
deformed
70.6 56.49
14 Unload valve spring 37.6 x 18.0 18.0 —
{7.2} {5.76}
3.43 2.75
15 LS selector piston spring 18.72 x 9.3 16.0 —
{0.35} {0.28}
98.1 78.5
16 Cooler bypass valve spring 43.8 x 13.2 29.0 —
{10.0} {8.0}
D31/37/39EX, PX-21 10-85

1. Cooler bypass valve 7. Suction valve (lift)

2. Unload valve 8. Pressure compensation valve R (lift)
3. Main relief valve 9. Pressure compensation valve F (tilt)
4. LS selector piston 10. Spool (tilt)
5. Pressure compensation valve F (lift) 11. Pressure compensation valve R (tilt)
6. Spool (lift)
a The F and R in the above list indicate the follow-

ing valves.
F: Flow control valve
R: Pressure reducing valve
10-86 D31/37/39EX, PX-21

1. Pressure compensation valve F (angle) 7. Spool (ripper)

2. Spool (angle) 8. Suction valve
3. Suction valve 9. Suction valve
4. Suction valve 10. Pressure compensation valve R (ripper)
5. Pressure compensation valve R (angle) 11. Safety valve
6. Pressure compensation valve F (ripper) 12. Pressure bleed plug
a The F and R in the above list indicate the following valves.

F: Flow control valve, R: Pressure reducing valve
Unit: mm

Replace
Installed Installed
Check valve spring Free length Installed spring if
13 load Free length load
(angle, ripper) x OD length damaged or
(N{kg}) (N{kg})
deformed
21.9 x 5.0 15.8 1.96 {0.2} — 1.57 {0.16}
D31/37/39EX, PX-21 10-87

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD CLSS
CLSS
1. Outline of CLSS
Features
CLSS stands for Closed center Load Sensing Sys-
tem, and has the following features.
• Fine control not influenced by load

• Control enabling digging even with fine control
• Ease of compound operation ensured by flow
divider function using area of opening of spool
during compound operations
Structure
• The CLSS consists of a gear pump, control
valve, and the actuators.
10-88 D31/37/39EX, PX-21

2. Basic principle
(1) Unload valve flow control
• The unload valve controls the LS differential

pressure, which is the difference between pump
discharge pressure PP and control valve outlet
port LS pressure PLS (actuator load pressure),
so that PLS becomes constant. (LS differen-
tial pressure PLS = pump discharge pressure
PP – LS pressure PLS)
• If the LS differential pressure becomes lower
than the set pressure, the unload valve reduces
the flow of the drain oil to the circuit. When the
pressure becomes higher than the set pressure,
it increases the flow.
a For details of the operation, see the section on

the unload valve.
D31/37/39EX, PX-21 10-89

(2) Pressure compensation control
• A pressure compensation valve to balance the

load is installed at the inlet port side of the con-
trol valve spool. When more than one actuator
is used in compound operations, this valve
makes the pressure difference P the same
between the upstream flow (inlet port) of each
spool notch and the downstream flow (outlet
port).
• In this way, the oil flow from the pump is divided
in proportion to the areas of opening S1 and S2
of each valve that is operated.
10-90 D31/37/39EX, PX-21

FUNCTIONS AND OPERATION OF EACH VALVE
1. Names of hydraulic circuits and valves
1. Unload valve 6. Check valve

2. Safety valve 7. Cooler bypass valve
(set pressure: 23.5 MPa {240 kg/cm2}) (cracking pressure: 0.5 MPa {5 kg/cm2})
3. Pressure compensation valve 8. Lift spool
4. Suction valve 9. Tilt spool
5. Main relief valve 10. Angle spool
(set pressure: 20.6 MPa {210 kg/cm2}) 11. Ripper spool
D31/37/39EX, PX-21 10-91

2. Unload valve
• In the case of a fixed pump system, the unload

valve has functions including those of variable
pump and LS valve.
(1) When control valve is at HOLD
Function
• When the control valve is at HOLD, pump dis-
charge amount Q is all relieved to the tank cir-
cuit. This reduces the pressure loss from the
pump to the tank.
Operation
• At the left end of spool (1), pump pressure PP2
(CPP1) is acting on area S1, and at the right end
of spool (1), pump pressure PP3 and the force
of spring (2) are acting on area S2. In addition,
LS pressure PLS is acting on area S3.
• When the control valve is at HOLD, LS pressure
PLS is not generated. Piston (3) is set at the left
position by spring (4), pressure PP3 is con-
nected to TS, and becomes much lower than
pump pressure PP1.
• Therefore, pump pressure PP2 (CPP1) is set
only by the force of spring (2) to a maximum of
0.53 MPa {5.4 kg/cm2}.
10-92 D31/37/39EX, PX-21

(2) Control valve operated
Function
• When the control valve is operated, an amount
of oil corresponding to the opening of the spool
flows to the actuator.
• When the control valve is operated, pump dis-
charge pressure PP1 is set to LS pressure PLS
+ 1.5 MPa {15 kg/cm2}.
Operation
• The operation is the same regardless of whether
the control valve is being fully operated or used
for fine control.
• When more than one actuator is used that the
same time, and the condition becomes pump
discharge < actuator demand, spool (1) moves
further to the left to the end of the stroke.
• As a result, pump circuits PP1 and PP2 and tank
circuit T are shut off, and all the pump discharge
amount flows to the actuators.
• When the control valve is operated fully, LS
pressure PLS is generated and acts on area S1
at the left end of piston (3) and area S3 at the
right end of spool (1).
• When LS pressure PLS reaches 0.07 MPa {0.7
kg/cm2}, piston (3) overcomes the force of spring
(4) and moves fully to the right.
• As a result, the connection between the spring
chamber of spring (2) and port TS is cut off and
the condition becomes PP1 = PP2.
• Spool (1) moves to the left so that the difference
in pressure between pump pressure PP1 and
LS pressure PLS becomes 1.5 MPa {15 kg/
cm2}.
• In addition, when the control valve is at neutral,
the oil being drained to the circuit T all flows to
the actuators.
D31/37/39EX, PX-21 10-93

3. Work equipment operated
(1) When lift is operated to LOWER
• When the 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.
• When this happens, the oil at the cylinder head
passes through cylinder port A and is drained.
(2) When lift is operated to FLOAT
• When the lift is operated to FLOAT, spool (1)

moves further to the right. The oil from the
pump does not enter bridge circuit C.
• The oil at cylinder port B is connected to the
drain circuit through bridge circuit C, opening a,
and cylinder port A.
10-94 D31/37/39EX, PX-21

4. LS bypass plug
PP : Pump circuit
PLS : LS circuit
TS : Seal drain circuit
A : To each valve
Function
• It releases the residual pressure of LS pressure
PLS.
• It makes the speed of the rise in pressure of LS
pressure PLS more gentle. In addition, with this
discarded throttled flow, it creates a pressure
loss in the throttled flow of the spool or shuttle
valve, and increases the stability by lowering
the effective LS differential pressure.
Operation
• The pressurized oil for LS circuit PLS passes
from clearance filter a (formed by the clearance
between LS bypass plug (1) and the valve body)
through orifice b and flows to seal drain circuit
TS.
D31/37/39EX, PX-21 10-95

5. Introduction of LS pressure
For lift, tilt, angle, ripper valve
Function
• The LS pressure is the actuator load pressure at • Actuator circuit pressure PA (=A) acts on the left
the outlet port end of the control valve. end of pressure reducing valve (3); the reduced
• It actually reduces pump pressure PP at pres- pump discharge pressure PP acts on the other
sure reducing valve (3) of the pressure compen- end.
sation valve to the same pressure as actuation • As a result, pressure reducing valve (3) is bal-
circuit pressure A, and sends it to the LS circuit anced at a position where actuator circuit pres-
PLS. sure PA and the pressure of spring chamber
PLS1 are the same. Pump discharge pressure
Operation PP is reduced at notch C, becomes actuator cir-
• When spool (1) is operated, pump discharge cuit pressure A, and is taken to LS circuit PLS.
pressure PP flows from flow control valve (2)
and notch a in spool (1) through bridge passage
b to actuator circuit A.
• At the same time, pressure reducing valve (3)
also moves to the right, so pump pressure PP
has its pressure reduced by the pressure loss at
notch C. It is introduced to LS circuit PLS, and
then goes to spring chamber PLS1.
• When this happens, LS circuit PLS is connected
to tank circuit TS from LS bypass plug (4). (See
the section on the LS bypass plug).
10-96 D31/37/39EX, PX-21

6. Pressure compensation valve
Function
• During compound operations, if the load pres-
sure becomes lower than the other actuator and
the oil flow tries to increase, compensation is
received. (When this happens, the other actua-
tor being used for compound operation (right
side) is at a higher load than the actuator on
this side (left side).)
Operation
• If the load pressure of the other actuator (right • Flow control valve (2) and pressure reducing
side) becomes higher during compound opera- valve (1) are balanced in position where the dif-
tions, the oil flow in actuator circuit A on this side ference in pressure between PLS and PA acting
(left side) tries to increase. on both ends of pressure reducing valve (2) and
• If this happens, the LS pressure PLS of the the pressure loss between PP and PPA on both
other actuator acts on spring chamber PLS1, sides of flow control valve (2) are the same.
and pressure reducing valve (1) and flow control • In this way, the pressure difference between
valve (2) are pushed to the left. upstream pressure PPA and downstream pres-
• Flow control valve (2) throttles the area of open- sure PA of both spools used during compound
ing between pump circuit PP and spool operations is the same, so the pump flow is
upstream PPA, and pressure loss is generated divided in proportion to the area of opening of
between PP and PPA. notch a of each spool.
D31/37/39EX, PX-21 10-97

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD PPC VALVE
PPC VALVE
a PPC: Abbreviation for Proportional Pressure Control
FOR BLADE LIFT, TILT, ANGLE
10-98 D31/37/39EX, PX-21

P : From control pump 1. Spool

T : To hydraulic tank 2. Metering spring
P1 : To blade tilt valve (left tilt) 3. Centering spring
P2 : To blade tilt valve (right tilt) 4. Piston
P3 : To blade lift valve (RAISE) 5. Disc
P4 : To blade lift valve (LOWER) 6. Cap (for connecting lever)
P5 : To blade angle valve (right angle) 7. Joint
P6 : To blade angle valve (left angle) 8. Plate
9. Retainer
10. Body
D31/37/39EX, PX-21 10-99

Operation
1. At Neutral
1) For blade lift
• Ports PA and PB of the blade lift control valve

and ports P3 and P4 of the PPC valve are con-
nected to drain chamber D through fine control
hole f of spool (1).
2) For blade tilt
• Ports PA and PB of the blade tilt control valve

and ports P1 and P2 of the PPC valve are con-
nected to drain chamber D through fine control
hole f of spool (1).
10-100 D31/37/39EX, PX-21

3) For blade angle
• Ports PA and PB of the blade angle control

valve and ports P5 and P6 of the PPC valve are
connected to drain chamber D through fine con-
trol hole f of spool (1).
2. During fine control (Neutral o fine control)
• 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.
• 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
passes through fine control hole f and flows
from port P4 to port PB.
• 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 pressure at port
P4.
• As a result, spool (1) moves up and down so
that the force of metering spring (2) is balanced
with the pressure at port P4. The relation
between the positions of spool (1) and body (10)
(fine control hole f is at the midpoint between
drain chamber D and pump pressure chamber
PP) does not change until retainer (9) contacts
spool (1).
• 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.
• 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.
D31/37/39EX, PX-21 10-101

3. During fine control

(when control lever is returned)
• When disc (5) starts to be returned, spool (1) is

pushed up by the pressure at port P4 and the
force of centering spring (3).
• As a result, fine control hole f is connected to
drain chamber D, so the pressure oil at port P4
is relieved.
• If the pressure at port P4 goes down too far,
spool (1) is pushed down by metering spring (2).
Fine control hole f is shut off from drain chamber
D, and at almost the same time, it is connected
to pump pressure chamber PP. Pump pressure
is supplied until the pressure at port P4 recov-
ers to a pressure equivalent to the position of
the lever.
• When the control valve spool returns, the oil at
drain chamber D flows in from fine control hole f'
in the valve on the side that is not moving. It
passes through port P3, is taken to chamber PA,
and the oil fills the chamber.
4. When lever is operated fully
• When disc (5) pushes down piston (4) and

retainer (9) pushes down spool (1), fine control
hole f is shut off from drain chamber D and is
connected to pump pressure chamber PP.
• Therefore, the pilot pressure oil from the control
pump passes through fine control hole f, is
taken from port P4 to chamber PB, and pushes
the control valve spool.
• The return oil from chamber PA passes from
port P3 through fine control hole f', and then
flows to drain chamber D.
10-102 D31/37/39EX, PX-21

5. When blade is operated to FLOAT
• When piston (4) at the port P4 LOWER side is

pushed by disc (5) and moves down, ball (11)
contacts protrusion a of the piston during the
stroke. (Detent starts to act.)
• When piston (4) pushed in further, ball (11)
pushes up collar (12), which is being held by
detent spring (13). While pushing up collar (12),
it escapes to the outside and passes over pro-
trusion a of the piston.
• When this happens, piston (4') on the opposite
side is pushed up by spring (14).
• As a result, the oil inside chamber F passes
through b and c, and flows to chamber E, and
piston (4') follows disc (5). Passage d is con-
nected to port P4, so more or less the same
pressure is applied as is applied to port P4.
• Chamber E is normally connected to drain
chamber D, but if ball (11) passes over protru-
sion a of the piston, passage d and chamber E,
which were shut off, are connected and the
pressure oil flows.
• At the same time, the control valve also moves
to the FLOAT position and the circuit is set to the
FLOAT condition.
• Piston (4') is being pushed up by the oil pres-
sure inside chamber E, so even if the lever is
released, it is held at the FLOAT position.
6. When blade is released from FLOAT
• When disc (5) is returned from the FLOAT posi-

tion, it is pushed down by a force greater than
the hydraulic force in chamber E.
• As a result, chamber E is shut off from passage
d and is connected to the drain chamber.
Therefore, the oil pressure inside chamber E is
lost, and the FLOAT position is canceled.
D31/37/39EX, PX-21 10-103

FOR RIPPER
P : From charge pump 1. Spool

T : To hydraulic tank 2. Metering spring
P1 : To ripper valve 3. Centering spring
P2 : To ripper valve 4. Piston
5. Lever
6. Plate
7. Retainer
8. Body
9. Filter
10-104 D31/37/39EX, PX-21

Unit: mm

Free length
Installed Installed Installed
x Outside Free length
10 Centering spring length load load If damaged or
diameter
deformed,
125 N 100 N replace spring
33.9 x 15.3 28.4 —
{12.7 kg} {10.2 kg}
16.7 N 13.3 N
11 Metering spring 22.9 x 8.10 22.0 —
{1.70 kg} {1.36 kg}
D31/37/39EX, PX-21 10-105

Operation
1. At neutral
• Ports A and B of the control valve and ports P1
and P2 of the PPC valve are connected to drain
chamber D via fine control hole f on spool (1).
2. During fine control (Neutral o fine control)

• As piston (4) is pushed by disc (5), retainer (7) is
pushed too. At the same time, spool (1) is also
pushed down via metering spring (2).
• By this move, connection of fine control hole f is
switched from drain chamber D to pump pres-
sure chamber PP, and pilot pressure oil of con-
trol pump is conducted from port P1 to port A.
• As port P1 pressure increases, spool (1) is
pushed back. By this move, connection of fine
control hole f is switched from pump pressure
chamber PP to drain chamber D, thereby reliev-
ing port P1 pressure.
• As the result, spool (1) moves up and down so
that force of metering spring (2) and port P1
pressure may be balanced.
• Positional relationship between spool (1) and
body (8) (fine control hole f is situated at mid
point between drain chamber D and pump pres-
sure chamber PP) remains unchanged until
retainer (7) is contacted against spool (1).
• Metering spring (2) is, therefore, compressed in
proportion to strokes of the control lever. Thus,
port P1 pressure too, increases in proportion to
strokes of the control lever.
• As the result, the control valve spool moves to
the position where the pressure of chamber A
(the same as port P1 pressure) is balanced
against force of the control valve spool return
spring.
10-106 D31/37/39EX, PX-21

3. During fine control

(when control lever is returned)
• As lever (5) starts returning, spool (1) is pushed
up by force of centering spring (3) and port P1
pressure. By this move, fine control hole f is
connected to drain chamber D and relieves
pressurized oil of port P1 to it.
• If port P1 pressure goes excessively low, spool
(1) is pushed down by metering spring (2), and
passage between fine control hole f and drain
chamber D is shut down. And, almost at the
same time, the hole is connected to pump pres-
sure chamber PP and starts supplying pump the
pressure. This supply continues until port P1
pressure is recovered to the level equivalent to
the lever position.
• When the control valve spool returns, oil in drain
chamber D flows in through fine control hole f’
on the not moving side valve. Oil is then con-
ducted via port P2 to chamber B to fill it up.
4. At full stroke
• When disc (5) pushes down piston (4) and
retainer (7) pushes down spool (1), connection
of fine control hole f is switched from drain
chamber D, to pump pressure chamber PP.
• Thus, pilot pressurized oil from the control pump
passes through fine control hole f and con-
ducted to chamber A via port P1 to push the
control valve spool.
• Return oil from chamber B is conducted from
port P2 to drain chamber D via fine control hole
f’.
D31/37/39EX, PX-21 10-107

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD WORK EQUIPMENT
WORK EQUIPMENT
a The diagram shows D37PX-21.
1. Tilt cylinder 5. Pitching rod

2. Cutting edge 6. Angle cylinder
3. End bit 7. U-frame
4. Blade 8. Lift cylinder
10-108 D31/37/39EX, PX-21

a The diagram shows D37PX-21.
D31/37/39EX, PX-21 10-109

D31EX/PX-21
D37EX/PX-21
Unit: mm

Clearance between frame size Shaft Hole clearance limit
1
connecting pin and bushing
+0.174 0.130 –
0.5
+0.100 – 0.250
–0.030
Clearance between frame ø60
–0.076 +0.300 0.130 –
2 connecting pin and U-frame 1.0
+0.100 – 0.376
bracket
Clearance between lift
–0.025 +0.039 0.025 –
3 cylinder bottom pin and frame ø45 1.0
–0.064 +0.039 – 0.103
bracket
–0.025 +0.400 0.125 –
4 cylinder head pin and ø45 1.0
–0.064 +0.100 – 0.464
U-frame bracket
Clearance between angle
–0.025 +0.400 0.125 –
5 cylinder bottom pin and ø40 1.0
–0.087 –0.100 – 0.487
U-frame bracket
Replace
–0.025 +0.400 0.125 –
6 cylinder head pin and blade ø40 1.0
–0.087 +0.100 – 0.487
bracket
Clearance between tilt
–0.025 +0.400 0.125 –
–0.064 +0.100 – 0.464
U-frame bracket
–0.025 +0.400 0.125 –
–0.064 +0.100 – 0.464
bracket
Clearance between pitching +0.039 0.025 –
9 0.5
rod pin and bushing –0.025 +0.039 – 0.103
ø40
Clearance between pitching –0.064 +0.300 0.125 –
10 1.0
rod pin and U-frame bracket +0.100 – 0.364
Clearance between blade
–0.250 +1.500 0.250 –
11 spherical portion and pitching S ø70 —
–0.750 +0.500 – 2.250
rod cap
12 center spherical portion and S ø148 — — 0.75 —
U-frame cap
Adjust shim
Standard shim thickness at
13 blade center spherical portion 8.0
and U-frame cap
10-110 D31/37/39EX, PX-21

D39EX/PX-21
Unit: mm

Clearance between frame size Shaft Hole clearance limit
1
connecting pin and bushing
+0.174 0.130 –
0.5
+0.100 – 0.250
–0.030
Clearance between frame ø60
–0.076 +0.300 0.130 –
2 connecting pin and U-frame 1.0
+0.100 – 0.376
bracket
–0.025 +0.039 0.025 –
3 cylinder bottom pin and frame ø50 1.0
–0.064 +0.039 – 0.103
bracket
–0.025 +0.400 0.125 –
–0.064 +0.100 – 0.464
U-frame bracket
–0.025 +0.400 0.125 –
–0.064 –0.100 – 0.464
U-frame bracket
Replace
–0.025 +0.400 0.125 –
–0.064 +0.100 – 0.464
bracket
–0.025 +0.400 0.125 –
–0.064 +0.100 – 0.464
U-frame bracket
–0.025 +0.400 0.125 –
8 cylinder bottom pin and blade ø45 1.0
–0.064 +0.100 – 0.464
bracket
Clearance between pitching +0.039 0.025 –
9 0.5
rod pin and bushing –0.025 +0.039 – 0.103
ø40
Clearance between pitching –0.064 +0.300 0.125 –
10 1.0
rod pin and U-frame bracket +0.100 – 0.364
–0.250 +1.500 0.250 –
11 spherical portion and pitching S ø70 —
–0.750 +0.500 – 2.250
rod cap
12 center spherical portion and S ø148 — — 0.75 —
U-frame cap
Adjust shim
Standard shim thickness at
13 blade center spherical portion 8.0
and U-frame cap
D31/37/39EX, PX-21 10-111

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD CUTTING EDGE, END BIT
CUTTING EDGE, END BIT
Unit: mm

1 Height of cutting edge
160 110
2 Height of end bit 160 110
D31EX 380 —
D31PX 380 (370) — Replace
D37EX 370 —
3 Width of end pit
D37PX 405 (370) —
D39EX 380 —
D39PX 370 (370) —
10-112 D31/37/39EX, PX-21

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD RIPPER
RIPPER
D31EX/D37EX/D39EX-21 (If equipped)
a The diagram shows D39EX-21.
Unit: mm

Clearance between pin and size Shaft Hole clearance limit
1
bushing
–0.025 +0.142 0.105 –
ø50 1.0 Replace
–0.064 +0.080 – 0.206
2 Wear of point
160 85
3. Support
4. Ripper cylinder
5. Shank
6. Point
7. Beam
D31/37/39EX, PX-21 10-113

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD CAB RELATED
CAB RELATED
AIR CONDITIONER PIPING
1. Compressor A: Fresh air intake port

2. Hot water pick-up piping B: Recirculated air circulation port
3. Hot water return piping C: Hot air/cold air vent
4. Receiver tank
5. Air conditioner unit
6. Condenser
7. Refrigerant piping
10-114 D31/37/39EX, PX-21

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD ENGINE CONTROL
ENGINE CONTROL
1. Battery Function
2. Battery relay • A limit switch is installed to the parking brake
3. Starting switch lever linkage and the HST controller controls the
4. Fusible link engine with it so that the engine can start only
5. Fuse box when the parking brake lever is in the LOCK
6. HST controller position and the joystick is in the N (Neutral)
7. Parking brake lever position.
8. Parking brake limit switch 1
9. Joystick (PCCS lever)
10. Electric lever
11. Neutral safety parking brake relay
12. Safety relay
13. Starting motor
14. Engine stop solenoid
10-116 D31/37/39EX, PX-21

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD HST CONTROL SYSTEM
HST CONTROL SYSTEM

a HST: Abbreviation for HydroStatic Transmission
1. Battery Input and output signals

2. Battery relay a. Controller power supply
3. Fusible link 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. Electric lever (For steering) g. Steering/directional/gear shift signal
9. Fuel control lever potentiometer h. Fuel control lever 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. EPC valve drive signal
14. L.H. HST motor forward EPC valve p. Solenoid valve drive signal
15. R.H. HST motor forward EPC valve
16. L.H. HST motor reverse EPC valve
17. R.H. HST motor 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. 2nd selector solenoid valve
23. 3rd selector solenoid valve
D31/37/39EX, PX-21 10-117

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD GEAR SHIFT CONTROL SYSTEM
GEAR SHIFT CONTROL SYSTEM

GEAR SHIFTING BY OPERATOR
Function Set travel speeds corresponding to gear speeds

• Upon receiving the gear shift signal from the
Bar graph gauge No. Gear Set travel speed (km/h)
shift-up or shift-down switch of the steering/
(Variable shift mode) speed A B C D E
directional/gear shift lever, the HST controller
decides the capacity of the HST pump and HST 1, 2 0.2 0.8 0.8 0.8 0.8 0.8
motor and shift the gear. 3, 4 0.3 0.9 1.0 1.1 1.2 1.3
• The operator can select the quick shift mode or 5, 6 0.5 1.2 1.5 1.7 1.9 2.2
the variable shift mode with the shift mode 7, 8 0.6 1.6 2.0 2.3 2.7 3.0
switch. 9, 10 0.8 2.0 2.4 2.9 3.4 3.8
• If the steering/directional/gear shift lever is 11, 12 0.9 2.3 2.9 3.5 4.1 4.7
leaned forward (for forward travel), a set travel 13, 14 1.0 2.7 3.4 4.1 4.8 5.5
speed is decided according to the gear speed of 15, 16 1.1 3.0 3.8 4.5 5.2 6.0
broken line (B) in the above graph.
17, 18 1.3 3.4 4.1 4.9 5.7 6.4
• If the steering/directional/gear shift lever is
19, 20 1.4 3.7 4.5 5.3 6.1 6.9
leaned backward (for reverse travel), a set travel
speed corresponding to the gear speed of set- 21, 22 1.6 4.0 4.9 5.7 6.5 7.4
tings (A) – (E) of the reverse travel speed setting 23, 24 1.8 4.4 5.2 6.1 7.0 7.8
switch is decided according to the above graph. 25, 26 2.0 4.7 5.6 6.5 7.4 8.3
• When the steering/directional/gear shift lever is 27, 28 2.2 5.1 6.0 6.9 7.8 8.5
in the neutral position, the set travel speed is 0 29, 30 2.3 5.5 6.4 7.3 8.2 8.5
km/h. 31, 32 2.4 5.9 6.8 7.7 8.5 8.5
33, 34 2.6 6.4 7.3 8.2 8.5 8.5
35, 36 2.7 6.8 7.7 8.5 8.5 8.5
37, 38 2.9 7.2 8.1 8.5 8.5 8.5
39, 40 3.0 7.6 8.5 8.5 8.5 8.5
a The values of bold-face type are for the quick

shift mode.
10-118 D31/37/39EX, PX-21

• If the fuel control lever or decelerator pedal is <Deceleration command map>

operated, a deceleration command is lowered
according to the deceleration command map.
• The deceleration command of fuel control lever
is higher than that of the decelerator pedal.
Accordingly, even if the fuel control lever is
returned from the "FULL SPEED" position,
higher output is secured.
a The deceleration command means the ratio to
the set travel speed.
Example)
• When the fuel control lever 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.
• When the fuel control lever 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.
• If the brake pedal is operated, a brake command <Brake command map>

is lowered according to the brake command
map.
a The brake command means the ratio to the set
travel speed.
Example)
• When the brake pedal is pressed halfway:
The travel speed is limited according to the for-
mula of Command travel speed = Brake com-
mand x Set travel speed / 100.
D31/37/39EX, PX-21 10-119

Changing travel speed according to change

of engine speed
When external load increases and engine speed <Command travel speed map>
lowers
• The HST controller lowers the command travel
speed according to command travel speed map
(A).
In addition, the HST controller decides the EPC
valve control signal and gear speed shifting
solenoid valve drive signal to lower the travel
speed according to the HST pump capacity
command map and the HST motor command
map.
When external load decreases and engine speed

rises
• The HST controller raise the command travel
speed according to command travel speed map
(A).
In addition, the HST controller decides the EPC
valve control signal and gear speed shifting
solenoid valve drive signal to raise the travel
speed according to the HST pump capacity
command map and the HST motor command
map.
Changing travel speed according to change <HST pump capacity command map>
of HST circuit oil pressure
When external load increases and HST circuit oil

pressure rises
• If the HST controller receives oil pressure sig-
nals from the right and left HST circuit oil pres-
sure sensors and judges that the HST circuit oil
pressure approaches the set relief pressure, it
lowers the command travel speed and increases
the HST motor capacity.
When external load decreases and HST circuit <HST motor capacity command map>
oil pressure lowers
• If the HST controller judges that the HST circuit
oil pressures on both sides are low, it returns the
command travel speed and HST motor capacity
to the original levels.
10-120 D31/37/39EX, PX-21

STRAIGHT TRAVEL CORRECTION

CONTROL SYSTEM
Function
• The HST controller monitors the operating con-
ditions of each lever and each pedal and con-
stantly controls the swash plate angle of the
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.
• While the machine is traveling straight forward, if

the right HST motor speed is higher than the left
HST motor speed, the HST controller lowers the
control signal of the right HST motor forward
EPC valve so that the machine will always travel
straight.
• Conditions for resetting straight travel correction

control system
1. The steering/directional/gear shift lever is set
in the RIGHT or LEFT steering position.
2. The steering/directional/gear shift lever is set
in the NEUTRAL travel direction position.
3. A pedal or the fuel control lever is operated
and the travel speed sensed by the HST mo-
tor speed sensor is 0.15 km/h or lower.
4. The HST motor speed sensor is judged de-
fective because of disconnection, etc.
Straight travel is secured when none of the

above condition is satisfied.
D31/37/39EX, PX-21 10-121

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD PARKING BRAKE CONTROL SYSTEM
PARKING BRAKE CONTROL SYSTEM
1. Battery Input and output signals

2. Battery relay a. Controller power supply
3. Fusible link b. Parking brake lever LOCK signal
4. Fuse box c. Brake pedal stroke signal
5. HST controller d. Solenoid valve drive signal
6. Engine e. Brake oil pressure signal
7. HST pump f. EPC valve drive signal
7a. EPC valve g. Decelerator pedal stroke signal
7b. Servo h. Steering/directional/gear shift signal
8. Brake pedal
9. Brake pedal potentiometer
10. Center brake limit switch
11. Parking brake lever
14. Decelerator pedal
15. Decelerator pedal potentiometer
16. Joystick (PCCS lever)
17. Electric lever (For steering)
18. Slow brake solenoid valve
19. Parking brake solenoid valve
20. Towing valve
21. Brake oil pressure sensor
22. HST motor
22a. Parking brake
10-122 D31/37/39EX, PX-21

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD PARKING BRAKE CONTROL SYSTEM
Function
• Parking brake limit switches 1 (12) and 2 (13)
and installed and connected to parking brake
lever (11) so that parking brake (22a) will be
released only when parking brake lever (11) is in
the FREE position.
• Center brake limit switch (10) is installed and
connected to brake pedal (8) so that slow brake
solenoid valve (18) will be de-energized and
parking brake (22a) will be applied when brake
pedal (8) is pressed fully.
Conditions for turning parking brake solenoid valve OFF
Operating condition Operation

1. (a) or (b) shown below is satisfied and travel speed is 0.6 km/h or lower.
2. (a) or (b) shown below is satisfied for 1 second continuously.
(a) Parking brake lever is in LOCK position. o Parking brake operates.

(Parking brake limit switch 1 is ON.)
(b) Brake pedal is pressed fully.
(Pedal stroke is 90% or more.)
Conditions for turning slow brake solenoid valve OFF
Operating condition Operation

1. (a) or (b) shown below is satisfied.
(a) Parking brake lever is in LOCK position.

o Parking brake operates.
(Parking brake limit switch 2 is ON.)
(b) Brake pedal is pressed fully.
(Center brake limit switch is ON.)
D31/37/39EX, PX-21 10-123

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD COMPONENT EQUIPMENT OF SYSTEM
COMPONENT EQUIPMENT OF SYSTEM

HST CONTROLLER
10-124 D31/37/39EX, PX-21

Input and output signals

DEUTSCH-24P [CN-ST1] DEUTSCH-40P (1) [CN-ST2] DEUTSCH-40P (2) [CN-ST3]
Pin Input/Output Pin Input/Output Pin Input/Output
Signal name Signal name Signal name
No. signal No. signal No. signal
1 Joystick position FR4 Input 1 NC — Power source
1 Input
Decelerator pedal 2 NC — (Controller)
2 Input
potentiometer 3 NC — 2 Power source (Solenoid) Input
Brake pedal 4 Flash ROM write (RXD) Input GND
3 Input 3 —
potentiometer Parking brake limit (Solenoid, common)
5 Input
4 GND (Signal) — switch 1 (NC) 4 For driving battery relay Output
Charge filter clogging 6 Cursor switch 2 (<) Input L.H. HST motor
5 Input 5 Output
sensor 7 NC — forward EPC valve
6 Service switch Input 8 Neutral safety relay Output L.H. HST motor reverse
6 Output
7 Joystick position ST2 Input 9 NC — EPC valve
Fuel control lever 10 NC — 3rd selector solenoid
8 Input 7 Output
potentiometer 11 NC — valve
HST oil temperature 12 CAN shield — 8 NC —
9 Input
sensor 13 Immobilize signal Input Parking brake limit
9 Input
10 GND (Signal) — 14 Flash ROM write (TXD) Output switch 2 (NO)
Brake oil pressure Parking brake limit 10 NC —
11 Input 15 Input
sensor switch 1 (NO) Power source
11 Input
12 Shift-up switch (NC) Input 16 Cursor switch 1 (>) Input (Controller)
13 Joystick position FR3 Input 17 NC — 12 Power source (Solenoid) Input
L.H. HST circuit oil 18 NC — GND
14 Input 13 —
pressure sensor 19 NC — (Solenoid, common)
15 Alternator (R) Input L.H. HST motor speed 14 Starting switch (ACC) Input
20 Input
Sensor power source sensor R.H. HST motor
16 Output 15 Output
(+24 V) 21 S-NET Input/Output forward EPC valve
17 NC — 22 CAN0 (L) Input/Output R.H. HST motor reverse
16 Output
18 Shift-down switch (NO) Input 23 CAN1 (L) Input/Output EPC valve
19 Joystick position ST1 Input Flash ROM write 2nd selector solenoid
24 Input 17 Output
R.H. HST circuit oil permission silnal valve
20 Input
pressure sensor Reverse travel speed 18 Back-up alarm Output
25 Input
21 GND (Analog) — setting switch (Up) 19 NC —
Sensor power source 26 Select switch (U) Input 20 NC —
22 Output
(+5 V) 27 NC — 21 GND (Power source) —
23 Shift-up switch (NO) Input 28 NC — 22 Power source (Solenoid) Input
24 Shift-down switch (NC) Input 29 GND (Pulse) — GND
23 —
R.H. HST motor speed (Solenoid, common)
30 Input
sensor 24 Starting switch (ACC) Input
31 GND (S-NET) — 25 NC —
32 CAN0 (H) Input/Output 26 NC —
33 CAN1 (H) Input/Output Parking brake solenoid
27 Output
34 GND (Flash ROM write) — valve
Reverse travel speed 28 NC —
35 Input
setting switch (Down) 29 NC —
Alarm buzzer cancel 30 NC —
36 Input
switch (t) 31 GND (Power source) —
37 Shift mode switch Input 32 GND (Power source) —
38 NC — 33 GND (Power source) —
39 GND (Pulse) — 34 NC —
40 Engine speed sensor Input 35 NC —
36 NC —
Slow brake solenoid
37 Output
valve
38 NC —
39 NC —
40 NC —
D31/37/39EX, PX-21 10-125

(4)
DECELERATOR PEDAL POTENTIOMETER

BRAKE PEDAL POTENTIOMETER
FUEL CONTROL LEVER POTENTIOMETER
1. Potentiometer
2. Connector
Function
• The potentiometer is connected to the decelera-
tor pedal, brake pedal, and fuel control lever and
its shaft is rotated according to the operating
angle of the pedal and lever.
• The movement of the shaft operates the internal
variable resistor, which generates a signal volt-
age by changing the source voltage of 5 V
according to the operating angle.
10-126 D31/37/39EX, PX-21

(2)
SAFETY RELAY
1. Relay body
S: To starting switch terminal C

R: To alternator terminal R
B: To starting motor terminal B
C: To starting motor terminal C
E: Ground
ELECTRIC LEVER (FOR STEERING)

a See section on electric lever (for steering).
EPC VALVE
a See section on HST pump.
2ND SELECTOR SOLENOID VALVE

3RD SELECTOR SOLENOID VALVE
PARKING BRAKE SOLENOID VALVE
SLOW BRAKE SOLENOID VALVE
a See section on solenoid valve.
MONITOR PANEL
a See section on monitor system.
D31/37/39EX, PX-21 10-127

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD MONITOR SYSTEM
MONITOR SYSTEM
a. Each sensor e. Battery

b. Sensor signal f. Power source
c. HST controller g. Alarm buzzer
d. CAN signal h. Alarm buzzer signal
• The monitor system notifies the operator of the • The monitor system consists of the monitor
machine condition. It monitors the machine con- panel, controller, sensors, alarm buzzer, and
dition with the sensors installed to the machine power supply.
and processes and displays the obtained infor- • The component parts are connected by wiring
mation on the monitor panel immediately. harnesses and the monitor panel is powered by
The contents displayed on the panel are roughly the battery.
classified as shown below. • If the machine has any trouble (and a sensor
1. Travel direction, gear speed, shift mode detects it), the monitor and alarm lamp flash and
(Display panel A) the alarm buzzer sounds to protect the machine.
2. Coolant temperature, reverse travel speed, The alarm buzzer can be turned OFF tempo-
HST oil temperature, and fuel level (Gauge rarily with the buzzer cancel switch.
section)
3. Machine trouble alarm (Monitor section)
4. Current, voltage, error code, of each sensor
and solenoid (Display panel B)
10-128 D31/37/39EX, PX-21

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD MONITOR SYSTEM
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 sent to the monitor panel according to the infor- CAN signal
mation of the HST controller.
2. Display of coolant temperature, HST oil temperature, and fuel level by gauge
• The controller processes the sensor signals and converts them into gauge CAN signal
levels and sends the result to the monitor panel.
Each sensor/solenoid
3. Display of trouble
O
• If there is any trouble, its failure code signal is sent to the monitor panel.
Controller
• Information about sounding the buzzer and flashing the caution lamp is
O
sent, according to the contents of the trouble.
Monitor panel
1) In normal state
An action code is displayed. CAN signal
2) In failure history display mode
A failure code (6-characteristics code) and the following are displayed.
• Elapsed time after first occurrence
• Elapsed time after latest occurrence
• Number of occurrences
Display of monitor panel

1. Display of each sensor, each solenoid, communicating state of CAN signal,
etc. Each sensor
CAN signal
• The signals of the item No. and condition of each device are sent to the O
monitor panel. Controller
2. Selection of each item with information switch, buzzer cancel switch, and up/ O
down (gear-shift) switch of the steering/directional/gear shift lever. (When CAN signal Monitor panel
using a mode for service, turn the service switch ON.)
a For details of the operating method, see TESTING AND ADJUSTING, Special functions of monitor panel
(EMMS).
Other items

1. Filter and oil maintenance mode
2. Pm clinic auxiliary mode
3. Failure code display mode
4. Adjustment mode (User) Each sensor
5. Maintenance interval change mode O
6. Electric system failure code display mode CAN signal Controller
7. Mechanical system failure code display mode O
8. Adjustment mode (Service) Monitor panel
9. Load saving display mode
10. Real-time monitoring mode
11. Dual display monitoring mode
a For details of the operating method, see TESTING AND ADJUSTING, Special functions of monitor panel
(EMMS).
D31/37/39EX, PX-21 10-129

(2)
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD MONITOR PANEL
MONITOR PANEL
Outline Operation
• The monitor panel consists of the monitor sec-
tion which outputs an alarm when the machine When power is turned ON
has any trouble and the gauge section and dis- (When starting switch is turned to ON position)
play panel which display the machine condition • All the LC segments and lamps of the monitor
constantly. panel light up for 2 seconds and the alarm
The monitor panel has a microcomputer, which buzzer sounds for 2 seconds.
processes and displays the signals from the
sensors, solenoids, and controllers. Check before starting
The items displayed on the monitor section and • After the operation performed when the power is
gauge section are shown in DISPLAY OF MON- turned ON, if there is any abnormal one in the
ITOR PANEL. check-before-starting items, the lamp of that
item flashes or the contents of the abnormality
are displayed on display panel B.
Caution items
• The caution items are checked constantly while
the engine is running.
If any item is abnormal, it and alarm lamp flash
synchronously. The alarm buzzer may sound at
this time.
10-130 D31/37/39EX, PX-21

Buzzer cancel switch

• If this switch is operated while the alarm buzzer
is sounding, the buzzer is turned OFF tempo-
rarily.
While the buzzer is turned OFF, if a new trouble
which turns on the buzzer is detected, the
buzzer sounds again.
a The lamp lights up and goes off at the intervals
of about 0.8 seconds.
a The flashing intervals of the lamp may change a
little when the temperature is low (below about
–10°C). This does not indicate a trouble.
Input and output signals

AMP070-20P [CN-S03] AMP070-12P [CN-S04]
Input/Output Input/Output
Pin No. Signal name Pin No. Signal name
signal signal
1 Power source (24 V) Input 1 CAN0-H Input/Output
2 Power source (24 V) Input 2 CAN0-H Input/Output
3 GND — 3 CAN0-L Input/Output
4 GND — 4 CAN0-L Input/Output
5 Service power (24 V) Input 5 CAN shield —
6 Service power (24 V) Input 6 NC —
7 Starting switch (C) Input 7 NC —
8 Night lighting Input 8 NC —
9 Preheating Input 9 Alternator (R) Input
10 NC — 10 Fuel level Input
11 NC — 11 Coolant temperature Input
12 Engine oil pressure Input 12 NC —
13 NC —
14 NC —
15 NC —
16 Service switch Input
17 NC —
18 Alarm buzzer Output
19 NC —
20 NC —
D31/37/39EX, PX-21 10-131

Monitor panel display

a The following figure shows an example of display in the quick shift mode.
The following is an example of display panel A in the

variable shift mode.
10-132 D31/37/39EX, PX-21

(2)
Alarm Alarm
Display Display
No. Display item Display range Display method lamp buzzer Remarks
section color
output output
Corresponding segment (1 place)
1a Gauge See figure at left — — Black LCD
lights up
Coolant Below 102°C OFF OFF OFF
temperature
1b Caution 102°C – 108°C Flashing Flashing OFF Red LED
Above 108°C Flashing Flashing ON
Corresponding segment (1 place)
2a Gauge See figure at left — — Black LCD
lights up
HST oil Below 100°C OFF OFF OFF Red LED
temperature
2b Caution 100°C – 110°C Flashing Flashing OFF
Above 110°C Flashing Flashing ON
Reverse travel [*1] Below corresponding segment
3 Gauge — — Black LCD
speed See figure at left All light up
Below corresponding segment
4 Gauge Fuel level See figure at left — —
All light up
P: Parking brake lever in LOCK,
Joystick in NEUTRAL
Travel direction
5a N: Joystick in NEUTRAL
(P, N, F, R)
F: Joystick in FORWARD
Indicator R: Joystick in REVERSE OFF OFF
[*2] 1: Joystick gear shift switch in 1st
Display panel A [*3]
5b 2: Joystick gear shift switch in 2nd
(Travel direction, Gear speed (1, 2, 3)
3: Joystick gear shift switch in 3rd Black LCD
gear speed, shift
[*1], [*4]
mode)
Intermediate gear Below corresponding segment
5c Gauge — —
speed All light up
(See figure at left)
5d Variable shift mode ON — —
Pilot
5e Quick shift mode ON — —
[*2]
Character Time is counted while engine is
6 Display panel B 0 – 99999.9 h — —
display running (alternator is generating)
(Service meter)
When charge is OFF (While engine is stopped) OFF OFF
7 Charge level
defective (Below 12 V) Flashing (While engine is running) Flashing OFF
Engine oil Below specified value OFF (While engine is stopped) OFF OFF
8
pressure (49 kPa {0.5 kg/cm2}) Flashing (While engine is running) Flashing ON
Caution Red
Charge filter Above specified value OFF (While engine is stopped) OFF OFF
9
clogging (200 kPa {2.0 kg/cm2}) Flashing (While engine is running) Flashing ON
HST charge oil Below specified value OFF (While engine is stopped) OFF OFF
10
pressure (785 kPa {8.0 kg/cm2}) Flashing (While engine is running) Flashing ON
11 Pilot Preheating In preheating mode ON OFF OFF Green LED
Before 30 h or more OFF
12 Maintenance Before 30 h – Replace- ON for 30 seconds after starting OFF OFF Orange
ment time switch is turned ON
13 Warning lamp See the “warning lamp output” column of this table — — Red
Caution Before 30 h or more OFF
Before 30 h – Replace-
Replacement time ON
14 ment time OFF OFF Yellow
of filter and oil
Passed replacement
Flashing
time
*1: For details, see HST CONTROL SYSTEM.

*2: For details in the service mode, see TESTING AND ADJUSTING, Special functions of monitor panel
(EMMS).
*3: Displayed only in the quick shift mode.
*4: Displayed only in the variable shift mode.
D31/37/39EX, PX-21 10-133

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD SENSORS
SENSORS
• The signals from the sensors are input directly to the controller or monitor panel.
• There are 4 types of sensors: contact type, resistance type, electromagnetic type, and semiconductor type.
• The contact type sensors always have one side connected to the chassis ground.
Category of display Type of sensor Method of sensor When normal When abnormal
Engine oil pressure Contact (N.C.) OFF (open) ON (closed)
Charge filter clogging Contact (N.O.) OFF (open) ON (closed)
Caution
Brake oil pressure
Contact (N.O.) ON (closed) OFF (open)
(HST charge oil pressure)
Coolant temperature Resistance — —
Gauges HST oil temperature Resistance — —
Fuel level Resistance — —
Engine speed Electromagnetic — —
— HST motor speed Electromagnetic — —
HST circuit oil pressure Semiconductor — —
ENGINE OIL PRESSURE SENSOR
1. Plug Function
2. Contact ring • The engine oil pressure sensor is installed to the
3. Contact engine cylinder block. Its diaphragm senses oil
4. Diaphragm pressure. If the oil pressure lowers below the
5. Spring set level, the switch is turned ON.
6. Terminal
10-134 D31/37/39EX, PX-21

CHARGE FILTER CLOGGING SENSOR
1. Internal ring Function

2. Contact • The charge filter clogging sensor is installed to
3. Spring the charge filter and its contact senses the pres-
4. Body sures before and after the filter. If the difference
5. Terminal between those pressures exceeds the set level,
the switch is turned ON.
BRAKE OIL PRESSURE SENSOR

(HST CHARGE OIL PRESSURE SENSOR)
1. Plug Function
2. Sensor • The brake oil pressure sensor is installed to the
3. Connector parking brake solenoid valve piping. It senses
the brake oil pressure when the brake is
released. If the brake oil pressure lowers below
the set level, the switch is turned ON.
D31/37/39EX, PX-21 10-135

FUEL LEVEL SENSOR
1. Float Function
2. Arm • The fuel level sensor is installed to the side of
3. Connector the fuel tank and its float moves up and down
4. Variable resistor according to the fuel level in the tank. The
5. Contact movement of the float operates the variable
6. Body resistor through the arm, and then signals are
generated according to the change of the resis-
tance.
10-136 D31/37/39EX, PX-21

COOLANT TEMPERATURE SENSOR

HST OIL TEMPERATURE SENSOR
1. Thermistor Function
2. Plug • The coolant temperature sensor is installed to
3. Connector the engine cylinder block. The HST oil tempera-
ture sensor is installed to the pump suction pip-
ing. They sense the changes of the temperature
as the changes of the resistance of the ther-
mistors in them, and then generate signals
according to the measured temperature.
ENGINE SPEED SENSOR
1. Wire Function
2. Magnet • The engine speed sensor is installed to the ring
3. Terminal gear of the flywheel housing and generates
4. Housing pulse voltages as the gear rotates.
5. Connector
D31/37/39EX, PX-21 10-137

HST CIRCUIT OIL PRESSURE SENSOR
1. Plug Function
2. Sensor • The HST circuit oil pressure sensor is installed
3. Connector to the HST pump. It senses the HST circuit
pressures on the right and left sides as the
changes of the voltage in its semiconductor
parts, and then generates signals according to
the measured pressures.
HST MOTOR SPEED SENSOR

a See HST MOTOR.
10-138 D31/37/39EX, PX-21

20 TESTING AND ADJUSTING
STANDARD VALUE TABLE

STANDARD VALUE TABLE FOR ENGINE ........................................................................................20-2
STANDARD VALUE TABLE FOR CHASSIS ......................................................................................20-5
TESTING AND ADJUSTING .................................................................................................................20-101
TROUBLESHOOTING ..........................................................................................................................20-301
★ Note the following when making judgements using the standard value tables for testing, adjusting, or trou-
bleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the
results of various tests. It is used for reference together with the state of repair and the history of operation
to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
k When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert the safety
pins, and use blocks to prevent the machine from moving.
k When carrying out work together with other workers, always use signals and do not let unauthorized people
near the machine.
k When checking the water level, always wait for the water to cool down. If the radiator cap is removed when
the water is still hot, the water will spurt out and cause burns.
k Be careful not to get caught in the fan, fan belt or other rotating parts.
D31/37/39EX, PX-21 20-1

(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE

D31EX,PX-21
Machine model D31EX-21, D31PX-21
Engine SAA4D102E-2
Standard
Cate- value for Service limit
Item Measurement conditions Unit
gory new value
machine
• Engine coolant temperature: +50 +50

Within operating range High idling rpm 2,200 -100 2,200 -100
• HST oil temperature
Engine speed
(hydraulic oil temperature):
Within operating range Low idling rpm 800 +50
800 +50
0 0
(40 – 60°C)
• Engine coolant temperature:

Within operating range
Intake air pressure kPa Min. 97 87
• HST oil temperature (hydraulic oil temperature):
(Boost pressure) {mmHg} {Min. 730} {650}
Within operating range (40 – 60°C)
• Stall pressure test mode + Work equipment relief
Exhaust temperature °C Max. 650 700
• All speed range (Outside temperature: 20°C)
• Stall pressure test mode
At sharp Bosch
Max. 4.5 6.5
• Engine coolant temperature: acceleration index
Exhaust gas color
Within operating range Bosch
At high idling Max. 1.0 2.0
index
Engine
Intake valve mm 0.25 —

Valve clearance • Normal temperature
Exhaust valve mm 0.51 —
• SAE30 or SAE15W-40 oil Compression MPa Min. 2.41 1.69
Compression pressure {Min. 24.6} {17.2}
• Engine oil temperature: {kg/cm2}
pressure
40 – 60°C Engine speed rpm 320 – 360 320 – 360
• Engine coolant temperature: Within operating range
• HST oil temperature (hydraulic oil temperature): Pa Max. 490 980
Blow-by pressure
Within operating range {mmH2O} {Max. 50} {100}
MPa 0.34 – 0.69 0.25
• SAE30 or SAE15W-40 oil At high idling
{kg/cm2} {3.5 – 7.0} {2.5}
Within operating range MPa Min. 0.15 0.07
At low idling
{kg/cm2} {Min. 1.5} {0.7}
Oil pressure
MPa 0.29 – 0.59 0.21
• SAE10W oil At high idling
{kg/cm2} {3.0 – 6.0} {2.1}
At low idling
{kg/cm2} {Min. 1.0} {0.7}
Oil temperature • All speed range (In oil pan) °C 90 – 110 120
Fuel injection timing • Before compression top dead center ° 11 ± 1 11 ± 1
Air compressor belt • Deflection under pressing force of about 98 N {10
mm 15 – 18 15 – 18
tension kg}
20-2 D31/37/39EX, PX-21

(1)
D37EX-21, D37PX-21
Engine SAA4D102E-2
Standard
gory new value
machine

+50 +50
Engine speed
Within operating range Low idling rpm 800 +50
800 +50
0 0
(40 – 60°C)

(Boost pressure) {mmHg} {Min. 860} {770}
At sharp Bosch
Max. 4.5 6.5
Exhaust gas color
index
Engine

pressure
Blow-by pressure
MPa 0.34 – 0.69 0.25
{kg/cm2} {3.5 – 7.0} {2.5}
At low idling
{kg/cm2} {Min. 1.5} {0.7}
Oil pressure
MPa 0.29 – 0.59 0.21
{kg/cm2} {3.0 – 6.0} {2.1}
At low idling
{kg/cm2} {Min. 1.0} {0.7}
mm 15 – 18 15 – 18
tension kg}
D31/37/39EX, PX-21 20-3

(1)
D39EX, PX-21
Engine SAA4D102E-2
Standard
gory new value
machine

+50 +50
Engine speed
Within operating range Low idling rpm 800 ± 50
800 ± 50
0 0
(40 – 60°C)

(Boost pressure) {mmHg} {Min. 1,010} {910}
At sharp Bosch
Max. 4.5 6.5
Exhaust gas color
index
Engine

pressure
Blow-by pressure
MPa 0.34 – 0.69 0.25
{kg/cm2} {3.5 – 7.0} {2.5}
At low idling
{kg/cm2} {Min. 1.5} {0.7}
Oil pressure
MPa 0.29 – 0.59 0.21
{kg/cm2} {3.0 – 6.0} {2.1}
At low idling
{kg/cm2} {Min. 1.0} {0.7}
mm 15 – 18 15 – 18
tension kg}
20-4 D31/37/39EX, PX-21

(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS

D31EX, PX-21
Standard
gory new value
machine
• Engine: Stopped
Fuel control lever Low – High mm 150 ± 20 150 ± 20
• Center of lever grip
Forward and • Engine: Stopped
PCCS lever
N → Forward/Reverse mm 29 ± 6 29 ± 6
reverse • Center of lever grip
• Engine: Stopped N – Sharp turn to right/
Steering mm 50 ± 10 50 ± 10
• Center of lever knob left
• Engine: Low idling
Brake pedal mm 78 ± 10 78 ± 10
• Center of pedal
Stroke
• Engine: Stopped
Decelerator pedal mm 68 ± 10 68 ± 10
• Center of pedal
Neutral – Raise mm 47 ± 10 47 ± 20
• Engine: Stopped Neutral – Lower mm 47 ± 10 47 ± 20
Work equipment • Center of lever knob Neutral – Float mm 71 ± 10 71 ± 20
control lever • Angle: Twisting angle Neutral – Left/Right tilt mm 52 ± 10 52 ± 20
of lever
Neutral – Left/Right
° 15 ± 3 15 ± 6
angle
N 29.4 ± 19.6 58.8
• Engine: Stopped Low – High
{kg} {3 ± 2} {6}
Fuel control lever • 20 mm from lever
knob end N 68.6 ± 19.6 108
High → Low
{kg} {7 ± 2} {11}
Forward and N 52.9 ± 9.8 52.9 ± 11.8
N – Forward/Reverse
Operating effort
reverse {kg} {5.4 ± 1.0} {5.4 ± 1.2}

N – Sharp turn to right/ N 40.2 ± 7.8 40.2 ± 9.8
PCCS lever
Steering • Engine: Stopped left {kg} {4.1 ± 0.8} {4.1 ± 1.0}

• Center of lever knob
• Button switch N 6.9 – 12.7 14.7
Shift-up
Shift-up/down {kg} {0.7 – 1.3} {1.5}
switch N 6.9 – 12.7 14.7
Shift-down
{kg} {0.7 – 1.3} {1.5}
• Engine: Low idling N 245 ± 49 343
Brake pedal
• Center of pedal {kg} {25 ± 5} {35}
D31/37/39EX, PX-21 20-5

(1)
Standard
gory new value
machine
• Engine: Stopped N 58.8 ± 19.6 9.8
Decelerator pedal
N 23.5 ± 10 39.2
Neutral – Raise
{kg} {2.4 ± 1.0} {4.0}
Operating effort
N 26.5 ± 10 39.2
Neutral – Lower
{kg} {2.7 ± 10} {4.0}
Work equipment • Engine: Low idling N 70.6 ± 22 118
Neutral – Float
control lever • Center of lever knob {kg} {7.2 ± 2.2} {12.0}
Neutral – Left/Right N 26.5 ± 10 39.2
tilt {kg} {2.7 ± 1.0} {4.0}
Neutral – Left/Right Nm 2.9 – 5.4 8.3
angle {kgm} {0.3 – 0.55} {0.9}
MPa 40.2 – 44.1 39.2 – 45.1
Left
{kg/cm2} {410 – 450} {400 – 460}
• Engine: High idling Forward
• HST oil temperature MPa 40.2 – 44.1 39.2 – 45.1
Right
Main circuit (hydraulic oil temperature): {kg/cm2} {410 – 450} {400 – 460}
pressure Within operating range MPa 40.2 – 44.1 39.2 – 45.1
HST oil pressure
(40 – 60°C) Left

{kg/cm2} {410 – 450} {400 – 460}
• Stall pressure test mode Reverse
MPa 40.2 – 44.1 39.2 – 45.1
Right
{kg/cm2} {410 – 450} {400 – 460}
• Engine: High idling PCCS lever: MPa 3.04 ± 0.29 3.04 ± 0.29
• HST oil temperature Neutral {kg/cm2} {31 ± 3.0} {31 ± 3.0}
Charge circuit (hydraulic oil temperature):
HST
pressure Within operating range PCCS lever: MPa 2.84 ± 0.29 2.84 ± 0.49
(40 – 60°C) Forward or reverse {kg/cm2} {29 ± 3.0} {29 ± 5.0}
2nd gear
Solenoid output pressure
During 2nd speed MPa 3.04 ± 0.29 3.04 ± 0.49

speed selec-
travel {kg/cm2} {31 ± 3.0} {31 ± 5.0}
tion pressure • Engine: High idling
3rd gear • HST oil temperature
During 3rd speed MPa 3.04 ± 0.29 3.04 ± 0.49
speed selec- (hydraulic oil temperature):
travel {kg/cm2} {31 ± 3.0} {31 ± 5.0}
tion pressure Within operating range
(40 – 60°C)
Parking brake Parking brake lever: MPa 3.04 ± 0.29 3.04 ± 0.49
pressure Free {kg/cm2} {31 ± 3.0} {31 ± 5.0}
20-6 D31/37/39EX, PX-21

(1)
Standard
gory new value
machine
• Engine: High idling 1st km/h 3.4 ± 0.2 3.4 ± 0.4
• Quick shift mode
• Reverse travel speed: Forward 2nd km/h 5.6 ± 0.3 5.6 ± 0.6
Set to center 3rd km/h 8.5 ± 0.5 8.5 ± 0.8
(hydraulic oil temperature): 1st km/h 4.1 ± 0.2 4.1 ± 0.4
Within operating range Reverse 2nd km/h 6.5 ± 0.3 6.5 ± 0.6
(40 – 60°C)
• Measure on flat place. 3rd km/h 8.5 ± 0.5 8.5 ± 0.8
Travel speed
• Engine: High idling
MIN km/h 0.6 ± 0.3 0.6 ± 0.4
• Variable shift mode
• Reverse travel speed: Forward
Set to center MAX km/h 8.5 ± 0.5 8.5 ± 0.8
(hydraulic oil temperature): MIN km/h 0.6 ± 0.3 0.6 ± 0.4
Within operating range Reverse
(40 – 60°C)
MAX km/h 8.5 ± 0.5 8.5 ± 0.85
• Measure on flat place.
HST

• 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)
Hydraulic drift of • Travel lock lever: Free
m Max. 3.6 Max. 4.0
travel • Stop machine on slope of 20°
• Posture of machine: With front side up and down
• Hydraulic drift (Hydraulic travel distance) in 1
minute
• Engine: High idling 20.6 +0.78
Work equipment MPa +0 17.6
relief pressure {kg/cm2} {210 +8 {180}
Within operating range (40 – 60°C) +0 }
MPa Min. 1.65 Min. 1.65

Neutral – Raise
{kg/cm2} {Min. 16.8} {Min. 16.8}
Work equipment
MPa Min. 1.37 Min. 1.37

• Engine: High idling Neutral – Lower
{kg/cm2} {Min. 14.0} {Min. 14.0}
Work equipment • HST oil temperature
MPa Min. 2.01 Min. 2.01
PPC valve output (hydraulic oil temperature): Neutral – Float
{kg/cm2} {Min. 21.0} {Min. 21.0}
pressure Within operating range
(40 – 60°C) Neutral – Left/Right MPa Min. 1.72 Min. 1.72
tilt {kg/cm2} {Min. 17.5} {Min. 17.5}
Neutral – Left/Right MPa Min. 1.96 Min. 1.96
angle {kg/cm2} {Min. 20.0} {Min. 20.0}
D31/37/39EX, PX-21 20-7

(1)
Standard
gory new value
machine
• HST oil temperature Raise sec 2.0 ± 0.2 2.5
Blade lifting Within operating range(40 – 60°C)
speed • Between max. lifting height
and ground Lower sec 1.4 ± 0.2 2.1
• For measuring posture, see
Work equipment relief pressure
“Work equipment 1”.

• HST oil temperature Left tilt sec 1.7 ± 0.2 2.1
Blade tilting Within operating range(40 – 60°C)
speed • Between max. left and right
tilting positions Right tilt sec 1.7 ± 0.2 2.1
• HST oil temperature Left angle sec 2.6 ± 0.5 3.3
Blade angling Within operating range(40 – 60°C)
angling positions Right angle sec 2.6 ± 0.5 3.3
Work equipment

Time lag
Blade lifting Within operating range (40 – 60°C)

sec 1.0 Max. 1.5
time lag • Lower blade from max. lifting height and meas-
ure time after blade comes in contact with
ground until starts rising.
• Measure on level and flat place.
• Engine: Stopped
• Lever: Neutral
Hydraulic drift of work equipment
Hydraulic drift • HST oil temperature (hydraulic oil temperature): mm/15

Max. 50 Max. 50
of lifted blade Within operating range (40 – 60°C) min
• Start measurement just after setting.
• Measure lowering distance (h) after 15 minutes.
• For measuring posture, see “Work equipment 4”.
• Engine: Stopped
• Lever: Neutral
Max. 100 Max. 100
of tilted blade Within operating range (40 – 60°C) min
Blade lift
Leakage from cylinder
• Engine: High idling cc/min 1.6 6.5

cylinder
Blade tilt
Within operating range (40 – 60°C) cc/min 1.6 6.5
cylinder
• Fully extend piston rod of cylinder to be meas-
ured and disconnect hose on head side.
Blade angle • Relieve circuit and measure leakage for 1 cc/min 1.5 6.0
cylinder minute.
20-8 D31/37/39EX, PX-21

(1)
D37EX, PX-21
Standard
gory new value
machine
• Engine: Stopped
PCCS lever
Steering mm 50 ± 10 50 ± 10
• Center of pedal
Stroke
• Engine: Stopped
• Center of pedal
of lever
° 15 ± 3 15 ± 6
angle
N 29.4 ± 19.6 58.8
{kg} {3 ± 2} {6}
knob end N 68.6 ± 19.6 108
High → Low
{kg} {7 ± 2} {11}
Forward and N 52.9 ± 9.8 52.9 ± 11.8
Operating effort
reverse {kg} {5.4 ± 1.0} {5.4 ± 1.2}

PCCS lever

• Button switch N 6.9 – 12.7 14.7
Shift-up
Shift-up/down {kg} {0.7 – 1.3} {1.5}
switch N 6.9 – 12.7 14.7
Shift-down
{kg} {0.7 – 1.3} {1.5}
Brake pedal
D31/37/39EX, PX-21 20-9

(1)
Standard
gory new value
machine
Decelerator pedal
N 23.5 ± 10 39.2
Neutral – Raise
{kg} {2.4 ± 1.0} {4.0}
Operating effort
N 26.5 ± 10 39.2
Neutral – Lower
{kg} {2.7 ± 10} {4.0}
Neutral – Float
tilt {kg} {2.7 ± 1.0} {4.0}
angle {kgm} {0.3 – 0.55} {0.9}
MPa 40.2 – 44.1 39.2 – 45.1
Left
{kg/cm2} {410 – 450} {400 – 460}
Right
HST oil pressure
(40 – 60°C) Left

{kg/cm2} {410 – 450} {400 – 460}
MPa 40.2 – 44.1 39.2 – 45.1
Right
{kg/cm2} {410 – 450} {400 – 460}
HST
2nd gear

speed selec-
travel {kg/cm2} {31 ± 3.0} {31 ± 5.0}
travel {kg/cm2} {31 ± 3.0} {31 ± 5.0}
(40 – 60°C)
20-10 D31/37/39EX, PX-21

(1)
Standard
gory new value
machine
• Quick shift mode
• Reverse travel speed: Forward 2nd km/h 5.6 ± 0.3 5.6 ± 0.6
Set to center 3rd km/h 8.5 ± 0.5 8.5 ± 0.8
(hydraulic oil temperature): 1st km/h 4.1 ± 0.2 4.1 ± 0.4
Within operating range Reverse 2nd km/h 6.5 ± 0.3 6.5 ± 0.6
(40 – 60°C)
• Measure on flat place. 3rd km/h 8.5 ± 0.5 8.5 ± 0.8
Travel speed
MIN km/h 0.6 ± 0.3 0.6 ± 0.4
• Variable shift mode
• Reverse travel speed: Forward
Set to center MAX km/h 8.5 ± 0.5 8.5 ± 0.8
(hydraulic oil temperature): MIN km/h 0.6 ± 0.3 0.6 ± 0.4
(40 – 60°C)
MAX km/h 8.5 ± 0.5 8.5 ± 0.85
HST

m Max. 3.6 Max. 4.0
minute
MPa Min. 1.65 Min. 1.65

Neutral – Raise
{kg/cm2} {Min. 16.8} {Min. 16.8}
Work equipment
MPa Min. 1.37 Min. 1.37

{kg/cm2} {Min. 14.0} {Min. 14.0}
MPa Min. 2.01 Min. 2.01
{kg/cm2} {Min. 21.0} {Min. 21.0}
tilt {kg/cm2} {Min. 17.5} {Min. 17.5}
D31/37/39EX, PX-21 20-11

(1)
Standard
gory new value
machine
• HST oil temperature Raise sec 2.0 ± 0.2 2.5
and ground Lower sec 1.4 ± 0.2 2.1

• HST oil temperature Left tilt sec 1.7 ± 0.2 2.1
tilting positions Right tilt sec 1.7 ± 0.2 2.1
• HST oil temperature Left angle sec 2.6 ± 0.5 3.3
angling positions Right angle sec 2.6 ± 0.5 3.3
Work equipment

Time lag

sec 1.0 Max. 1.5
• Engine: Stopped
• Lever: Neutral

Max. 50 Max. 50
of lifted blade Within operating range (40 – 60°C) min
• Engine: Stopped
• Lever: Neutral
Max. 100 Max. 100
of tilted blade Within operating range (40 – 60°C) min
Blade lift
• Engine: High idling cc/min 1.6 6.5

cylinder
Blade tilt
Within operating range (40 – 60°C) cc/min 1.6 6.5
cylinder
Blade angle • Relieve circuit and measure leakage for 1 cc/min 1.5 6.0
cylinder minute.
20-12 D31/37/39EX, PX-21

(1)
D39EX, PX-21
Standard
gory new value
machine
• Engine: Stopped
PCCS lever
Steering mm 50 ± 10 50 ± 10
• Center of pedal
Stroke
• Engine: Stopped
• Center of pedal
of lever
° 15 ± 3 15 ± 6
angle
N 29.4 ± 19.6 58.8
{kg} {3 ± 2} {6}
knob end N 68.6 ± 19.6 108
High → Low
{kg} {7 ± 2} {11}
Forward and N 52.9 ± 9.8 52.9 ± 11.8
Operating effort
reverse {kg} {5.4 ± 1.0} {5.4 ± 1.2}

PCCS lever

• Button switch N 6.9 – 12.7 14.7
Shift-up
Shift-up/down {kg} {0.7 – 1.3} {1.5}
switch N 6.9 – 12.7 14.7
Shift-down
{kg} {0.7 – 1.3} {1.5}
Brake pedal
D31/37/39EX, PX-21 20-13

(1)
Standard
gory new value
machine
Decelerator pedal
N 23.5 ± 10 39.2
Neutral – Raise
{kg} {2.4 ± 1.0} {4.0}
Operating effort
N 26.5 ± 10 39.2
Neutral – Lower
{kg} {2.7 ± 10} {4.0}
Neutral – Float
tilt {kg} {2.7 ± 1.0} {4.0}
angle {kgm} {0.3 – 0.55} {0.9}
MPa 40.2 – 44.1 39.2 – 45.1
Left
{kg/cm2} {410 – 450} {400 – 460}
Right
HST oil pressure
(40 – 60°C) Left

{kg/cm2} {410 – 450} {400 – 460}
MPa 40.2 – 44.1 39.2 – 45.1
Right
{kg/cm2} {410 – 450} {400 – 460}
HST
2nd gear

speed selec-
travel {kg/cm2} {31 ± 3.0} {31 ± 5.0}
travel {kg/cm2} {31 ± 3.0} {31 ± 5.0}
(40 – 60°C)
20-14 D31/37/39EX, PX-21

(1)
Standard
gory new value
machine
• Quick shift mode Forward 2nd km/h 5.6 ± 0.3 5.6 ± 0.6
• Reverse travel speed:
3rd km/h 8.5 ± 0.5 8.5 ± 0.8
Set to center
• HST oil temperature 1st km/h 4.1 ± 0.2 4.1 ± 0.4
(hydraulic oil temperature): 2nd km/h 6.5 ± 0.3 6.5 ± 0.6
(40 – 60°C) 3rd km/h 8.5 ± 0.5 8.5 ± 0.8
Travel speed
• Engine: High idling MIN km/h 0.6 ± 0.3 0.6 ± 0.4
• Variable shift mode Forward
• Reverse travel speed: MAX km/h 8.5 ± 0.5 8.5 ± 0.8
Set to center
• HST oil temperature MIN km/h 0.6 ± 0.3 0.6 ± 0.4
(40 – 60°C) MAX km/h 8.5 ± 0.5 8.5 ± 0.85
HST

m Max. 3.6 Max. 4.0
minute
MPa Min. 1.65 Min. 1.65

Neutral – Raise
{kg/cm2} {Min. 16.8} {Min. 16.8}
Work equipment
MPa Min. 1.37 Min. 1.37

{kg/cm2} {Min. 14.0} {Min. 14.0}
MPa Min. 2.01 Min. 2.01
{kg/cm2} {Min. 21.0} {Min. 21.0}
tilt {kg/cm2} {Min. 17.5} {Min. 17.5}
D31/37/39EX, PX-21 20-15

(1)
Standard
gory new value
machine
• HST oil temperature Raise 2.0 ± 0.2 2.5
and ground Lower 1.7 ± 0.2 2.1

• HST oil temperature Left tilt 1.7 ± 0.2 2.1
tilting positions Right tilt 1.7 ± 0.2 2.1
• HST oil temperature Left angle 2.7 ± 0.5 3.4
angling positions Right angle 2.7 ± 0.5 3.4
Work equipment
Work equipment

Time lag

1.0 Max. 1.5
• Engine: Stopped
• Lever: Neutral
Hydraulic drift • HST oil temperature (hydraulic oil temperature):

Max. 50 Max. 50
of lifted blade Within operating range (40 – 60°C)
• Engine: Stopped
• Lever: Neutral
Hydraulic drift • HST oil temperature (hydraulic oil temperature):
Max. 100 Max. 100
of tilted blade Within operating range (40 – 60°C)
Blade lift
• Engine: High idling 1.6 6.5

cylinder
Blade tilt
Within operating range (40 – 60°C) 1.6 6.5
cylinder
Blade angle • Relieve circuit and measure leakage for 1 1.5 6.0
cylinder minute.
20-16 D31/37/39EX, PX-21

(1)
Performance measuring posture and measuring Work equipment 2: Blade tilting speed
method
Travel 1: Travel deviation
Work equipment 3: Blade angling speed
Travel 2: Hydraulic drift of travel
Work equipment 4: Hydraulic drift of lifted blade
Work equipment 1: Blade lifting speed
D31/37/39EX, PX-21 20-17

(1)
Work equipment 5: Hydraulic drift of tilted blade
20-18 D31/37/39EX, PX-21

(1)
TESTING AND ADJUSTING
List of tools for testing, adjusting, and troubleshooting................................................................................20-102
Sketch of special tool...................................................................................................................................20-104
Measuring engine speed .............................................................................................................................20-105
Measuring intake air pressure (boost pressure) ..........................................................................................20-106
Measuring exhaust temperature..................................................................................................................20-108
Measuring exhaust gas color.......................................................................................................................20- 110
Adjusting valve clearance............................................................................................................................20- 111
Measuring compression pressure ...............................................................................................................20- 113
Measuring blow-by pressure .......................................................................................................................20- 114
Measuring engine oil pressure ....................................................................................................................20- 115
Testing and adjusting fuel injection timing ...................................................................................................20- 116
Bleeding air from fuel circuit ........................................................................................................................20- 118
Adjusting engine stop solenoid linkage .......................................................................................................20- 119
Adjusting engine speed sensor ...................................................................................................................20-120
Replacement of fan belt...............................................................................................................................20-120
Testing and adjusting air conditioner compressor belt tension (WITH CAB) ............................................20-120-1
Adjusting fuel control lever and decelerator pedal.......................................................................................20-121
Testing and adjusting HST oil pressure .......................................................................................................20-124
Measuring HST solenoid valve outlet pressure ...........................................................................................20-128
Testing travel deviation ................................................................................................................................20-130
Adjusting HST motor speed sensor.............................................................................................................20-131
Adjusting parking brake lever ......................................................................................................................20-134
Procedure of simple test of brake performance...........................................................................................20-135
Adjusting brake pedal linkage......................................................................................................................20-136
Method of releasing parking brake (Procedure for emergency escape)......................................................20-137
Testing and adjusting idler clearance ..........................................................................................................20-139
Testing and adjusting track shoe tension.....................................................................................................20-140
Testing and adjusting work equipment oil pressure.....................................................................................20-141
Measuring work equipment PPC valve output pressure..............................................................................20-143
Adjusting play of work equipment PPC valve ..............................................................................................20-145
Adjusting work equipment lock lever ...........................................................................................................20-146
Measuring leakage in work equipment cylinder...........................................................................................20-147
Releasing residual pressure in hydraulic circuit ..........................................................................................20-148
Bleeding air from hydraulic circuit................................................................................................................20-149
Adjusting play of blade center ball...............................................................................................................20-150
Procedure for testing diodes........................................................................................................................20-151
Special functions of monitor panel (EMMS).................................................................................................20-152
Preparation work for troubleshooting for electric system.............................................................................20-193
Pm-clinic ......................................................................................................................................................20-194
D31/37/39EX, PX-21 20-101

(5)
TESTING AND ADJUSTING LIST OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
LIST OF TOOLS FOR TESTING, ADJUSTING, AND

TROUBLESHOOTING
Testing and adjusting item Symbol Part No. Part name Q'ty Remarks
Measuring intake air –101 – 200 kPa
A 799-201-2202 Boost gauge kit 1
pressure (boost pressure) {–760 – 1,500 Hg}
Measuring exhaust
B 799-101-1502 Digital thermometer 1 –99.9 – 1,299°C
temperature
Handy smoke
1 799-201-9001 1
Measuring exhaust checker
C Bosch index: 0 – 9
gas color Commercially
2 Smoke meter 1
available
1 795-799-1131 Gear 1 For 102 Series engine
Adjusting valve clearance D Commercially Air intake side: 0.25 mm,
2 Feeler gauge 1
available Exhaust side: 0.51 mm
Measuring compression 1 795-502-1590 Compression gauge 1 0 – 7 MPa {0 – 70 kg/cm2}
E
pressure 2 795-502-1700 Adapter 1 For 102 Series engine
Measuring blow-by 1 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH2O}
F
pressure 2 795-790-1950 Tool (Nozzle) 1 —
Pressure gauge: 2.5, 6, 40,
799-101-5002 Hydraulic tester 1 60 MPa
1 {25, 60, 400, 600 kg/cm2}
Measuring engine oil
G Digital hydraulic Pressure gauge: 60 MPa
pressure 790-261-1204 1
tester {600 kg/cm2}
Pressure gauge: 1 MPa
2 799-401-2320 Hydraulic tester 1
{10 kg/cm2}
1 795-799-1131 Gear 1
Measuring fuel injection
H 2 795-799-1900 Pin assembly 1 For 102 Series engine
timing
3 795-799-1950 Lock pin 1
799-101-5002 Hydraulic tester 1
1 Digital hydraulic Same as G1
Testing and adjusting HST 790-261-1204 1
J tester
oil pressure
799-101-5220 Nipple 4
2 Size: 10 x 1.25 mm
07002-11023 O-ring 4
1 Digital hydraulic Same as G1
790-261-1204 1
tester
Measuring solenoid valve 799-401-3100 Adapter 1 Size: 02
K
output pressure for HST 2
799-401-3200 Adapter 1 Size: 03
799-101-5230 Nipple 1
3 Size: 14 x 1.5 mm
07002-11423 O-ring 1
Adjusting HST motor
L 791T-265-1110 Wrench 1 a See sketch of special tool
speed sensor
Method of releasing park- 1 790-190-1500 Pump assembly 1 —
ing brake (Procedure for M 799-101-5220 Nipple 4
emergency escape) 2 Size: 10 x 1.25 mm
07002-11023 O-ring 4
20-102 D31/37/39EX, PX-21

(5)
TESTING AND ADJUSTING LIST OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
1 Digital hydraulic
Testing and adjusting work 790-261-1204 1
N tester Same as J
equipment oil pressure
790-101-5220 Nipple 4
2
07002-11023 O-ring 4
Measuring work 1 Same as G1
Digital hydraulic
equipment PPC valve P 790-261-1204 1
tester
output pressure
2 799-401-3100 Adapter 1 Size: 02
Measuring leakage in work Commercially
Q Measuring cylinder 1
equipment cylinder available
799-601-4101
or
799-601-4201
or T-adapter assembly
799-601-9000
or
Diagnosis for engine 799-601-9200
related controller, sensor, — For DT2P (Fuel level sensor)
actuator and harness
Fo r DT2P (F uel system air
bleeding pump)
799-601-9020 • T-adapter for DT For DT2P (Engine coolant tem-
perature sensor)
For DT2P (Engine speed sen-
sor)
799-601-7000
or
799-601-7100
799-601-7400
or
799-601-8000
799-601-7020 • T-adapter for X For X2P
799-601-7040 • T-adapter for X For X4P
799-601-7090 • T-adapter for M For M2P
799-601-7130 • T-adapter for M For M6P
For SWP8P (Except 799-601-
799-601-7060 • T-adapter for SWP
Diagnosis for chassis 8000)
related controller, sensor, — For X1P (Except 799-601-7000
actuator and harness 799-601-7010 • T-adapter for X
and 799-601-7100))
799-601-4101
or
799-601-4201
799-601-9000
or
799-601-9200
799-601-9020 • T-adapter for DT For DT2P
799-601-9000
799-601-9200
D31/37/39EX, PX-21 20-103

(5)
LIST OF TOOLS FOR TESTING, ADJUST-
TESTING AND ADJUSTING ING, AND TROUBLESHOOTING
• T-adapter for DT
799-601-9060 For DT8P (Gray)
(Gray)
799-601-9070 For DT8P (Black)
(Black)
799-601-9110 For DT12P (Gray)
(Gray)
799-601-9120 For DT12P (Black)
(Black)
Diagnosis for chassis • T-adapter for DT
related controller, sensor, — 799-601-9130 For DT12P (Green)
(Green)
actuator and harness
799-601-7500 T-adapter assembly
799-601-7520 • T-adapter for 070 For 070-12P
799-601-7550 • T-adapter for 070 For 070-20P
799-601-9300 T-adapter assembly
• T-adapter for
799-601-9360 For DRC26-24P
DRC26
• T-adapter for
799-601-9350 For DRC26-40P
DRC26
OUT OF KIT
799-601-7320 T-adapter SWP For SWP16P
Measuring water tempera-
— 799-101-1502 Digital thermometer 1 Same as B
ture and oil temperature
Measuring operating effort 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
—
and pressing force 79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
Measuring stroke and Commercially
— Scale 1 —
hydraulic drift available
Measuring work Commercially
— Stopwatch 1 —
equipment speed available
Measuring voltage and Commercially
— Circuit tester 1 —
resistance available
20-103-1 D31/37/39EX, PX-21

(5)
TESTING AND ADJUSTING SKETCH OF SPECIAL TOOL
SKETCH OF SPECIAL TOOL

Note: We will not be liable for any result of use of special tools manufactured according to the following drawing.
L: Wrench (791T-265-1110)
20-104 D31/37/39EX, PX-21

(1)
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED

★ Measure the engine speed under the following
condition.
• Engine coolant temperature: Within operat-
ing range
• 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 pre-
pare for measurement of the engine speed.
★ For the operating method, see “Special func-
tions of monitor panel (EMMS)”.
• Monitoring code: 01002-ENG SPEED
• 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

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

in the high idle position.
2) Set the PCCS lever and work equipment
control lever in neutral and press the decel-
erator pedal and measure the engine speed.
★ The engine speed when the decelerator ped-
al is pressed to the stroke end is the same as
the low idle speed.
D31/37/39EX, PX-21 20-105

(4)
TESTING AND ADJUSTING MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
MEASURING INTAKE AIR 3. Turn the starting switch ON, set the monitor
panel in the “Adjustment mode”, and prepare for
PRESSURE (BOOST PRESSURE) stalling the HST.
★ When performing this operation, set the
★ Measuring instruments for intake air pressure parking brake lever in the LOCK position and
(boost pressure) the PCCS lever in the neutral position.
Symbol Part No. Name tions of monitor panel (EMMS)”.
A 799-201-2202 Boost gauge kit • Adjustment code: 3016-STALL CHECK
k When installing and removing the measuring in-

struments and measuring the intake air pres-
sure, take care not to touch a hot part or a rotary
part of the engine.
★ Measure the intake air pressure (boost pressure)
under the following condition.
ing range
1. Open the left engine side cover and remove

intake air pressure pickup plug (1) from the air
4. Run the engine at a medium or higher speed
intake connector.
and drain the oil from the hose.
★ 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.
★ If Pm kit (A) is available, you may drain the
oil by using the air-bleeding coupling (790-
261-1130) in that kit.
★ If oil is left in the hose, the gauge does not
work. Accordingly, be sure to drain the oil.
5. While keeping the parking brake lever in the

LOCK position, set the work equipment lock
lever in the FREE position and raise the blade to
the stroke end.
2. Install nipple [1] of boost gauge kit A and con- ★ Stall the HST with the parking brake lever in
nect them to boost gauge [2]. the LOCK position.
20-106 D31/37/39EX, PX-21

(1)
TESTING AND ADJUSTING MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
6. While running the engine at high idle, operate

PCCS lever in the forward or reverse position to
stall the HST and relieve the blade circuit by
raising the blade, and then measure the intake
air pressure (boost pressure).
★ If the PCCS lever is set in the forward or re-
verse position, the HST stalls. If the PCCS
k While the HST is stalled, the oil temperature

lever is returned, stalling of the HST stops.
rises sharply and locally. Accordingly, do

not stall the HST continuously for more than
30 seconds.
7. After finishing measurement, remove the mea-

suring instruments and return the removed
parts.
D31/37/39EX, PX-21 20-107

(4)
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST 3. When measuring the maximum exhaust temper-

ature for troubleshooting, observe the following
TEMPERATURE procedure.
Operate the machine actually and measure the
★ Measuring instruments for exhaust temperature maximum exhaust temperature.
★ Set the digital thermometer in the PEAK
Symbol Part No. Name mode.
B 799-101-1502 Digital thermometer ★ The exhaust temperature largely depends
on the ambient temperature (intake air tem-
k Install and remove the measuring instrument af-

perature of the engine). Accordingly, if any
abnormal value is obtained, correct it by the
ter the exhaust manifold is cooled. following calculation.
★ Measure the exhaust temperature under the fol- • Corrected value [°C] = Measured value + 2 ×
lowing condition. (20 – Ambient temperature)
ing range
1. Open the right engine side cover and remove

exhaust temperature pickup plug (1) from the
exhaust manifold.
4. When measuring the exhaust temperature peri-

odically for preventive maintenance (Pm Clinic),
observe the following procedure.
1) Turn the starting switch ON, set the monitor
panel in the “Adjustment mode”, and pre-
pare for stalling the HST.
parking brake lever in the LOCK position and
2. Install sensor [1] of digital thermometer B and the PCCS lever in the neutral position.
connect them to meter [2]. ★ For the operating method, see “Special func-
★ Clamp the wiring harness of the digital ther- tions of monitor panel (EMMS)”.
mometer so that it will not touch a hot part • Adjustment code: 3016-STALL CHECK
during measurement.
2) Start the engine and keep the parking brake

lever in the LOCK position.
★ Stall the HST with the parking brake lever in
the LOCK position.
20-108 D31/37/39EX, PX-21

(1)
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
3) While running the engine at high idle, oper-

ate PCCS lever in the forward or reverse
position to stall the HST and measure the
exhaust temperature.


30 seconds.

parts.
D31/37/39EX, PX-21 20-109

(4)
TESTING AND ADJUSTING MEASURING EXHAUST GAS COLOR
MEASURING EXHAUST GAS

COLOR
★ Measuring instruments for exhaust gas color
Symbol Part No. Name

1 799-201-9000 Handy smoke checker
C Commercially
2 Smoke meter
available
k When installing and removing the measuring in-

struments, take care not to touch a hot part.
★ If an air source and an electric power source are 2) Connect the probe hose, receptacle of the
not available in the field, use handy smoke accelerator switch, and air hose to smoke
checker C1. When recording official data, use meter C2.
smoke meter C2. ★ Limit the supplied air pressure to 1.5
★ Measure the exhaust gas color under the follow- MPa {15 kg/cm2}.
ing condition. 3) Connect the power cable to a receptacle of
• Engine coolant temperature: Within operat- AC socket.
ing range ★ Before connecting the cable, check that
the power switch of the smoke meter is
1. Measuring with handy smoke checker C1 turned OFF.
1) Stick a sheet of filter paper to smoke checker 4) Loosen the cap nut of the suction pump and
C1. fit the filter paper.
2) Insert the exhaust gas intake pipe in ★ Fit the filter paper securely so that the
exhaust pipe (1). exhaust gas will not leak.
3) Run the engine. 5) Turn on the power switch of smoke meter
4) Accelerate the engine suddenly or run it at C2.
high idling 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 idling and press the accelerator pedal
5) Remove the filter paper and compare it with of smoke meter C2 and collect the exhaust
the attached scale. gas into the filter paper.
6) After finishing measurement, remove the 8) Place the contaminated filter paper on the
m easuri ng in st rume nt and ret urn th e clean filter paper (at least 10 sheets) in the
removed parts. filter paper holder and read the indicated
value.
2. Measuring with smoke meter C2 9) After finishing measurement, remove the
1) Insert probe [1] of smoke meter C2 in the m easuri ng in st rume nt and ret urn th e
outlet of exhaust pipe (1) and fix it to the removed parts.
exhaust pipe with a clip.
20-110 D31/37/39EX, PX-21

(1)
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE 4. Remove plug (2) of the fuel injection pump and
turn over timing pin (3), then crank the flywheel
CLEARANCE forward with gear D1 until the cut of the pin
meshes with projection (a) in the pump.
★ Adjusting instruments for valve clearance ★ Since you cannot push the timing pin on the
front timing gear side, use the timing pin on
Symbol Part No. Name the fuel injection pump side to set the No. 1
1 795-799-1131 Gear cylinder to the compression top dead center.
★ When the pin meshes, make match marks
D Commercially
2 Feeler gauge on the crank pulley and front timing gear
available case.
1. Open the right and left engine side covers and

remove the air cleaner assembly and muffler
and bracket assembly.
2. Remove all the cylinder head covers.
5. When the timing pin meshes, adjust the clear-

ances of the valves marked q in the valve
arrangement drawing according to the following
procedure.
3. Remove the flywheel housing cap and set gear

D1 to the flywheel.
D31/37/39EX, PX-21 20-111

(1)
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
1) Insert feeler gauge D2 in the clearance (b)

between rocker arm (4) and valve stem (5)
and adjust the clearance with adjustment
screw (6).
★ While the feeler gauge is inserted, tight-
en the adjustment screw to a degree that
the feeler gauge moves lightly.
2) Fix adjustment screw (6) and tighten locknut
3 Locknut:
(7).
24 ± 4 Nm {2.45 ± 0.41 kgm}

★ After tightening the locknut, check the
valve clearance again.
★ After adjusting all the valves marked with
q, go to the next step.
6. Rotate the crankshaft forward by 1 turn with

gear D1 to match the match marks made on the
crank pulley and front timing gear cover accu-
rately.
7. When the match marks are matched to each

other, adjust the clearances of the valves
marked with Q in the valve arrangement draw-
ing.
★ Adjust the valve clearances according to
step 5.
8. After finishing adjustment, return the removed
3 Head cover mounting bolt:

parts.
24 ± 4 Nm {2.45 ± 0.41 kgm}
20-112 D31/37/39EX, PX-21

(1)
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION 4. Install adapter E2 to the nozzle holder mounting

part, then connect gauge [1] of compression
PRESSURE
3 Adapter: 60 ± 9 Nm {6.12 ±0.92 kgm}
gauge E1.
★ Measuring instruments for compression pres-

sure

1 795-502-1205 Compression gauge
E
2 795-502-1700 Adapter
k When measuring the compression pressure,

take care not to burn yourself on the exhaust
manifold, muffler, etc. or get caught in a rotating
part.
★ Measure the compression pressure under the
following condition.
• Engine oil temperature: 40 – 60°C 5. Disconnect terminals CN-T17 and CN-T18 (2) of
the engine stop solenoid.
1. Run the engine and warm up the engine oil tem- ★ Tape the disconnected terminals so that they
perature to 40 – 60°C. will not touch a metallic part.
★ Since the air cleaner assembly and muffler
and bracket assembly must be removed be-
fore adjustment of the valve clearance, warm
up the engine first.
2. Adjust the valve clearance.

★ See ADJUSTING VALVE CLEARANCE.
3. Remove nozzle holder (1) of the cylinder to be

measured.
6. Turn the starting switch ON and prepare for

measuring the engine speed.
★ See MEASURING ENGINE SPEED.
7. Crank the engine with the starting motor and

measure the compression pressure.
★ Read the pressure when the pointer of the
compression gauge is stabilized.
★ While measuring the compression pressure,
measure the engine speed, too, and check
that it is in the measurement condition range.

parts.
2 Nozzle holder: Seizure prevention
3 Nozzle holder:
compound (MOLYCOAT 100)
60 ± 9 Nm {6.12 ± 0.92 kgm}
D31/37/39EX, PX-21 20-113

(1)
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY
PRESSURE
★ Measuring instrument for blow-by pressure

1 799-201-1504 Blow-by checker
F
2 795-790-1950 Tool (Nozzle)
★ Measure the blow-by pressure under the follow-

ing condition.
ing range 4. While keeping the parking brake lever in the
• HST oil (Hydraulic oil) temperature: Within LOCK position, set the work equipment lock
operating range (40 – 60°C) lever in the FREE position and raise the blade to
the stroke end.
1. Open the right engine side cover and pull out ★ Stall the HST with the parking brake lever in
blow-by hose (1). the LOCK position.
2. Install nozzle tool F2 to blow-by hose (1) and 5. While running the engine at high idle, operate
connect it to gauge [1] of blow-by checker F1. PCCS lever in the forward or reverse position to
stall the HST and relieve the blade circuit by
raising the blade, and then measure the blow-by
pressure.


30 seconds.
3. Turn the starting switch ON, set the monitor

panel in the “Adjustment mode”, and prepare for
stalling the HST.
parking brake lever in the LOCK position and
the PCCS lever in the neutral position.
• Adjustment code: 3016-STALL CHECK

parts.
20-114 D31/37/39EX, PX-21

(4)
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL 3. Run the engine and measure the oil pressure at
low idle and high idle.
PRESSURE
★ Measuring instruments for engine oil pressure

799-101-5002 Hydraulic tester
1
G 790-261-1203 Digital hydraulic tester
2 799-401-2320 Hydraulic tester
★ Measure the engine oil pressure under the fol-

lowing condition.
ing range
1. Open the right engine side cover and remove
parts.
engine oil pressure pickup plug (1) of the oil filter
head.
2. Install adapter [1] and nipple [2] of hydraulic

tester G1 and connect them to hydraulic tester
G2.
D31/37/39EX, PX-21 20-115

(4)
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING

FUEL INJECTION TIMING
★ Testing and adjusting instruments for fuel injec-
tion timing

1 795-799-1131 Gear
H 2 795-799-1900 Pin assembly
3 795-799-1950 Lock pin
Testing 4. Remove plug (3) of the fuel injection pump.
1. Open the left engine side cover and remove 5. Turn over and insert timing pin (4) of the fuel
work equipment pump assembly (1). injection pump and check that its cut is fitted to
6
projection (a) in the pump.
Hydraulic tank: 47 l ★ If you can insert the timing pin smoothly, the
injection timing is correct.
★ If you cannot insert the timing pin, the injec-
tion timing is not correct. In this case, adjust
the injection timing.
★ If it is difficult to check with the timing pin in-
stalled to the fuel injection pump, you may
use metallic pin assembly H3.
2. Remove the flywheel housing cap and set gear

H1 to the flywheel.
3. Rotate the crankshaft forward with tool H1 until

timing pin (2) is pushed in the front cover, and
then fix the timing gear.
★ For the ease of positioning, remove the tim-
ing pin on the fuel injection pump side and 6. After finishing testing, remove the measuring
rotate the crankshaft, watching the projec- instruments and return the removed parts.
tion in the pump (See ADJUSTING VALVE ★ Return timing pin (2) of the drive gear and
CLEARANCE). timing pin (4) of the fuel injection pump with-
★ Since the injection timing must be adjusted out fail.
accurately, be sure to fix the drive gear with ★ When adjusting, leave gear H1 and timing
the pin. pin (2) as they are.
★ Push-in depth of pin: Approx. 8 mm
★ If it is difficult to check with the timing pin in-
stalled to the engine, you may use metallic
pin assembly H2.
20-116 D31/37/39EX, PX-21

(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
Adjusting
★ If the fuel injection timing is not correct, adjust it
according to the following procedure.
1. Using timing pin (2) of the drive gear, check that
the drive gear is fixed.
★ If the timing pin was returned after testing, in-
sert it again according to the testing proce-
dure.
2. Remove the fuel injection pump assembly.

★ See DISASSEMBLY AND ASSEMBLY, Re-
moval, installation of fuel injection pump as-
sembly.
3. Turn over and insert timing pin (4) of the fuel

injection pump and rotate the pump shaft to fit
the cut of the pin to projection (a) in the pump.
★ After adjusting the timing of the fuel injection
pump, tighten and fix plug (3).
4. Install the fuel injection pump assembly.

★ See DISASSEMBLY AND ASSEMBLY, Re-
moval, installation of fuel injection pump as-
sembly.
5. After finishing adjustment, remove the adjusting

instruments and return the removed parts.
★ Before starting the engine, check that timing
pin (2) of the drive gear and timing pin (4) of
the fuel injection pump are returned.
D31/37/39EX, PX-21 20-117

(1)
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT
BLEEDING AIR FROM FUEL 2. Bleeding air manually

★ If the fuel circuit air bleeding pump is not in-
CIRCUIT stalled, bleed air according to the following
procedure.
★ If the fuel injection pump or the fuel circit pipings ★ Air can be bled in a shorter time if the fuel
have been removed and installed, bleed air ac- tank is full.
cording to the following procedure. 1) Open the left engine side cover and loosen
air bleed plug (1) on the fuel filter head.
1. Bleeding air automatically 2) Loosen the knob of feed pump (2) and move
it up and down several tens of times.
★ If the fuel circuit air bleeding pump is in- ★ Move the knob until bubbles do not
stalled, bleed air according to the following come out of the air bleed plug any more.
procedure. 3) Tighten the air bleed plug (1).
★ Air can be bled in a shorter time if the fuel
tank is full.
1) Set the fuel control lever to the medium
speed (half) position and set the parking
brake lever in the LOCK position.
2) Turn the starting switch from the ON posi-
tion to the START position and hold it there
for 20 seconds.
★ The fuel circuit air bleeding pump oper-
ates only while the starting switch is in
the START position. Accordingly, keep
the starting switch in the START position
for 20 seconds to bleed all air, even after
the engine is started.
★ If the engine does not start, do not crank
it for more than 20 seconds to prevent
burning of the starting motor.
3) If the engine does not start in step 2), stop
the starting motor for 30 seconds, then
repeat step 2).
4) After the engine starts, keep its speed at low
idle and check that its rotation is stable.
★ If the engine stops, repeat step 2).
20-118 D31/37/39EX, PX-21

(4)
TESTING AND ADJUSTING ADJUSTING ENGINE STOP SOLENOID LINKAGE
ADJUSTING ENGINE STOP 3. Connect terminals CN-T17 and CN-T18 (4) of

the solenoid.
SOLENOID LINKAGE ★ When connecting the terminals, be sure to
turn the starting switch OFF.
★ If the fuel injection pump or the engine stop sole-
noid has been removed and installed, adjust
them according to the following procedure.
1. Assemble solenoid (1) and rod (2) to the speci-

fied dimensions.
• Rod length (a): 163 mm
• Screwing depth on solenoid side (b): 6 mm
• Screwing depth on joint side (c): 15 mm
2 Threads of rod: Adhesive (LT-2)

• Screwing depth on rod end side (d): 12 mm
★ Apply the adhesive to part (e) of the rod. Do

not apply it range (f) of 5 mm from each rod
3 Locknut: 3.9 – 5.9 Nm {0.4 – 0.6 kgm}

end to prevent fixing of the joint.
4. Turn the starting switch ON and operate the
solenoid.
5. Adjust the installed position of solenoid and rod

assembly (3) so that clearance (h) between stop
lever (5) of the fuel injection pump and stopper
(6) will be the specified value when the solenoid
is operated.
• Clearance (h): 1 – 2 mm
k If the clearance is 0 mm, the solenoid may

burn in a short time. Accordingly, be sure to
secure the specified clearance.
2. Install solenoid and rod assembly (3) to the

engine.
★ Install the solenoid and rod assembly with
the grease fitting at the rod end up.
★ The bracket (4) has oblong mounting holes.
Install the solenoid and rod assembly to po-
sition (g) nearer to the fuel injection pump
side.
6. Tighten the mounting bolts of the solenoid and

rod assembly permanently, operate the solenoid
several times, and check the following points.
1) The solenoid is not heated when it is oper-
ated.
2) The bellows and linkage of the solenoid do
not interfere with the other engine parts.
D31/37/39EX, PX-21 20-119

(1)
ADJUSTING ENGINE SPEED SENSOR
TESTING AND ADJUSTING REPLACEMENT OF FAN BELT
ADJUSTING ENGINE SPEED REPLACEMENT OF FAN BELT

SENSOR ★ Since the auto-tensioner is installed, the fan belt
★ If the engine speed sensor has been removed tension usually does not need to be checked or
and installed or its signal contains an error, ad- adjusted.
k Stop the machine on a level ground and lower
just it according to the following procedure.
★ Remove engine speed sensor (1) before adjust- the work equipment to the ground.
ing it and check that its tip is free from steel chips
(The engine speed sensor is installed to the left 1. Remove the fan.
top of the flywheel housing). 2. Put wrench [1] in part "A" (width across flats:
12.7 mm) of tensioner assembly (1) and turn it in
the direction to decrease the tension of fan belt
(2).
k Set the wrench securely to part "A" of ten-
sioner assembly (1) before turning it. (The
spring of tensioner assembly (1) is strong. If
the wrench is set incompletely and turned, it
comes off and that is very dangerous.)
k Take care not to catch your finger between
the pulley and fan belt (2) during work.
1. Screw in sensor (1) until its tip touches the tooth
2 Threads: Gasket sealant (LG-6)

tip of flywheel ring gear (2).
2. Return sensor (1) by the specified angle.

★ Returning angle of sensor: 1 ± 1/6 turn
★ After this adjustment, clearance (a) between
the sensor tip and gear tooth tip is 1.25 –
1.75 mm.
3. Remove and replace fan belt (2).
2 Nut: 49.0 – 68.6 Nm {5 – 7 kgm}

3. Fixing sensor (1), tighten nut (3). ★ Check each pulley for breakage and crack-
ing.
k After removing the fan belt and installing a
new belt, return tensioner assembly (1)
slowly and carefully.
4. After finishing adjustment, check that the moni-

tor panel displays the engine speed normally in
the “Real-time monitoring mode”.
• Monitoring code: 01002-ENG SPEED
20-120 D31/37/39EX, PX-21

(5)
TESTING AND ADJUSTING AIR CONDI-
TESTING AND ADJUSTING TIONER COMPRESSOR BELT TENSION

AIR CONDITIONER
COMPRESSOR BELT
TENSION (WITH CAB)
Testing
1. Open the left engine side cover.
2. Press the intermediate point of the belt between

the fan pulley and compressor pulley with a fin-
ger and measure deflection “a” of the belt.
• Force to press belt: 98 N {10 kg}
• Deflection: 15 – 18 mm
Adjusting
★ If the deflection of the belt is abnormal, adjust it

1. Loosen 4 compressor mounting bolts (1).
2. Loosen locknut (2) and adjust the belt tension

with adjustment bolt (3).
3. Tighten locknut (2) and 4 mounting bolts (1).
D31/37/39EX, PX-21 20-120-1

(5)
ADJUSTING FUEL CONTROL LEVER AND
TESTING AND ADJUSTING DECELERATOR PEDAL
ADJUSTING FUEL CONTROL 2. Adjusting bracket assembly

1) Adjust stopper bolt (8) to the specified
LEVER AND DECELERATOR dimension.
PEDAL • Installed height (d) of stopper bolt: 9 mm
2) Adjust the installed length of rod (10) so that
★ If the fuel control linkage (fuel control lever and the installed length of spring (9) will be
decelerator pedal assembly) has been removed proper.
and installed, adjust it according to the following • Installed length (e) of spring:
procedure. 164 – 166 mm
• Installed length (f) of rod: 241.5 mm
1. Adjusting fuel control lever
1) Adjust stopper bolt (1) to the specified
dimension.
• Installed height (a) of stopper bolt: 19 mm
2) Assemble rod assembly (2) and connect it
to fuel control lever (3) and lever (4).
• Distance (b) between pins of rod assem-
bly: 122 mm
• Screwing depth in yoke at each end of
rod: 10 mm
3) Assemble rod assembly (5) and connect it
to levers (4) and (6).
• Distance (c) between pins of rod assem-
bly: 101 mm
• Screwing depth in yoke at each end of
rod: 12 mm
4) Pull fuel control lever (3) toward the high idle
position until it touches the stopper bolt.
5) Assemble cable assembly (7), connect it to
lever (6), and secure it to the floor frame.
• Screwing depth in yoke at end of cable:
15 mm
D31/37/39EX, PX-21 20-121

(4)
3. Adjusting decelerator pedal linkage 4. Adjusting whole assembly

1) Adjust the full position of decelerator pedal 1) Connect rod (14) and adjust its length so
(11) properly with stopper bolt (12). that governor lever (15) of the fuel injection
• Height (g) of decelerator pedal: 52 mm pump will touch the full stopper.
• Distance (j) between rod pins:
D31EX, PX-21: 355 – 371 mm
D37EX, PX-21: 355 – 371 mm
D39EX, PX-21: 365 – 375 mm
★ After adjusting the rod length, check that
there is not clearance between the pin at
part (k) and oblong hole of the rod.
2) Check that the fuel control lever is at the
high idle position and connect cable (7) to
lever (16).
2) Assemble cable assembly (13), connect it to

decelerator pedal (11), and secure it to the
floor frame.
• Screwing depth in yoke at end of cable:
11 mm
• Installed dimension (h) of cable: 169 mm
3) Install the stopper plate of the fuel control

lever according to the following procedure.
i) Remove rubber cover (17).
ii) Loosen mounting bolt (19) of stopper
plate (18).
iii) Move stopper plate (18) backward.
iv) Push back fuel control lever (3) toward
the front of the machine until the gover-
nor lever of the fuel injection pump
touches the low idle stopper.
★ You may start the engine and adjust
the fuel control lever while measur-
ing the engine speed in the real-time
monitoring mode.
★ For the operating method, see “Spe-
cial func tions of monitor panel
(EMMS)”.
• Monitoring mode: 01002-ENG SPEED
• Speed for adjustment: 825 ± 25 rpm
v) While stopper face (m) of stopper plate
(18) is in contact with fuel control lever
(3), tighten mounting bolt (19).
20-122 D31/37/39EX, PX-21

(4)
7) After finishing adjustment, check the follow-

ing points.
i) Each rod end (21) rotates smoothly.
ii) Each yoke (22) slides smoothly.
4) Fix the decelerator pedal to the full position

as shown in the following figure, start the
engine, and prepare for measuring the
engine speed in the real-time monitoring 5. Executing adjustment mode
mode. After finishing all the adjustment, initialize all the
• Pedal height (n) at full position: Approx. related items in the adjustment mode of the
203 mm monitor panel.
• Monitoring mode: 01002-ENG SPEED ★ For the operating method, see "Special func-
5) Set the fuel control lever in the high idle tions of monitor panel (EMMS)"
position and adjust the engine speed at this • Adjustment code: 3009-DECEL HI>LO
time by adjusting screwing depth (p) of • Adjustment code: 3010-THROTTLE LO
cable (13) in the yoke.
• Engine speed for adjustment:
D31EX, PX-21: 2,200 +– 100
50
rpm
+ 50
D37EX, PX-21: 2,200 – 100 rpm
D39EX, PX-21: 2,400 +– 100
50
rpm
6) Press the decelerator pedal to the stroke
end and adjust the engine speed at this time
by adjusting installed height (q) of stopper
bolt (20) of decelerator pedal (11).
• Engine speed for adjustment: 825 ± 25 rpm
D31/37/39EX, PX-21 20-123

(4)
TESTING AND ADJUSTING TESTING AND ADJUSTING HST OIL PRESSURE
TESTING AND ADJUSTING 2) Start the engine and keep the parking brake
HST OIL PRESSURE ★ Stall the HST with the parking brake le-
ver in the LOCK position.
★ Testing and adjusting instruments for HST oil 3) While running the engine at high idle, oper-
pressure ate PCCS lever in the forward or reverse
position to stall the HST and measure the
Symbol Part No. Name HST main circuit pressure.
799-101-5002 Hydraulic tester ★ If the PCCS lever is set in the forward or
1 reverse position, the HST stalls. If the
790-261-1204 Digital hydraulic tester PCCS lever is returned, stalling of the
J
k While the HST is stalled, the oil temper-

799-101-5220 Nipple HST stops.
2
07002-11023 O-ring ature rises sharply and locally. Accord-
ingly, do not stall the HST continuously
Measuring for more than 30 seconds.
★ Measure the HST oil pressure under the follow-
ing condition. 2. Measuring HST charge circuit pressure
k Loosen the oil filler cap of the hydraulic tank

slowly to release the residual pressure in
1. Measuring HST main circuit pressure the hydraulic tank.
★ Measure the HST main circuit pressure in 1) Remove the inspection cover at the left of
the floor, and then HST charge circuit pres-
k If the HST is stalled while the bypass valve
the “Adjustment mode” of the monitor panel.
sure pickup plug (1) of the 4-spool solenoid
(tow valve) of the parking brake circuit is valve.
closed, the HST equipment may be dam-
aged or it may move beyond your expecta-
tions. Accordingly, do not stall the HST out
of the “Adjustment mode”.
1) Turn the starting switch ON, set the monitor
panel in the “Adjustment mode”, and pre-
pare for stalling the HST.
parking brake lever in the LOCK position
and the PCCS lever in the neutral posi-
tion.
★ For the operating method, see “Special
functions of monitor panel (EMMS)”.
• Adjustment code: 3016-STALL CHECK
• If the HST main circuit pressure is se- 2) Install nipple [1] of hydraulic tester J1 and
lected in the adjustment mode, it is disconnect them to oil pressure gauge [2].
played in MPa. ★ Use the oil pressure gauge of 6 MPa {60 kg/
(The figure shows the item displayed cm2}.
first (engine speed) when the mode is
selected.)
20-124 D31/37/39EX, PX-21

(5)
3) Turn the starting switch ON, set the monitor 6) After finishing measurement, remove the
panel in the “Adjustment mode”, and pre- measuring instruments and return the
pare for stalling the HST. removed parts.
parking brake lever in the LOCK position 3. Measuring HST pump EPC valve output pres-
and the PCCS lever in the neutral posi- sure
k Since the machine will be stopped and driv-

tion.
★ For the operating method, see “Special
functions of monitor panel (EMMS)”. en actually to measure the EPC valve out-
• Adjustment code: 3016-STALL CHECK put pressure, work on a flat place where

there is not an obstacle.

the hydraulic tank.
1) Remove the inspection cover at the left of

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
4) Start the engine and keep the parking brake

★ Stall the HST with the parking brake le-
ver in the LOCK position.
ate PCCS lever in the neutral position and
forward or reverse position to stall the HST
and measure the HST charge circuit pres-
sure.
★ 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.
ature rises sharply and locally. Accord-

ingly, do not stall the HST continuously
for more than 30 seconds.
★ If the HST is not stalled, only the charge
safety valve on the pump side operates.
If the HST is stalled, the charge relief
valve on the motor side operates, too.
D31/37/39EX, PX-21 20-125

(4)
2) Install nipple J2 and connect it to oil pres- Adjusting

sure gauge [2]. ★ The HST main circuit pressure and the HST
★ Use the oil pressure gauge of 6 MPa {60 kg/ pump EPC valve output pressure cannot be ad-
cm2}. justed.
1. Adjusting HST charge circuit pressure (on pump

side)
★ If the HST charge circuit pressure (only
when the HST is in neutral) is abnormal, ad-
just charge safety valve (6) of the HST pump
★ When adjusting charge safety valve (6) of
the HST pump, remove the HST pump un-
dercover.
4 Undercover of HST: 30 kg
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) While the engine is running at high idle, set
the PCCS lever in the neutral position and
forward or reverse position and measure the
EPC valve output pressure.
★ If the EPC valve output pressure is as
follows, it is normal.
EPC valve output
During travel
pressure
1) Fixing adjustment screw (7), loosen locknut
Neutral 0 MPa {0 kg/cm2}
(8).
Travel in F1 Min. 1.0 MPa 2) Turn adjustment screw (7) to adjust the
Travel in R1 {Min. 10 kg/cm2}
pressure.
★ If the adjustment screw is
• turned to the right, the pressure ris-
es.
• turned to the left, the pressure low-
ers.
★ Quantity of adjustment per turn of adjust-
ment screw: Approx. 1.55 MPa {Approx.
15.38 kg/cm2}
3) Fixing adjustment screw (7), tighten locknut
(8).
3 Locknut: 58.8 – 78.5 Nm {6 – 8 kgm}
6) After finishing measurement, remove the

measuring instruments and return the
removed parts.
20-126 D31/37/39EX, PX-21

(5)
4) After finishing adjustment, check that the 4) After finishing adjustment, check that the
HST charge circuit pressure is normal HST charge circuit pressure is normal
according to the measurement procedure according to the measurement procedure
described above. described above.
3. Initializing HST pump EPC valve
2. Adjusting HST charge circuit pressure (on motor The HST pump EPC valve does not need to be
side) adjusted. If it is replaced, however, initialize the
★ If the HST charge circuit pressure (only related items in the adjustment mode of the
when the HST is stalled) is abnormal, adjust monitor panel.
charge relief valve (9) of the HST motor ac- ★ For the operating method, see "Special func-
cording to the following procedure. tions of monitor panel (EMMS)".
★ When adjusting charge relief valve (9) of the • Adjustment code (When adjusting while
HST pump, remove the HST motor covers track shoe is driven idle)
(right and left). 1) 3001-PUMP AJST F
2) 3002-PUMP AJST R
• Adjustment code (When adjusting while ma-
chine is traveling actually)
1) 3003-PU F-UP MAP
2) 3004-PU R-UP MAP
3) 3005-PU F-HF MAP
4) 3006-PU R-HF MAP
1) Fixing adjustment screw (10), loosen lock-

nut (11).
2) Turn adjustment screw (10) to adjust the
pressure.
★ If the adjustment screw is
• turned to the right, the pressure ris-
es.
• turned to the left, the pressure low-
ers.
★ Quantity of adjustment per turn of adjust-
ment screw: Approx. 1.02 MPa {Approx.
10.4 kg/cm2}
3) Fixing adjustment screw (10), tighten lock-
3 Locknut: 58.8 – 78.5 Nm {6 – 8 kgm}

nut (11).
D31/37/39EX, PX-21 20-127

(1)
TESTING AND ADJUSTING MEASURING HST SOLENOID VALVE OUTLET PRESSURE
MEASURING HST SOLENOID

VALVE OUTLET PRESSURE
★ Measuring instruments for HST solenoid valve
outlet pressure

1
790-261-1204 Digital hydraulic tester
799-401-3100 Adapter
K 2
799-401-3200 Adapter
799-101-5230 Nipple 3) If the hoses are disconnected, insert adapt-

3 ers K2 and connect the hoses again.
07002-11423 O-ring 4) Install nipple [1] or nipple K3 of hydraulic
tester K1 to the plug hole and connect it to
★ Measure the HST solenoid valve outlet pressure oil pressure gauge [2].
under the following condition. ★ Use the oil pressure gauge of 6 MPa {60
• HST oil (Hydraulic oil) temperature: Within kg/cm2}.
operating range (40 – 60°C) ★ The figure shows the measuring instru-
ments installed to the outlet hose of the
1. Preparation work 3rd travel speed selection solenoid
★ If the pressures in the 2nd and 3rd travel valve.
speed selection solenoid valves are meas-
ured simultaneously, the operation can be
checked easily.
★ If the pressures in the parking brake solenoid
valve and slow brake solenoid valve are not
measured simultaneously, the operation

cannot be checked.

the hydraulic tank.
the floor.
2) Disconnect solenoid valve outlet hoses (1),
(2), and (3) of the circuit to be measured or
remove oil pressure pickup plug (4). 2. Measuring 2nd travel speed selection solenoid
• Hose (1): 2nd travel speed selection so- valve and 3rd travel speed selection solenoid
lenoid valve valve
• Hose (2): 3rd travel speed selection so- k Since the machine will be stopped and driv-
lenoid valve en actually to measure the 2nd and 3rd travel
• Hose (3): Parking brake solenoid valve speed selection solenoid valves, work on a
• Plug (4): Slow brake solenoid valve flat place where there is not an obstacle.
1) Start the engine and set the travel mode in
the quick shift mode.
2) While running the engine at high idle,
change the travel speed and measure the
solenoid valve output pressure.
★ If the output pressure is as shown in Ta-
ble 1, the solenoid valve is normal.
removed parts.
20-128 D31/37/39EX, PX-21

(5)
TESTING AND ADJUSTING MEASURING HST SOLENOID VALVE OUTLET PRESSURE
3. Measuring parking brake solenoid and slow

brake solenoid
1) Start the engine.
ate the parking brake lever and brake pedal
and measure the solenoid valve output
pressure.
★ The relationship between the output
pressure and operating states of the so-
lenoids is shown in Table 2.
removed parts.
Table 1. Output pressures of 2nd travel speed selection solenoid valve and 3rd travel speed selection
solenoid valve (when normal)
Travel speed and Output pressure of 2nd travel speed Output pressure of 3rd travel speed
Travel mode
travel condition selection solenoid valve selection solenoid valve
Stopped in 1st 0 MPa {0 kg/cm2} 0 MPa {0 kg/cm2}
3.04 ± 0.49 MPa

Quick shift mode Traveling in 2nd 0 MPa {0 kg/cm2}
{31 ± 5 kg/cm2}
3.04 ± 0.49 MPa
Traveling in 3rd 0 MPa {0 kg/cm2}
{31 ± 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
3.04 ± 0.49 MPa 3.04 ± 0.49 MPa
Both are normal
{31 ± 5 kg/cm2} {31 ± 5 kg/cm2}
3.04 ± 0.49 MPa Parking brake has trouble
FREE Released 0 MPa {0 kg/cm2}
{31 ± 5 kg/cm2} (Sticking, etc.)
Slow brake has trouble
0 MPa {0 kg/cm2} 0 MPa {0 kg/cm2}
(Sticking, etc.)
0 MPa {0 kg/cm2} 0 MPa {0 kg/cm2} Both are normal

LOCK Pressed (fully)
3.04 ± 0.49 MPa Slow brake has trouble
0 MPa {0 kg/cm2}
{31 ± 5 kg/cm2} (Sticking, etc.)
★ The operation state (ON/OFF) of the solenoid valve can be checked in the monitoring mode of the monitor
panel (For the operating method, see “Special functions of monitor panel (EMMS)”).
• Monitoring code: 40913-S/T SW4
• From left;
1st: 3rd travel speed selection solenoid valve: ON
2nd: 2nd travel speed selection solenoid valve: ON
3rd: Parking brake solenoid valve: ON
4th: Slow brake solenoid valve: ON
Others: (Unused)
D31/37/39EX, PX-21 20-129

(4)
TESTING AND ADJUSTING TESTING TRAVEL DEVIATION
TESTING TRAVEL DEVIATION
★ Test the travel deviation under the following con- • Monitoring code: 52503-HST L PRES
dition. • Monitoring code: 52501-HST R PRES
• 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.
★ While measuring the travel deviation, check
the HST main circuit pressures on the right
and left sides.
20-130 D31/37/39EX, PX-21

(4)
TESTING AND ADJUSTING ADJUSTING HST MOTOR SPEED SENSOR
ADJUSTING HST MOTOR 3) If the speed sensor is removed from the

HST motor, the oil in the motor case flows
SPEED SENSOR out, even if the residual pressure has been
released. Accordingly, make ready so that
★ Measuring instruments for HST motor speed you can install the new speed sensor imme-
sensor diately.
4) Prepare an oil pan to receive the oil flowing
Symbol Part No. Name out.
L 791T-265-1110 Wrench ★ If you replace the speed sensor quickly,
the oil does not flow out more than 400 cc.
★ It is recommended to manufacture the wrench L
shown in the “Sketch of special tool”. A spanner 2. Removing speed sensor

commercially available, the width across flats of
which is 27 mm, may be worked to the equivalent
dimensions sketch as shown below. (The tight- slowly to release the residual pressure in
ening torque applied to the wrench is about 132 the hydraulic tank.
Nm {13.5 kgm} at maximum.) 1) Remove the HST motor covers (center,
right, and left).
4 Travel motor cover (center): 27 kg

2) Clean around the HST motor and blow air
against it so that foreign matter will not enter
it when you replace the speed sensor.
★ Carefully clean around the speed sensor
in particular.
3) Disconnect connector CN-LRS or CN-RRS
(4) and remove all clamps (5).
★ If the HST motor sensor has been removed and

installed or its signal contains an error, adjust it
1. Preparation work and precautions for adjusting

speed sensor
1) 1) Put the machine in a pit, lower the work

equipment to the ground, and stop the
engine.
★ If a pit is not available, put the rear part of the
track shoe (sprocket side) on a wood block
20 – 30 cm high so that you can work easily. 4) Using wrench L, loosen locknut (6) and turn
2) When replacing the speed sensor, fully and remove speed sensor (7).
move the locknut (1), washer (2), and O-ring ★ Check that the locknut is loosened fully
(3) of the new speed sensor toward the and take care not to twist only the hose.
hose.
D31/37/39EX, PX-21 20-131

(1)
3. Installing and adjusting speed sensor 4) Under the above condition, check match
1) Insert speed sensor (7) in the motor case marks (b) on speed sensor (7) and match
and turn it slowly until it touches the bottom. marks (c) on the mounting plate, and then
★ When inserting the speed sensor in the match the nearer one of match marks (b) to
motor case, take care not to damage its the nearer one of match marks (c) by turning
tip. speed sensor (7).
★ If the speed sensor is tightened too ★ The match marks on the speed sensor
strongly, its tip may be damaged. Ac- are the 2 V-grooves at the hexagonal
cordingly, do not tighten it with a tool but part 27 mm wide across flats. (There
tighten with your hand (Torque: Max. may be 2 white lines on the hexagonal
2.45 Nm {0.25 kgm}). part. Note that those white lines are not
the match marks.)
★ The match marks on the mounting plate
are the 2 punch holes on the seating
face.
★ Since the turning limit for this work is 90 °,
be sure to match the nearer match marks
to each other.
2) When the sensor tip touches the bottom,

measure its projection (a) with slide calipers
and record the result.
★ Standard projection (a) of sensor:
23.4 ± 0.5 mm
★ If the projection of the sensor exceeds
the upper limit (23.9 mm), the sensor is
probably not in contact with the bottom. 5) Check the positions of the match marks
In this case, tighten the sensor further again and tighten locknut (6) with wrench L.
with your hand until it touches the bot- ★ Check that the wrench does not interfere
tom. with a bolt head, etc. and tighten the
★ When loosening and tightening the sen- locknut securely.
3 Locknut:
sor again, move the O-ring back fully to-
ward the hose according “Preparation
work and precautions”. 84 – 132 Nm {8.5 – 13.5 kgm}
★ The difference limit between the match
marks after this work is 30°. If the differ-
ence exceeds 30°, match the match
marks again.
★ If you look at the match marks diagonal-
ly, you may not able to check them accu-
rately. Accordingly, look them in parallel
with the axis of the speed sensor.
3) After checking that the sensor is in contact

with the bottom, return it by 360° (1 turn).
20-132 D31/37/39EX, PX-21

(1)
6) After tightening the locknut, measure projec- 8) Start the engine and check that oil does not
tion (a) of the sensor with slide calipers and leak from the speed sensor.
record the result.
★ Standard projection (a) of sensor: 4. Checking operation of speed sensor
24.9 ± 1.9 mm 1) Set the monitor panel in the ”Dual-time dis-
★ If measured projection (a) of the sensor play monitoring mode”.
is out of the standard, move the O-ring ★ For the operating method, see “Special
back fully toward the hose according to functions of monitor panel (EMMS)”.
“Preparation work and precautions”, and • Monitoring code: 40002-R SPEED
then repeat 1) – 5). • Monitoring code: 40003-L SPEED
★ The difference between the projection ★ If you use the “Dual-time display monitor
measured in 2) and the projection meas- mode”, you can check the right and left
ured in this step is the air gap at the speed sensors simultaneously. You
speed sensor tip. may check 1 speed sensor by 1 with the
“Real-time monitoring mode”, however.
7) Install 4 clamps (5) and connect connector

CN-LRS or CN-RRS (4). 2) Slowly drive the machine forward or in
★ Before inserting the connector, check reverse and check that the travel speed is
that it and terminal are free from dirt and displayed on the monitor panel.
oil. Clean them, blow compressed air ★ The actual travel speed is displayed in
against them, and dry them, if neces- 0.01 km/h on the monitor panel.
sary. 3) After checking the operation of the speed
★ Insert the connector securely until it sensor, check the tightening torque of the
clicks. locknut again and make an OK mark at the
locknut in white paint.
4) Install the HST motor covers (center, right,
and left).
4 Travel motor cover (center): 27 kg
D31/37/39EX, PX-21 20-133

(1)
TESTING AND ADJUSTING ADJUSTING PARKING BRAKE LEVER
ADJUSTING PARKING BRAKE 3. Set the parking brake lever (1) in the LOCK
position and adjust clearance (c) between lever
LEVER (4) and 2 limit switches (5).
★ Clearance (c) between lever and limit switch:
★ If any part related to the parking brake lever has 0 mm
been removed and installed or replaced, adjust ★ When adjusting, do not operate the limit
the parking brake lever according to the following switch.
procedure.
1. Set the parking brake lever (1) in the FREE posi-

tion and adjust installed height (a) of stopper
bolt (2) so that lever (1) will be level.
★ Standard installed height (a) of stopper bolt:
11.3 mm
4. Check that the limit switch is operated as shown

below when the parking brake lever is operated.
• When lever is in LOCK position: Switch is
turned ON
• When lever is in FREE position: Switch is
turned OFF
★ The operation state (ON/OFF) of the limit
2. Set the parking brake lever (1) in the LOCK switches 1 and 2 can be checked in the mon-
position and adjust installed height (b) of stopper itoring mode of the monitor panel
bolt (3). (For the operating method, see “Special
★ Standard installed height (b) of stopper bolt: functions of monitor panel (EMMS)”).
16.7 mm • Monitoring code: 40911-S/T SW2
• Monitoring code: 40911-S/T SW3
20-134 D31/37/39EX, PX-21

(1)
TESTING AND ADJUSTING PROCEDURE OF SIMPLE TEST OF BRAKE PERFORMANCE
PROCEDURE OF SIMPLE
TEST OF BRAKE
PERFORMANCE
★ Carry out the simple test of the brake perform-
ance under the following condition.
• Check point:
Since the test will be carried out while the
machine is traveling, work on a sufficiently
wide place so that you can avoid an accident
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 measuring 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 and set the PCCS

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

pedal and check the stopping condition of the
machine.
★ If the machine stops securely, the brake is
normal.
D31/37/39EX, PX-21 20-135

(4)
TESTING AND ADJUSTING ADJUSTING BRAKE PEDAL LINKAGE
ADJUSTING BRAKE PEDAL LINKAGE
★ If any part related to the brake pedal has been re- 4. After adjusting the linkage, check that brake limit
moved and installed or replaced, adjust the switch (4) operates as explained below.
brake pedal according to the following proce- 1) When brake pedal (1) is pressed to 2nd
dure. spring operation point (e), limit switch (3)
must not be turned ON.
1. Adjust installed dimension (b) of stopper bolt (2) 2) When brake pedal (1) is pressed to the
so that stroke (a) of brake pedal (1) will be the stroke end, limit switch (3) must be turned
specified value. ON.
★ Adjust the pedal stroke without removing the
spring. 5. After finishing all the adjustment, initialize all the
• Specified pedal stroke (a): 89 ± 1 mm related items in the adjustment mode of the
• Standard installed dimension (b) of stopper monitor panel.
bolt: 35 mm ★ For the operating method, see “Special func-
2. Set brake pedal (1) to the 0 position of the • Adjustment code: 0005-BRAKE N-SET
stroke and install brake limit switch (3) so that its • Adjustment code: 3007-BRAKE END
roller end will be in contact with position (c) of
lever (4).
• Contact point (c) of limit switch: 9 – 10 mm
★ After reducing the clearance between the

limit switch and lever to 0 mm, do not operate
the limit switch.
3. Adjust installed dimension (d) of spring (5) and

install it to lever (3) and floor frame.
• Installed dimension (d) of spring: 38.8 ± 0.5 mm
20-136 D31/37/39EX, PX-21

(1)
METHOD OF RELEASING PARKING
TESTING AND ADJUSTING BRAKE (PROCEDURE FOR EMERGENCY
METHOD OF RELEASING ★ After finishing adjustment, open the

PARKING BRAKE valve of the volume pump to release the
(PROCEDURE FOR residual pressure in the pump.
EMERGENCY ESCAPE) ★ After finishing adjustment, remove the
plug (R1/4) and connect the hose and
★ Tools to release parking brake quick coupler [5].
2. Opening HST pump

★ If the machine is towed after the parking
1 790-190-1500 Pump assembly brake is released, the HST motor works as a
M 799-101-5220 Nipple pump to make the oil flow. Accordingly,
2 open the forward travel circuit and reverse
07002-11023 O-ring travel circuit of the HST pump.
★ If the engine cannot be started and the parking k Fit a block to the track shoe securely.
brake of the HST motor cannot be released, re- 1) Remove the undercover of the HST pump.
4 Undercover of HST pump: 30 kg

lease it according to the following procedure.
1. Testing pump assembly M1 2) Loosen locknuts (3) of towed valve (1) for
the left pump towed valve (2) for the right
k If the following work is performed while the pump, and then loosen plugs (4) by 2 turns.
pressure of the pump assembly is abnor- 3) Tighten locknuts (3) lightly and secure them
mal, the brake piston of the HST motor may so that they will not come off when the
be damaged. Accordingly, be sure to test machine is towed.
the pump assembly.
1) Check that pump assembly M1 is connected
in the following order.
[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

the hydraulic tank.
the floor and install pump assembly M1 onto
the floor frame.
2) Remove the hose and quick coupler [5] and 2) Remove lock pin (6) of bypass valve (tow
block the volume pump [1] side with a plug valve) (5) and turn lever (7) down until it
(R1/4). stops.
3) Close the valve of volume pump [1] and 3) Remove plug (8) and install nipple M2.
operate the handle to adjust relief valve [2]
so that it will relieve at the specified pres-
sure.
• Specified relief pressure:
2.7 – 3.1 MPa {28 – 32 kg/cm2}
D31/37/39EX, PX-21 20-137

(5)
TESTING AND ADJUSTING METHOD OF RELEASING PARKING BRAKE (PROCEDURE FOR EMERGEN-
4) Connect the quick coupler at the end of 2) Remove the block of the track shoe and tow
pump assembly M1 to nipple M2. the machine at speed lower than 2 km/h.
k If the supply pressure lowers below 1.5

MPa {15 kg/cm2}, the parking brake is
not released completely (it works par-
tially). Accordingly, keep checking oil
pressure gauge [4] while towing the ma-
chine. If the oil pressure lowers, oper-
ate 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 parking
brake circuit.
4. Releasing parking brake and towing 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 park- ★ After towing the machine to a safe place,
ing brake circuit. take the following remedy without fail to re-
★ Increase the supply pressure until relief turn the machine to the condition before tow-
valve [2] relieves once. ing.
★ Check that the supply pressure is lower 1) Remove pump assembly M1 and nipple M2
than the specified relief pressure with oil and install plug (8).
pressure gauge [4]. 2) Return lever (7) of bypass valve (tow valve)
• Specified relief pressure: (5) and secure it with pin (6).
3) Install the inspection cover to the right of the
k If the supply pressure rises above the
2.7 – 3.1 MPa {28 – 32 kg/cm2}
floor.
specified relief pressure, the brake pis- 4) Return plugs (4) of towed valves (1) and (2)
ton of the HST motor may be damaged. of the HST pump and secure them with lock-
3 Plug and locknut:

Accordingly, if the supply pressure ex- nuts (3).
ceeds the specified relief pressure,
open the valve of the volume pump im- 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
mediately and adjust the relief pressure 5) Install the undercover of the HST pump.
4
by the method in 1.
★ If the supply pressure becomes the Undercover of HST pump: 30 kg
specified relief pressure, the parking
brake is released.
20-138 D31/37/39EX, PX-21

(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING IDLER CLEARANCE
TESTING AND ADJUSTING 3. Tighten mounting bolt (3) of guide plate (2).
IDLER CLEARANCE
Testing
★ If the idler vibrates laterally or it slants so much
that the track shoe comes off or is warn uneven-
ly, the guide plate may be worn. In this case,
check according to the following procedure.
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).
★ Measure clearance (a) on inside and outside
of the right and left idlers.
• Clearance limit (a): Max. 4 mm
Adjusting
★ If the clearance is exceeds the limit, adjust it ac-
cording to the following procedure.
1. Loosen mounting bolt (3) of guide plate (2).

★ 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).
• Adjusted clearance (a): 0.5 – 1.0 mm
• Thickness shim x quantity for new machine:
1.0 mm x 5 pieces (for each place)
D31/37/39EX, PX-21 20-139

(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING TRACK SHOE TENSION

TRACK SHOE TENSION
Testing
1. Drive the machine slowly on a level place, and
then stop it.
★ Do not apply the brake when stopping.
2. Place straight steel bar (1) between the idler and

carri er rol ler and measure cl earance (a)
between the bottom of the steel bar and shoe
grouser.
★ As the steel bar, use an L-shape steel, etc.
which will be deflected less. 2. When tension is low
• Standard clearance (a): 20 – 30 mm 1) Using a grease pump, add grease through
grease fitting (2).
2) After adjusting, check the tension again
ac cording to the proc edure desc ribed
above.
Adjusting
★ If the track shoe tension is abnormal, adjust it ac-
★ When adjusting the track shoe tension, remove
the outer covers from the track frames. ★ You may supply grease until distance (b) be-
tween the idler guide and frame end is 20
1. When tension is too high mm. If the tension is still low, the pin and
1) Loosen valve (1) slowly to discharge the bushing are worn excessively. In this case,
grease. turn over or replace the pin and bushing.
k Since the valve may jump out because

of the high-pressure 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 Valve: 58.8 – 88.2 Nm {6 – 9 kgm}

3) Tighten valve (1).
4) After adjusting, check the tension again

according to the proc edure desc ribed
above.
20-140 D31/37/39EX, PX-21

(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE
TESTING AND ADJUSTING 2. Install nipple N2 and connect it to oil pressure

gauge [1] of hydraulic tester N1.
WORK EQUIPMENT OIL ★ Use the oil pressure gauge of 40 MPa {400
PRESSURE kg/cm2}.
★ Testing and adjusting instruments for work

equipment oil pressure

1
790-261-1204 Digital hydraulic tester
N
799-101-5220 Nipple
2
07002-11023 O-ring
Measuring
★ Measure the work equipment oil pressure under
the following condition. 3. Run the engine at high idle and relieve the blade
• HST oil (Hydraulic oil) temperature: lift, tilt, and angle cylinders one by one at the
stroke end and measure the work equipment oil
pressure.
slowly to release the residual pressure in the hy- ★ The relief pressure of the main relief valve of
draulic tank. the control valve is indicated when each of
the above operation is performed. If only the
1. Open the left engine side cover and remove oil pressure in the angle circuit is low, the
work equipment oil pressure pickup plug (1) centralized safety valve must be defective,
from the work equipment pump outlet piping. since the bottom side and head side of the
angle cylinder are connected to the central-
ized safety valve.

parts.
D31/37/39EX, PX-21 20-141

(5)
TESTING AND ADJUSTING TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE
Adjusting
★ If the oil pressure is abnormal, adjust main relief
valve (2) of the control valve according to the fol-
lowing procedure.
★ When adjusting main relief valve (2) of the con-
trol valve, fold the operator's seat and bracket to-
gether toward the dashboard.
1. Fixing adjustment nut (3), loosen locknut (4).
2. Turn adjustment nut (3) to adjust the pressure.
k Do not remove the adjustment nut.

If it is removed, the internal parts may fall.
★ If the adjustment nut is
• turned to the right, the pressure rises.
• turned to the left, the pressure lowers.
★ Quantity of adjustment per turn of adjustment
nut:
Approx. 19.6 MPa {Approx. 200 kg/cm2}
3 Locknut: 39 – 49 Nm {4 – 5 kgm}
3. Fixing adjustment nut (3), tighten locknut (4).
4. After finishing adjustment, check the oil pres-

sure again according to the measurement pro-
cedure described above.
20-142 D31/37/39EX, PX-21

(1)
MEASURING WORK EQUIPMENT PPC
TESTING AND ADJUSTING VALVE OUTPUT PRESSURE
MEASURING WORK
EQUIPMENT PPC VALVE
OUTPUT PRESSURE
★ Testing and adjusting instruments for work
equipment PPC valve output pressure

1
P 790-261-1204 Digital hydraulic tester
2 799-401-3100 Adapter
4. Run the engine at high idle and operate the
★ Measure the work equipment PPC valve oil pres- blade control lever in the lifting, tilting, and
sure under the following condition. angling direction, and measure the PPC valve
• HST oil (Hydraulic oil) temperature: output pressure each time.

Within operating range (40 – 60°C) ★ Measure the pressure with the blade control
lever at the stroke end in each direction, ex-
slowly to release the residual pressure in the hy- cept the lifting down direction,
draulic tank. ★ Since the output pressures at the lowering
position and floating position in the blade lift-
1. Fold the operator's seat and bracket together ing down direction are different, measure at
toward the dashboard. each position.
2. Disconnect hose (1) of the circuit to be mea-

sured, insert adapter P2, and connect the hose
again.
★ For the circuit to be measured and the hose
to be disconnected, see the connection dia-
gram of the PPC circuit.

parts.
3. Install nipple [1] of hydraulic tester P1 to adapter

P2 and connect them to oil pressure gauge [2].
★ Use the oil pressure gauge of 6 MPa {60 kg/
cm2}.
D31/37/39EX, PX-21 20-143

(5)
TESTING AND ADJUSTING MEASURING WORK EQUIPMENT PPC VALVE OUTPUT PRESSURE
Connection diagram of PPC circuit

★ The positions of the PPC valve ports are seen from the blade control lever (upper) side.
20-144 D31/37/39EX, PX-21

(1)
TESTING AND ADJUSTING ADJUSTING PLAY OF WORK EQUIPMENT PPC VALVE
ADJUSTING PLAY OF WORK

EQUIPMENT PPC VALVE
★If the play of the blade control lever in the lifting
and tilting directions is large, adjust it according

to the following procedure.
slowly to release the residual pressure in the hy-

draulic tank.
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.

★ At this time, take care not to move piston (4).
★ Play of lever:
Max. 3 mm (at center of lever knob)
★ When cap (3) is tightened, the play of the le-
ver is reduced a little. Count in this reduc-
tion, 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.
★ After installing the blade control lever, check
that its play is proper.
D31/37/39EX, PX-21 20-145

(1)
TESTING AND ADJUSTING ADJUSTING WORK EQUIPMENT LOCK LEVER
ADJUSTING WORK EQUIPMENT LOCK LEVER
★ If any part related to the work equipment lock le-

ver has been removed and installed or replaced,
adjust the work equipment lock lever according
★ The details of the PPC lock valve in the drawing
is seen from outside of the machine.
1. Set work equipment lock lever (1) in the FREE

position and adjust the lever to the level position
with stopper bolt (2).
2. Set work equipment lock lever (1) in the LOCK

position and adjust clearance (a) between the
lever and stopper of PPC lock valve (3) to the
specified value with stopper bolt (4).
• Specified clearance (a) between lever and
stopper: 0.1 – 0.5 mm
<Reference>
• Installed length (b) of rod (5): 274.5 mm
20-146 D31/37/39EX, PX-21

(1)
TESTING AND ADJUSTING MEASURING LEAKAGE IN WORK EQUIPMENT CYLINDER
MEASURING LEAKAGE IN 4) Run the engine at high idle and move the
blade control lever to the lowering position
WORK EQUIPMENT to relieve the lift cylinder.
CYLINDER
k Do not move the blade control lever to
★ Measuring instruments for leakage in work the raising position.
equipment cylinder 5) Start measuring the oil leakage 30 seconds
after the relief is started and measure the
Symbol Part No. Name leakage in 1 minute.
Commercially
Q Measuring cylinder measuring instruments and return the
available
removed parts.
★ Measure the leakage in the work equipment cyl- 2. Measuring leakage in blade tilt cylinder
inder under the following condition. 1) Start the engine and raise the blade to about
• HST oil (Hydraulic oil) temperature: 1 m above the ground.
Within operating range (40 – 60°C) 2) Extend the tilt cylinder to the left tilting stroke
end and stop the engine.
k Operate the blade control lever in the

1. Measuring leakage in blade lift cylinder
1) Start the engine and put the front part of the
track shoe (idler side) on a wood block, etc. tilting direction several times within 15
to raise the front part of the machine. seconds after stopping the engine, and
k Raise the front part of the machine to a

then loosen the oil filler cap of the hy-
draulic tank slowly to release the resid-
height where the blade will not touch ual pressure in the cylinder and tank.
the ground when the blade lift cylinder 3) Remove the cylinder cover, disconnect hose
k Set the parking brake lever in the LOCK

is extended to the lowering stroke end. (2) on the head side, and block the hose
side with a plug.
position and put a block to the rear of ★ Plug used to block hose: 07376-70210
the track shoe. (# 02)
2) Extend the lift cylinder to the lowering stroke
end and stop the engine.

lifting direction several times within 15
seconds after stopping the engine, and
then loosen the oil filler cap of the hy-
ual pressure in the cylinder and tank.
3) Remove the cylinder cover on the side to be
measured, disconnect hose (1) on the head
side, and block the hose side with a plug.
★ Plug used to block hose: 07376-70422
(# 04)
4) Run the engine at high idle and move the
blade control lever to the left tilting position
to relieve the tilt cylinder.

the right tilting position.
5) Start measuring the oil leakage 30 seconds
leakage in 1 minute.
removed parts.
D31/37/39EX, PX-21 20-147

(4)
MEASURING LEAKAGE IN WORK EQUIPMENT CYLINDER
TESTING AND ADJUSTING RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT
3. Measuring leakage in blade angle cylinder

1) Start the engine and raise the blade to about
RELEASING RESIDUAL
50 cm above the ground. PRESSURE IN HYDRAULIC
2) Extend the angle cylinder on the side to be CIRCUIT
measured to the angling stroke end and
stop the engine. ★ When removing any hydraulic equipment or dis-

connecting any piping from the HST circuit or
work equipment circuit, release the residual
angling direction several times within 15 pressure according to the following procedure.
seconds after stopping the engine, and
then loosen the oil filler cap of the hy- 1. Stop the machine on a hard and level place.
ual pressure in the cylinder and tank. 2. Lower the blade to the ground and stop the
3) Remove the cylinder cover on the side to be engine.
measured, disconnect hose (3) on the head
side, and block the hose side with a plug. 3. Operate the blade control lever in each direction
★ Plug used to block hose: 07376-70315 to the stroke end several times within 15 sec-
(# 03) onds after stopping the engine to release the
residual pressure in the circuit.
4. Loosen oil filler cap (1) of the hydraulic tank

slowly to release the residual pressure in the
tank.
k Since the oil may spout out, depending on

the condition in the tank, loosen the oil filler
cap slowly.
★ Once the residual pressure is released, tight-
en the oil filler cap to prevent dirt from enter-
ing the tank.
4) Run the engine at high idle and move the

blade control lever to the angling position to
relieve the angle cylinder.

the opposite position.
5) Start measuring the oil leakage 30 seconds
leakage in 1 minute.
meas uring instruments and return the
removed parts.
20-148 D31/37/39EX, PX-21

(4)
TESTING AND ADJUSTING BLEEDING AIR FROM HYDRAULIC CIRCUIT
BLEEDING AIR FROM 5) Set the parking brake lever in the FREE
position and set the PCCS lever in the for-
HYDRAULIC CIRCUIT ward and reverse travel positions at least 20
times.
★ If any hydraulic equipment/piping of the HST cir- • Forward o Neutral o Reverse o Neutral
cuit or work equipment circuit was removed/dis- ★ Repeat the operation cycle of setting the
connected and installed/connected, bleed air PCCS lever in the forward and reverse
according to the following procedure after finish- positions at least 20 times.
ing the work.
★ Before and after bleeding air, check that the oil 4. Bleeding air from cylinders
level in the hydraulic tank is normal and no bub- 1) While running the engine at low idle, extend
bles are contained in the oil. and retract each cylinder to before each
stroke end 4 – 5 times.
1. Bleeding air from HST pump ★ Stop the piston rod of each cylinder
1) Remove the inspection cover at the left of about 100 mm before the stroke end to
the floor and the oil filler cap of the hydraulic avoid relieving.
tank under it. 2) Keep running the engine at low idle and
2) Loosen air bleeder (1) at the top of the HST extend and retract each cylinder to each
pump and check that oil oozes out. stroke end 3 – 4 times.
★ If oil oozes out, air has been bled. 3) Keep running the engine at high idle and
3) Tighten air bleeder (1). extend and retract each cylinder to each
stroke end 4 – 5 times.
5. Operating machine
1) After bleeding air, stop the engine and leave
it for 5 minutes.
★ By this operation, the bubbles in the oil in
the hydraulic tank are discharged.
2) Check for oil leakage. If no oil is leaking,
operate the machine.
2. Starting engine
Start the engine and run it at low idle for 10 min-
utes.
3. Bleeding air from HST pump servo section

k Since the machine will travel forward and in
reverse a little during the following work,
stop the machine in a place where it can
travel.
1) Warm up the engine until the HST oil tem-
perature (hydraulic oil temperature) reaches
80°C.
★ Air is bled more effectively when the
HST oil temperature (hydraulic oil tem-
perature) is high.
2) Set the shift mode switch in the variable shift
mode position.
3) While the 1st gear speed is selected, press
the shift-up switch twice.
4) Set the reverse travel speed set switch to
the left once to set the reverse travel speed
to the forward travel speed.
D31/37/39EX, PX-21 20-149

(4)
TESTING AND ADJUSTING ADJUSTING PLAY OF BLADE CENTER BALL
ADJUSTING PLAY OF BLADE

CENTER BALL
★ If the blade was disassembled and assembled or
transported, adjust the play of the center ball ac-
1. Install cap (1) and tighten mounting bolt (2) with-

out inserting any shim.
2. Measure clearance (a) between frame (3) and

cap (1).
3. Calculate the thickness of a shim to be inserted

from measured clearance (a), and then select
shims to be inserted.
• Thickness of shim to be inserted =
(Measured clearance (a)) + (0.2 to 1.2 mm)
• Thickness of prepared shims: 1.0 mm, 2.0 mm
4. Loosen mounting bolts (1), insert prepared shim

(4), and tighten the mounting bolt.
20-150 D31/37/39EX, PX-21

(1)
TESTING AND ADJUSTING PROCEDURE FOR TESTING DIODES
PROCEDURE FOR TESTING

DIODES
★ Test the assembled-type diode (8-pin) and the
single diode (2-pin) according to the following
procedure.
★ The conductive directions of the assembled-type
diode are shown in the following figure.
2. When using analog circuit tester

1) Set the tester in the resistance range.
2) Apply the leads of the tester as shown below
and check the movement of the pointer.
i) Apply the red (+) lead of the tester to the
anode (P) side of the diode and apply
the black (-) lead to the cathode (N)
side.
ii) Apply the red (+) lead of the tester to the
★ The conductive direction of the single diode is in- cathode (N) side of the diode and apply
dicated on the surface of the diode. the black (-) lead to the anode (P) side.
3) Judge the condition of the diode by the move-
ment of the pointer.
• The pointer does not move in i) but
moves in ii): The diode is normal (The
moving range (resistance) depends on
the type and selected range of the tester,
however).
• The pointer moves in both i) and ii): The
diode is defective (Internal short circuit).
• The pointer moves in neither of i) and ii):
The diode is defective (Internal discon-
nection).
1. When using digital circuit tester

1) Set the tester in the diode range and check
the indicated value.
★ When an ordinary circuit tester is used,
the voltage of the internal battery is indi-
cated.
2) Apply the red (+) lead of the tester to the
anode (P) side of the diode and apply the
black (-) lead to the cathode (N) side and
check the indicated value.
3) Judge the condition of the diode by the indi-
cated value.
• The indicated value does not change:
The diode do not have conductivity (De-
fective).
• The indicated value changes: The diode
has conductivity (Normal).
Note: In the case of a silicon diode, a
value in the range from 460 to 600
is indicated.
D31/37/39EX, PX-21 20-151

(1)
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)

★ EMMS: Equipment Management Monitoring System
Display section of special Operation section 1 of special Operation section 2 of special

functions functions (Basic operation) functions (Selecting operation)
1. Gear speed/Set travel speed/
3. Service switch (in cover) 4. Buzzer cancel switch
Shift mode indicator section
2. Multi-information section 5. Information switch
6. Shift-up switch
7. Shift-down switch
20-152 D31/37/39EX, PX-21

(1)
Ordinary functions and special functions of monitor panel (EMMS)

The monitor panel (EMMS) has the ordinary function and special functions and displays information of various
types on the gear speed/set travel speed/shift mode indicator section at its center and on the multi-information
section.
Some items are displayed automatically according to the internal setting of the monitor panel and the others are
displayed according to the operation of the switches.
1) Ordinary function: Operator mode

With this function, the operator can display and change the items displayed ordinarily.
2) Special function: Service mode
With this function, a serviceman can display and change the displayed items with special switches for test-
ing, adjusting, and troubleshooting.
D31/37/39EX, PX-21 20-153

(1)
Operation and display in operator mode 1. Maintenance mode

(Outline) (1-OIL, FILTER MAINTENANCE MODE)
In this mode, the time up to the next replace-
★ In this section, only the outline of the operator ment of oils and filters is displayed on the multi-
mode is described. For details of the contents information section (2) and reset after the
and operation method of each function and replacement.
mode, see Operation Manual. ★ Gear speed/Set travel speed/Shift mode in-
dicator section (1) keeps displaying ordinari-
Ordinary display mode (Default) ly.
The monitor panel displays the following information
ordinarily.
Gear speed/Set travel speed/Shift mode indicator

section (1):
• Left side: Travel direction (P/N/F/R)
• Right side: Gear speed (1/2/3)
• Graphic: Set travel speed
• Lower line: Selected shift mode
★ The items on the right side are displayed only
while the quick shift mode is selected.
★ The items in the graphic section are displayed
only while the variable shift mode is selected.
★ The following figure shows the monitor panel dis-
played while the machine is traveling forward at ★ The following items are displayed in the main-
the 1st gear speed in the quick shift mode. tenance mode.
Multi-information section (2): No. Display Item

• Upper line (16 characters): Not displayed nor- 1 01 : ENG OIL Engine oil
mally
• Lower line (16 characters): Service meter or 2 02 : ENG FILT Engine oil filter
engine speed 3 03 : FUEL FILT Fuel filter
★ The following figure shows the monitor panel dis-
played while the service meter display is select- 4 04 : HYD FILT Hydraulic oil filter
ed. 5 05 : CORR RES Corrosion resistor (*)
6 06 : BYPS FILT Bypass filter (*)
7 07 : DAMP OIL Damper oil (*)
8 08 : FNL OIL Final drive oil
9 09 : HYD OIL Hydraulic oil
10 10 : POWL OIL Power train oil (*)
11 11 : POWL FILT Power train oil filter (*)
12 12 : HST FILT HST charge filter
★ The items marked with (*) are displayed but not

used for this machine.
20-154 D31/37/39EX, PX-21

(1)
2. Pm clinic auxiliary mode (2-PM CLINIC MODE) 3. Fault code display mode
In this mode, the condition of the machine is dis- (3-FAULT CODE DISPLAY MODE)
played on multi-information section (2) as an In this mode, the contents of each fault in the
auxiliary function of the periodic diagnoses such machine are displayed by a 6-character fault
as the Pm clinic, even if any measuring instru- code on the multi-information section (2).
ment is not connected. When the user or the operator needs to be noti-
★ Gear speed/Set travel speed/Shift mode in- fied of the fault code of each fault, this mode is
dicator section (1) keeps displaying ordinari- applied.
ly. ★ Gear speed/Set travel speed/Shift mode in-
ly.
★ The following items are displayed in the Pm

clinic auxiliary mode.
★ When a serviceman needs to check the fault
No. Display Item Unit
codes for troubleshooting, the Electric sys-
1 01-ENG SPEED Engine speed rpm
tem fault code display mode and the Me-
2 02-BATTERY VOLT Battery voltage mV chanical system fault code display mode
3 03-HST TEMP HST oil temperature °C should be used for more detailed informa-
4 04-VEHICLE SPEED Travel speed km/h tion.
★ Method of checking fault code:
★ When changing the items in the Pm clinic Set buzzer cancel switch (4) in the [U] posi-
auxiliary mode, set the parking brake lever in tion on the screen shown above, and all the
the LOCK position. fault codes detected currently are displayed
at the interval of about 2 seconds. (To finish
displaying, turn the buzzer cancel switch to
the [t] position.)
★ For details of the displayed fault codes, see
the fault codes list in “Troubleshooting when
fault code is displayed (Fault code)”.
D31/37/39EX, PX-21 20-155

(1)
4. Adjustment mode (4-USER ADJUST MODE)

In this mode, the display condition of the monitor
panel can be adjusted on the multi-information
section (2).
★ Gear speed/Set travel speed/Shift mode in-
ly.
★ Part (a) flashes.
★ The following items are displayed in the ad-

justment mode.
Adjustment of back
1 01 : LCD BRIGHTNES %
light of LCD gauge
Adjustment of back
2 02 : DSP BRIGHTNES light of multi-informa- %
tion section
Adjustment of LCD
3 03 : DSP CONTRAST contrast of multi- %
information section
20-156 D31/37/39EX, PX-21

(1)
Action code display function

If a fault to be notified to the operator occurs during
work, an action code and a phone No. are displayed
on the multi-information section (2).
★ Gear speed/Set travel speed/Shift mode indica-
tor section (1) keeps displaying ordinarily.
★ The phone No. is displayed for only important ac-
tion codes. The display shown below is an ex-
ample. (The form of the displayed phone No.
depends on the form of the input No.)
★ If an important action code is displayed, the cau-
tion lamp flashes and the caution buzzer sounds.
<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 fault code in the “Electric system fault
code display mode” and “Mechanical system fault
code display mode” of the service mode.
Action codes table

Action code Indication method of fault Contents of fault Remedy notified to operator
• Functions are defective or they
stop partially, but operator can
• Trouble of pressure sensor work safely.
E01 • Only action code is displayed.
• Trouble of backup alarm • After finishing work, however,
call your Komatsu distributor
for repair.
• Trouble of fuel control lever or • Important functions are defec-
decelerator pedal tive or they stop partially.
• Action code is displayed.
• Trouble of shift switch • When continuing work, take
E02 • Caution lamp flashes.
• Trouble of neutral safety relay care extremely.
• Caution buzzer sounds.
• Trouble of speed shifting sole- • After finishing work, call your
noid Komatsu distributor for repair.
• Trouble of travel and steering • Move machine to safe place
system 1 and stop it immediately.
• Action code is displayed.
• Trouble of network • Call your Komatsu distributor
CALL E03 • Caution lamp flashes.
• Trouble of brake input system for repair.
• Caution buzzer sounds.
• Trouble of engine speed sensor
• Trouble of 1 pump EPC
• Trouble of travel and steering • Stop machine immediately.
• Action code is displayed. system 2 • Call your Komatsu distributor
CALL E04 • Caution lamp flashes. • Lowering of source voltage of for repair.
• Caution buzzer sounds. controller
• Trouble of brake output system
D31/37/39EX, PX-21 20-157

(1)
Operation and display in service mode ★ The following items are displayed in the
service mode.
Method of changing to service mode
★ When using the service mode, change the Gear
screen by the following special operation. speed
No. indica- Item
1) Special operation of switches tor sec-
tion
Set the monitor panel in the service mode by
operating service switch (3) and buzzer cancel 5-EXCHG. INTVAL. SET MODE
switch (4). 1 1C
Maintenance interval change mode
★ Keeping the service switch in the ON posi-
tion, hold the buzzer cancel switch in the [U] 6-ELEC. FAULT CODE MODE
2 EE
position for 2.5 seconds. Electric system fault code display mode
★ If the monitor panel is set in the service
mode, [1C] is displayed on the Gear speed/ 7-MACHINE FAULT CODE MODE
3 bE
Set travel speed/Shift mode indicator section Mechanical system fault code display mode
(1).
8-SERVICE ADJUST MODE
★ When the service mode is selected, “Mainte- 4 Cb
nance interval change mode” is displayed Adjustment mode
first. 9-LOAD MEMORY DISPLAY MODE
5 Ld
Load memory display mode
10-REAL TIME MONITORING MODE
6 5R
Real-time monitoring mode
11-DUAL DISPLAY MONITORING MODE
7 dR
Dual display monitoring mode
3) Finishing mode and function

The current mode and function can be finished
by either of the following method, regardless of
the current mode and hierarchy.
i) When continuing the operation in another
2) Selecting and executing mode to be used mode or function or in the operator mode:
Select the mode to be used with information Return to the mode screen or function
switch (5) and execute it with buzzer cancel screen to be used next by operating buzzer
switch (4). cancel switch (4).
• [>]: Next mode No. • [t]: Screen returns.
• [<]: Previous mode No. ii) When finishing the all operation:
• [U]: Execute mode. Turn OFF the starting switch.
★ For details of operation in each mode, see
the following pages.
★ If each mode is selected, a 2-character code
is displayed in Gear speed/Set travel speed/
Shift mode indicator section (1).
20-158 D31/37/39EX, PX-21

(1)
5. Maintenance interval change mode 3) Contents of information screen

(5-EXCHAG. INTVAL. SET MODE) The following items are displayed on the
In this mode, you can check and set the mainte- information screen.
nance interval times of various filters and oils (a): Code
which are the bases of the maintenance display (b): Maintenance item
function in the operator mode. (c): Replacement interval time (Set time)
★ The items shown below are examples.
★ If the replacement interval does not need
to be changed, finish the operation on
this screen.
★ If the replacement interval needs to be
changed, go to step 4).
1) Selecting and executing mode

i) Select “Maintenance interval change
mode” on the mode selection screen.
★ If the mode is selected, code [1C] is
displayed on Gear speed/Set travel
speed/Shift mode indicator section
(1) and the title is displayed on multi- 4) Changing replacement interval time
information section (2). i) Change the set time by operating infor-
ii) Display the maintenance item selection mation switch (5), shift-up switch (6),
screen by operating buzzer cancel and shift-down switch (7).
switch (4). • [>]: Move cursor to right.
• [U]: Execute mode. • [<]: Move cursor to left.
• [UP]: Increase number.
• [DOWN]: Decrease number.
2) Selecting and displaying maintenance item

i) Operate information switch (5) on the
maintenance item selection screen to
select a maintenance item.
• [>]: Next code
• [<]: Previous code
ii) Display the maintenance item informa-
tion screen by operating buzzer cancel
switch (4).
• [U]: Execute item.
D31/37/39EX, PX-21 20-159

(1)
★ If you do not use the maintenance ★ If the change is not finished normal-
function, set the all times to 0. ly, the information display screen
before the change appears after the
screen shown below. In this case,
execute the above operation again.
ii) If the input time is correct, enter the

change of setting by operating buzzer
cancel switch (4).
• [U]: Enter change.
★ If the change is finished normally,
the information display screen ap-
pears after the screen shown below
Maintenance items table

Replacement interval time
No. Display Item
1st time (Cannot be changed) 2nd time (Can be changed)
1 01 : ENG OIL Engine oil 0500h 0500h
2 02 : ENG FILT Engine oil filter 0500h 0500h
3 03 : FUEL FILT Fuel filter 0500h 0500h
4 04 : HYD FILT Hydraulic oil filter 2000h 2000h
5 05 : CORR RES Corrosion resistor (*) — —
6 06 : BYPS FILT Bypass filter (*) — —
7 07 : DAMP OIL Damper oil (*) — —
8 08 : FNL OIL Final drive oil 1000h 1000h
9 09 : HYD OIL Hydraulic oil 2000h 2000h
10 10 : POWL OIL Power train oil (*) — —
11 11 : POWL FILT Power train oil filter (*) — —
12 12 : HST FILT HST charge filter 2000h 2000h
★ The first interval time cannot be changed. If it needs to be changed for a particular reason, assume that the
first maintenance has been finished in the maintenance mode of the operator mode, then change the 2nd
and after interval times.
★ The items marked with (*) are displayed but not used for this machine.
20-160 D31/37/39EX, PX-21

(1)
6. Electric system fault code display mode 3) Display in the case where 1 or more codes
(6-ELEC. FAULT CODE MODE) are recorded
In this mode, you can check the past electric If any fault code has been output up to now,
system fault codes. the information section displays as shown
below.
(a) Record No. (Up to 20)
(b) Fault code (Code being output currently
is flashing)
(c) Number of past occurrences
(d) Time measured by service meter after
first occurrence
(e) Time measured by service meter after
last occurrence
★ The items shown below are examples.
★ For details of the displayed fault codes,
see the “Fault codes list” in “Trouble-
shooting when fault code is displayed
(Fault code)”.
i) Select “Electric system fault code dis-
play mode” on t he mode selection
screen.
★ If the mode is selected, code [EE] is
(1) and the title is displayed on multi-
information section (2).
ii) Display the fault code display screen by
operating buzzer cancel switch (4).
• [U]: Execute mode.
2) Display in the case where no codes are

recorded ★ Flashing and lighting of fault code
If no fault codes have been output up to Flashing: Code is being output currently.
now, the information section displays as Lighting: Code is not being output cur-
shown below. rently.
★ Condition for detecting and keeping fault
code
If a fault code is output, it keeps flashing
until the starting switch is turned OFF.
After the starting switch is turned on or
the engine is started again, the fault
code keeps lighting until the same fault
is detected.
D31/37/39EX, PX-21 20-161

(1)
4) Operation to perform when multiple codes 7. Mechanical system fault code display mode
are recorded (7-MACHINE FAULT CODE MODE)
When multiple codes are recorded, they can In this mode, you can check the mechanical sys-
be displayed one by one by operating infor- tem fault codes among the codes of the faults
mation switch (5). which occurred in the past or which are occur-
• [>]: Next code ring currently in the machine.
★ The fault codes are displayed from the
oldest one in order of length of time after
they were output.
5) Method of deleting fault code

While fault codes are displayed, operate
shift-up switch (6) or shift-down switch (7),
and all of the past fault codes are deleted.
• [UP] or [DOWN]: Delete fault code.
★ A fault code which is being output cur-
rently (which is flashing) cannot be delet-
ed.

i) Select “Mechanical system fault code
display mode” on the mode selection
screen.
★ If the mode is selected, code [bE] is
ii) Display the fault code display screen by
operating buzzer cancel switch (4).
2) Display in the case where no codes are

recorded
If no fault codes have been output up to
now, the information section displays as
shown below.
20-162 D31/37/39EX, PX-21

(1)
3) Display in the case where 1 or more codes 4) Operation to take when multiple codes are
are recorded recorded.
If any fault code has been output up to now, When multiple codes are recorded, they can
the information section displays as shown be displayed one by one by operating infor-
below. mation switch (5).
(a) Record No. • [>]: Next code
(b) Fault code (Code being output currently • [<]: Previous code
is flashing) ★ All the error codes, including the error
(c) Number of past occurrences codes which are not output, are dis-
(d) Service meter reading at first occur- played in the order set internally.
rence.
(e) Service meter reading at last occur- 5) Method of deleting fault code
rence. The mechanical system fault codes cannot
★ The items shown below are examples. be deleted.
★ For details of the displayed fault codes,
see the “Fault codes list” in “Trouble-
shooting when fault code is displayed
(Fault code)”.
★ Flashing and lighting of fault code

Flashing: Code is being output currently.
Lighting: Code is not being output cur-
rently.
★ Condition for detecting and keeping fault
code
If a fault code is output, it keeps flashing
until the starting switch is turned OFF.
After the starting switch is turned on or
the engine is started again, the fault
code keeps lighting until the same fault
is detected.
D31/37/39EX, PX-21 20-163

(3)
8. Adjustment mode ★ If an incorrect code is input, the adjust-

(8-SERVICE ADJUST MODE) ment code input screen appears again
In this mode, you can adjust the control system after the screen shown below. In this
and various devices of the machine. case, execute the above operation
again.

i) Select “Adjustment mode” on the mode 3) Contents of display on adjustment screen
selection screen. (a): Code
★ If the mode is selected, code [Cb] is (b): Adjustment item
displayed on Gear speed/Set travel (c): Related information
speed/Shift mode indicator section ★ For the detailed information and adjust-
(1) and the title is displayed on multi- ment procedure, see “Adjustment mode
information section (2). table and adjustment procedure”.
ii) Display the adjustment code input screen
by operating buzzer cancel switch (4).
2) Selecting adjustment items

i) On the adjustment code input screen,
input the 4-digit code of the item to be
adjust ed by operat ing informat ion
switch (5), shift-up switch (6), and shift-
down switch (7).
• [>]: Move cursor to right.
• [<]: Move cursor to left.
ii) After inputting the code, press buzzer
cancel switch (4) to display the adjust-
ment screen.
• [U]: Settle input.
20-164 D31/37/39EX, PX-21

(1)
4) When operating machine in adjustment mode

If the parking brake lever is set in the FREE
position, Gear speed/Set travel speed/Shift
mode indicator section (1) displays normally
and the machine can be operated normally.
★ In the ordinary display mode, if the
PCCS lever is in neutral, the speed does
not change, even if shift-up switch (6) or
shift-down switch (7) is operated.
If the speed needs to be changed, set
the PCCS lever in the forward or reverse
travel position and operate shift-up
switch (6) or shift-down switch (7) while
the machine is traveling.
5) Changing adjustment item in order (Limited

function)
Once some adjustment items are selected,
they can be selected in order with the infor-
mation switch (5) without inputting the codes
again.
• [>]: Next code
★ This function is limited to the items hav-
ing numbers in the change-in-order col-
umn of the “Adjustment mode table”.
Those items are changed in the order of
their numbers.
★ This operation is not accepted while the
parking brake lever is in the FREE posi-
tion. Take care.
★ An adjustment item can be also selected
by returning to the input screen and in-
putting the code for that item.
D31/37/39EX, PX-21 20-165

(1)
Adjustment mode table and adjustment procedure

No. Code Display Item Related information Change in order
1 0001 INP TEL NO. Phone No. input mode Phone No.
2 0002 M-CODE Model code set Model code A1
3 0004 BODY TYPE Specification code set Specification code A2
Brake potentiometer neutral
4 0005 BRAKE N-SET Potentiometer voltage B6
set
Steering lever left
5 1010 S/T H. L-SET counter-rotation set Potentiometer voltage B2
(Operating effort difference)
Steering lever right
6 1011 S/T H. R-SET counter-rotation set Potentiometer voltage B4
(Operating effort difference)
7 1012 S/T N-SET Steering lever neutral set Potentiometer voltage B1
8 1013 S/T M. L-SET Steering lever left max. set Potentiometer voltage B3
9 1014 S/T M. R-SET Steering lever right max. set Potentiometer voltage B5
Forward pump set
10 3001 PUMP AJST F Command current A3
(For running track shoe idle)
Reverse pump set
11 3002 PUMP AJST R Command current A4
(For running track shoe idle)
Forward pump rise/max.
12 3003 PU F-UP MAP Command current C1
delivery set (For travel)
Reverse pump rise/max.
13 3004 PU R-UP MAP Command current C2
Forward pump intermediate
14 3005 PU F-HF MAP Command current C3
Reverse pump intermediate
15 3006 PU R-HF MAP Command current C4
16 3007 BRAKE END Brake potentiometer max. set Potentiometer voltage B7
17 3008 ENG HI-SET Engine high idling set Engine speed B8
18 3009 DECLE HI>LO Deceleration set Engine speed B9
19 3010 THROTTLE LO Fuel control lever set Engine speed B10
Engine speed
HST oil temperature (Hydraulic oil temperature)
20 3016 STALL CHECK Stall pressure test mode
Right HST main circuit pressure
Left HST main circuit pressure
21 3019 SHIFT LIMIT Gear speed limit mode Gear speed limit
<Changing adjustment item in order>

★ If any item having a number in the "Change in order" column of the above table is selected, the other items
in the same alphabet group are selected in the order of their numbers by operating the information switch.
<Items adjusted after disassembly and assembly>
• When HST controller assembly is replaced (Either of following):
1) Items of [A1], [A2], [A3], [A4], [B1], [B2], [B3], [B4], [B5], [B6], [B7], [B8], [B9], and [B10]
2) Items of [A1], [A2], [B1], [B2], [B3], [B4], [B5], [B6], [B7], [B8], [B9], [B10], [C1], [C2], [C3], and [C4]
• When HST pump assembly or HST pump EPC valve is replaced (Either of following):
1) Items of [A3] and [A4]
2) Items of [C1], [C2], [C3], and [C4]
• When PCCS lever assembly is replaced: Items of [B1], [B2], [B3], [B4], and [B5]
• When fuel linkage is adjusted, when fuel lever potentiometer is replaced, when decelerator pedal potenti-
ometer is replaced, or after floor assembly is assembled: Items of [B8], [B9], and [B10]
• When brake linkage is adjusted or when brake potentiometer is replaced: Items of [B6] and [B7]
20-166 D31/37/39EX, PX-21

(3)
[0001]: Phone No. input mode [0002] Model code set (Changed in normal order: A1)
• This code is used to input and change the • This code is used to make the HST controller
phone No. displayed together with the action recognize the machine model and to initialize
code. the set values of the memory in the controller.
• The phone No. and symbols are displayed on • The model code is displayed on the lower line.
the lower line.
• Adjustment method:
• Usable characters: i) Select a correct model code by operating
0, 1, 2, 3, 4, 5, 6, 7, 8, 9, :, ;, <, >, ?, = the shift-up switch (6).
• Using method • Select [D31], [D37], or [D39].
i) Input the phone No. and symbols by operat- ii) Set buzzer cancel switch (4) in the [U] posi-
ing information switch (5), shift-up switch tion and check that the caution buzzer
(6), and shift-down switch (7). sounds.
k If an item is settled with this code, the
• [>]: Move cursor to right.
• [<]: Move cursor to left.
memory in the controller is initialized.
• [UP]: Increase number or select next
Accordingly, use this code only when
character (in the order of usable charac-
required. If any item is settled with this
ters).
code, initialize all the items again.
k If the model name of the machine is dif-
• [DOWN]: Decrease number or select
previous character (in the order of usa-
ble characters). ferent from the setting in the controller,
ii) Set buzzer cancel switch (4) in the [U] posi- the machine may move abnormally or
tion and check that the caution buzzer make an error. Accordingly, be sure to
sounds. set the correct model name in the con-
★ There are 16 places for the phone No. Input troller.
symbols other than digits to empty places to ★ Even if this code is turned OFF, the setting is
prevent confusion. effective.
★ All the 16 places on the lower line are filled
with 0 when the machine is shipped.
★ Even if this code is turned OFF, the setting is
effective.
D31/37/39EX, PX-21 20-167

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[0004] Specification code set (Changed in normal [0005]: Brake potentiometer neutral set (Changed in
order: A2) normal order: B6)
• This code is used to make the HST controller • This code is used to adjust the neutral position
recognize the machine specification. of the brake pedal potentiometer.
• The machine specification code is displayed on • The signal output of the brake pedal potentiom-
the lower line. eter is displayed by voltage on the lower line.
(Display range: 0 – 5000)
★ The setting of this code is reset when “Model • Adjustment method:
code set” is executed. Accordingly, adjust i) Check that the brake pedal is in neutral (it is
this code after executing “Model code set”. not pressed).
i) Select a correct specification code by oper- ii) Set buzzer cancel switch (4) in the [U] posi-
ating the shift-up switch (6). tion and check that the caution buzzer
• Select [PX] or [EX]. sounds.
ii) Set buzzer cancel switch (4) in the [U] posi- ★ The display of the lower line does not change
tion and check that the caution buzzer after adjustment.
k If the actual machine specification is differ-

sounds. ★ Even if this code is turned OFF, the setting is
effective.
ent from the setting in the controller, the ma- ★ This adjustment is performed to make the
chine may move unexpectedly or an error is HST controller recognize the neutral position
made. Accordingly, be sure to set the ma- of the brake pedal potentiometer. It is not
chine specification correctly. performed to adjust the effect of the brake.
effective.
20-168 D31/37/39EX, PX-21

(1)
[1010] Steering lever left counter-rotation set [1011] Steering lever right counter-rotation set
(Operating effort difference) (Changed in normal (Operating effort difference) (Changed in normal
order: B2) order: B4)
• This code is used to adjust the left counter-rota- • This code is used to adjust the right counter-
tion (operating effort difference) position of the rotation (operating effort difference) position of
steering potentiometer of the PCCS lever. the steering potentiometer of the PCCS lever.
• The signal output of the steering potentiometer • The signal output of the steering potentiometer
is displayed by voltage on the lower line (Display is displayed by voltage on the lower line (Display
range: 0 – 5000). range: 0 – 5000).
• Adjustment method: • Adjustment method:

i) Set the PCCS lever in the left counter-rota- i) Set the PCCS lever in the right counter-rota-
tion (operating effort difference) position. tion (operating effort difference) position.
ii) Set buzzer cancel switch (4) in the [U] posi- ii) Set buzzer cancel switch (4) in the [U] posi-
tion and check that the caution buzzer tion and check that the caution buzzer
sounds. sounds.
★ The display of the lower line does not change ★ The display of the lower line does not change
after adjustment. after adjustment.
★ Even if this code is turned OFF, the setting is ★ Even if this code is turned OFF, the setting is
effective. effective.
★ This code is not used to adjust the steering ★ This code is not used to adjust the steering
performance, etc. performance, etc.
D31/37/39EX, PX-21 20-169

(5)
[1012] Steering lever neutral set (Changed in normal [1013] Steering lever left max. set (Changed in nor-
order: B1) mal order: B3)
• This code is used to adjust the neutral position • This code is used to adjust the left maximum
of the steering potentiometer of the PCCS lever. position of the steering potentiometer of the
• The signal output of the steering potentiometer PCCS lever.
is displayed by voltage on the lower line (Display • The signal output of the steering potentiometer
range: 0 – 5000). is displayed by voltage on the lower line (Display
range: 0 – 5000).
i) Set the PCCS lever in the neutral position. • Adjustment method:
ii) Set buzzer cancel switch (4) in the [U] posi- i) Set the PCCS lever to the left steering
tion and check that the caution buzzer stroke end.
sounds. ii) Set buzzer cancel switch (4) in the [U] posi-
★ The display of the lower line does not change tion and check that the caution buzzer
after adjustment. sounds.
★ Even if this code is turned OFF, the setting is ★ The display of the lower line does not change
effective. after adjustment.
★ This code is not used to adjust the steering ★ Even if this code is turned OFF, the setting is
performance, etc. effective.
★ This code is not used to adjust the steering
performance, etc.
20-170 D31/37/39EX, PX-21

(5)
[1014] Steering lever right max. set (Changed in nor-

mal order: B5)
• This code is used to adjust the right maximum
position of the steering potentiometer of the
PCCS lever.
• The signal output of the steering potentiometer
is displayed by voltage on the lower line (Display
range: 0 – 5000).
i) Set the PCCS lever to the right steering
stroke end.
ii) Set buzzer cancel switch (4) in the [U] posi-
tion and check that the caution buzzer
sounds.
★ The display of the lower line does not change
after adjustment.
effective.
★ This code is not used to adjust the steering
performance, etc.
D31/37/39EX, PX-21 20-171

(5)
[3001] Forward pump set (For running track shoe idle) v) After adjustment is finished, set the PCCS
(Changed in normal order: A3) lever in the neutral position and set the park-
• This code is used to adjust the command cur- ing brake lever in the LOCK position.
rent of the forward pump while the track shoe is ★ When starting adjustment again after inter-
running idle. rupting it, perform the procedures from ii).
• The command current of the forward pump is ★ Even if this code is turned OFF, the setting is
displayed on the lower line. effective.
★ If adjustment is interrupted and an error is
displayed, check the following devices.
• When the track shoe does not move:
HST pump EPC valve
• When the track shoe moves:
HST motor speed sensor
i) Jack up the rear frame bottom of the
machine and brace the blade in the lowering
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 se-
curely above the ground.
ii) Run the engine at high idling.
iii) Check that the parking brake lever is in the
LOCK position and the PCCS lever is in the
neutral position and [Cb] is flashing in the
gear speed/set travel speed/shift mode indi-
cator section.
iv) Set the parking brake lever in the FREE
ward travel position, and adjustment starts.
k If adjustment starts, the pump com-
mand current increases and the track
shoe starts running automatically. (The
track shoe starts running idle, then
k The caution buzzer keeps sounding

stops and starts again. Take care.)
k The command current of the forward

during adjustment.
pump increases to 700 mA, then the

track shoe stops.
★ When adjustment is finished, [SET-
TING NOW!!] is displayed on the
k When stopping (interrupting) the track

lower line.
shoe during adjustment, return the

PCCS lever to the neutral position.
(Operations of steering with the PCCS
lever, brake pedal, fuel control lever,
and decelerator pedal are not accepted
during adjustment. Take care.)
20-172 D31/37/39EX, PX-21

(1)
[3002] Reverse pump set (For running track shoe idle) v) After adjustment is finished, set the PCCS
(Changed in normal order: A4) lever in the neutral position and set the park-
rent of the reverse pump while the track shoe is ★ When starting adjustment again after inter-
running idle. rupting it, perform the procedures from ii).
• The command current of the reverse pump is ★ Even if this code is turned OFF, the setting is
displayed, check the following devices.
• When the track shoe does not move:
HST pump EPC valve
• When the track shoe moves:
i) Jack up the rear frame bottom of the
machine and brace the blade in the lowering
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 se-
curely above the ground.
cator section.
mand current increases and the track
shoe starts running automatically. (The
track shoe starts running idle, then

stops and starts again. Take care.)
k The command current of the reverse

during adjustment.

track shoe stops.
k When stopping (interrupting) the track

lower line.
shoe during adjustment, return the

PCCS lever to the neutral position.
(Operations of steering with the PCCS
lever, brake pedal, fuel control lever,
and decelerator pedal are not accepted
during adjustment. Take care.)
D31/37/39EX, PX-21 20-173

(1)
[3003] Forward pump rise/max. delivery set (For travel) ★ When moving the machine after inter-
(Changed in normal order: C1) rupting adjustment, operate it as usually.
• This code is used to adjust the command cur- The travel speed at the time of interrup-
rent of the rise and maximum delivery of the for- tion is kept, however.
ward pump while the machine is traveling. v) After adjustment is finished, set the PCCS
• The command current of the forward pump is lever in the neutral position and set the park-
displayed on the lower line. ing brake lever in the LOCK position.
★ When starting adjustment again after inter-
rupting it, perform the procedures from i).
effective.
displayed, adjust the following parts.
• When machine does not move:
HST pump EPC valve
• When machine moves:
i) Move the machine to a wide and flat place
where it can travel straight for at least 30 m.
k Since the machine will travel straight
forward during adjustment, work in a
place where there is not an obstacle
through length of at least 30 m.
cator section.
k If adjustment starts, the pump command
current increases and the machine starts
traveling forward automatically. (The ma-
chine starts traveling forward, then stops

and starts again. Take care.)

during adjustment.
pump increases to 700 mA, then the ma-

chine stops.
k If the PCCS lever, fuel control lever, de-

lower line.
celerator pedal, or brake pedal is operat-

ed during adjustment, the machine moves
as operated. In this case, however, ad-
justment is interrupted, the caution buzzer
stops sounding, and gear speed/set travel
speed/shift mode indicator section stops
flashing and lights up.
20-174 D31/37/39EX, PX-21

(1)
[3004] Reverse pump rise/max. delivery set (For travel) ★ When moving the machine after inter-
(Changed in normal order: C2) rupting adjustment, operate it as usually.
rent of the rise and maximum delivery of the tion is kept, however.
reverse pump while the machine is traveling. v) After adjustment is finished, set the PCCS
• The command current of the reverse pump is lever in the neutral position and set the park-
effective.
HST pump EPC valve
k Since the machine will travel straight in
reverse during adjustment, work in a
cator section.


during adjustment.

chine stops.

lower line.

D31/37/39EX, PX-21 20-175

(1)
[3005] Forward pump intermediate delivery set (For ★ When moving the machine after inter-
travel) (Changed in normal order: C3) rupting adjustment, operate it as usually.
rent of the intermediate delivery position of the tion is kept, however.
forward pump while the machine is traveling. v) After adjustment is finished, set the PCCS
• The command current of the forward pump is lever in the neutral position and set the park-
effective.
HST pump EPC valve
k Since the machine will travel straight
forward during adjustment, work in a
cator section.


during adjustment.

chine stops.

lower line.

20-176 D31/37/39EX, PX-21

(1)
[3006] Reverse pump intermediate delivery set (For v) After adjustment is finished, set the PCCS
travel) (Changed in normal order: C4) lever in the neutral position and set the park-
rent of the intermediate delivery position of the ★ When starting adjustment again after inter-
reverse pump while the machine is traveling. rupting it, perform the procedures from i).
• The command current of the reverse pump is ★ Even if this code is turned OFF, the setting is
HST pump EPC valve
k Since the machine will travel straight in
reverse during adjustment, work in a
cator section.
mand current increases and the ma-
c h in e s t a r t s t r a v e l i ng i n r e v e r s e

automatically.
k The command current of the reverse

during adjustment.

machine stops.

lower line.
celerator pedal, or brake pedal is oper-

ated, the machine moves as operated.
In this case, however, adjustment is in-
terrupted, the caution buzzer stops
sounding, and caution lamp lights up.
★ When moving the machine after inter-
rupting adjustment, operate it as usually.
The travel speed at the time of interrup-
tion is kept, however.
D31/37/39EX, PX-21 20-177

(1)
[3007] Brake potentiometer max. set (Changed in [3008] Engine high idle set (Changed in normal
normal order: B7) order: B8)
• This code is used to adjust the maximum posi- • This code is used to make the HST controller
tion of the brake pedal potentiometer recognize the high idling positions of the fuel
• The signal output of the brake pedal potentiom- control lever potentiometer and decelerator
eter is displayed by voltage on the lower line. pedal potentiometer.
• The engine speed is displayed on the lower line.
i) Press and hold the brake pedal at the stroke • Adjustment method:
end. ★ Perform the following adjustment after per-
ii) Set buzzer cancel switch (4) in the [U] posi- forming “Adjusting fuel control lever and de-
tion and check that the caution buzzer celerator pedal”.
sounds. i) Start the engine and set the fuel control
★ The display of the lower line does not change lever in the high idle position.
after adjustment. ii) Check that the brake pedal is in neutral (it is
★ Even if this code is turned OFF, the setting is not pressed).
effective. iii) Set buzzer cancel switch (4) in the [U] posi-
★ This code is used to make the HST controller tion and check that the caution buzzer
recognize the maximum position of the brake sounds.
pedal potentiometer. It is not used to adjust ★ Even if this code is turned OFF, the setting is
the brake performance. effective.
20-178 D31/37/39EX, PX-21

(4)
[3009] Deceleration set (Changed in normal order: B9) [3010] Fuel control lever set (Changed in normal
• This code is used to make the HST controller order: B10)
recognize each stroke end and low idling posi- • This code is used to make the HST controller
tion of the decelerator pedal potentiometer. recognize each stroke end and low idling posi-
• The engine speed is displayed on the lower line. tion of the fuel control lever potentiometer.
• The engine speed is displayed on the lower line.
★ Perform the following adjustment after per- • Adjustment method:
forming “Adjusting fuel control lever and de- ★ Perform the following adjustment after per-
celerator pedal”. forming “Adjusting fuel control lever and de-
i) Start the engine, set the fuel control lever in celerator pedal”.
the high idle position, and set the decelera- i) Start the engine, set the fuel control lever in
tor pedal in neutral (release it). the high idle position, and set the decelera-
★ If the engine is not running at high idle at tor pedal in neutral (release it).
this time, an error is displayed. If the en- ★ If the engine is not running at high idle at
gine speed is increased to high idle at this time, an error is displayed. If the en-
this time, however, the error is turned gine speed is increased to high idle at
OFF and adjustment can be continued. this time, however, the error is turned
ii) Press the decelerator pedal slowly and keep OFF and adjustment can be continued.
it at the stroke end. ii) Return the fuel control lever slowly and keep
★ Take 5 seconds or more in pressing the it at the low idle position.
decelerator pedal to make the HST con- ★ Take 5 seconds or more in returning the
troller recognize each stroke end of the fuel control lever to make the HST con-
decelerator pedal. troller recognize each stroke end of the
iii) Set buzzer cancel switch (4) in the [U] posi- fuel control lever.
tion and check that the caution buzzer iii) Set buzzer cancel switch (4) in the [U] posi-
sounds. tion and check that the caution buzzer
★ When the buzzer cancel switch is oper- sounds.
ated, if the engine speed is not at low ★ When the buzzer cancel switch is oper-
idling, an error is displayed. In this case, ated, if the engine speed is not at low
perform “Adjusting fuel control lever and idling, an error is displayed. In this case,
decelerator pedal”, then start adjustment perform “Adjusting fuel control lever and
again. decelerator pedal”, then start adjustment
★ Even if this code is turned OFF, the setting is again.
effective. ★ Even if this code is turned OFF, the setting is
effective.
D31/37/39EX, PX-21 20-179

(4)
[3016] Stall pressure test mode i) While the engine is running, select an item
• This code is used to test the engine speed, HST to be displayed by operating information
oil temperature (hydraulic oil temperature), and switch (5).
right and left HST main circuit pressures while • [>]: Next code
the HST is stalled. • [<]: Previous code
• The engine speed, HST oil temperature, right ★ The following items can be displayed.
HST main circuit pressure, or left HST main cir-
cuit pressure is displayed on the lower line.
1 ENG-REV Engine speed rpm
2 HST TEMP HST oil temperature °C
3 R PRESS Right HST main circuit pressure MPa
4 L PRESS Left HST main circuit pressure MPa
ii) Check that the parking brake lever is in the

LOCK position.
★ Stall the HST while the parking brake le-
ver is in the LOCK position.
iii) Set the PCCS lever in the FORWARD or
REVERSE position to stall the HST and test
the necessary items.
★ If the PCCS lever is set in the FOR-
• How to use: WARD or REVERSE position, the HST
k Check that the HST oil temperature (hy-

stalls. If the PCCS lever is returned,

stalling of the HST stops.
draulic oil temperature) is in the range from
40 to 60 oC while the HST is stalled. (Do ature rises sharply and locally. Accord-
not stall the HST while the oil temperature is ingly, do not stall the HST continuously
k Before selecting this code, check that the

out of the specified range.) for more than 30 seconds.
★ The displayed item can be changed
parking brake lever is in the LOCK position even while the HST is stalled.
and the PCCS lever is in the neutral posi-
tion.
★ If this code is selected, the HST is stalled au-
tomatically. (The HST is stalled only when
the PCCS lever is set in the FORWARD or
REVERSE position, however.)
• Travel speed: 3rd (Min. delivery of HST
motor)
• Parking brake solenoid valve: OFF
k The following errors are set in this code for

• Slow brake solenoid valve: OFF
safety. If one of them is turned ON, the

command current to the HST pump EPC
valve is stopped.
• No. 1: When the machine is set in this
mode, it is moving.
• No. 3: After the machine is set in this
mode, it is moving.
• No. 4: The parking brake release pres-
sure is increased.
• No. 0: The above errors are reset.
20-180 D31/37/39EX, PX-21

(1)
[3019] Gear speed limit mode

• This code is used to prevent shifting the gear to
the 3rd position.
• The usable gear speeds are displayed on the
lower line.
• Using method:
i) Select use of the highest gear speed by
operating shift-up switch (6).
• [3RD]: Permit use of 3rd gear speed.
• [2ND]: Limit use of 3rd gear speed.
ii) Set the buzzer cancel switch (4) in the [U]
position to enter the setting.
★ If the gear speed is limited, it is not shifted to
the 3rd position, even if the shift-up switch is
operated.
★ The setting becomes effective when the
starting switch is turned OFF and ON.
★ The setting is effective in both quick shift
mode and variable shift mode.
D31/37/39EX, PX-21 20-181

(1)
9. Load memory display mode 3) Display of 1,000 rpm service meter

(9-LOAD MEMORY DISPLAY MODE) This code is used to display the service
In this mode, you can check the load on the meter which integrates the operation hours
machine, odometer, and reverse odometer. only while the engine speed is higher than
1,000 rpm.
★ The data cannot be reset.

i) Select “Load memory display mode” on
the mode selection screen. 4) Display of forward odometer
★ If the mode is selected, code [Ld] is On this screen, the integrated forward travel
displayed on Gear speed/Set travel distance is displayed.
speed/Shift mode indicator section ★ The data cannot be reset.
ii) Display the information screen by oper-
ating buzzer cancel switch (4).
2) Changing information screen

Change the information screen by operating
information switch (5).
• [>]: Next screen.
• [<]: Previous screen.
★ The following items can be displayed.
1 01-1,000 rpm SMR 1,000 rpm service meter 0.1h
5) Display of reverse odometer
2 02-FOWARD ODO M Forward odometer m
On this screen, the integrated reverse travel
3 03-REVERCE ODO M Reverse odometer m distance is displayed.
★ The data cannot be reset.
20-182 D31/37/39EX, PX-21

(1)
6) When operating machine in load memory

display mode
★ In the ordinary display mode, if the
PCCS lever is in neutral, the speed does
not change, even if shift-up switch (6) or
★ If the speed needs to be changed, set
★ When selecting another screen, set the
temporarily, and then perform the nec-
essary operation.
D31/37/39EX, PX-21 20-183

(1)
10. Real-time monitoring mode ii) After inputting the code, display the
(10-REAL TIME MONITORING MODE) monitoring screen by operating buzzer
In this mode, the speeds, oil pressures, oil tem- cancel switch (4).
peratures, currents, voltages, etc. can be moni- • [U]: Enter input code.
tored by using the signal s f rom sens ors, ★ If the input code is normal, the mon-
switches, and solenoids installed various parts itoring screen shown below ap-
of the machine. pears.
★ This mode is used to monitor only 1 item.
When monitoring 2 items simultaneously,
use the “Dual display monitoring mode”.
★ If the input code is abnormal, the

code input screen appears again af-
ter the screen shown below.
i) Select “Real-time monitoring mode” on
the mode selection screen.
★ If the mode is selected, code [5R] is
ii) Display the monitoring code input screen
2) Selecting and entering monitored items

i) On the code input screen, input the 5-
digit code of the item to be monitored by
operating information switch (5), shift-up
switch (6), and shift-down switch (7).
• [>]: Move cursor to left.
• [<]: Move cursor to right.
20-184 D31/37/39EX, PX-21

(1)
3) Contents of display on monitoring screen 5) When operating machine in monitoring mode

(Figure shown below is an example) If the parking brake lever is set in the FREE
(a): Code position, Gear speed/Set travel speed/Shift
(b): Monitoring item mode indicator section (1) displays normally
(c): Information and the machine can be operated normally.
(d): Unit (Not displayed for some items) ★ In the ordinary display mode, if the
★ For details, see the “Monitoring mode ta- PCCS lever is in neutral, the speed does
ble”. not change, even if shift-up switch (6) or
★ If the speed needs to be changed, set
★ When selecting another screen, set the
temporarily, and then perform the nec-
essary operation.
4) Function of holding monitoring information

If an information item such as the engine
speed is not stabilized and cannot be read
easily in the monitoring mode, it can be held
and released by operating buzzer cancel
switch (4).
• [U]: Hold and release.
★ While the monitored item is held, the let-
ter “H” is displayed at the left end of the
lower line.
6) Changing monitored items in order (Limited
function)
Once some monitoring items are selected,
they can be selected in order with the infor-
mation switch (5) without inputting the codes
again.
• [>]: Next code
★ This function is limited to the items hav-
ing numbers in the Change-in-order col-
umn of the “Monitoring mode table”.
Those items are changed in the order of
their numbers.
★ This operation is not accepted while the
parking brake lever is in the FREE posi-
tion. Take care.
★ A monitoring item can be also selected
by returning to the input screen and in-
putting the code for that item.
D31/37/39EX, PX-21 20-185

(1)
Monitoring mode table

Change
No. Code Item Unit Remarks
in order
1 00200 MCHN CODE Model code Number Refer to a
2 01002 ENG SPEED Engine speed rpm 1
3 01007 ENG SPEED Engine speed sensor frequency Hz
4 03002 FUEL DIAL Fuel control lever potentiometer voltage mV
5 03003 FUEL DIAL Fuel control lever command speed rpm 2
6 03200 BATTERY HST controller constant power supply voltage mV
7 03201 ACC Volt. Starting switch ACC signal input voltage mV
8 03202 CONTROLLER HST controller power supply voltage mV
9 04102 ENG. TEMP. Engine coolant temperature °C 3
10 04106 ENG. TEMP. Engine coolant temperature sensor voltage mV
11 04200 FUEL SENS Fuel level sensor voltage mV 4
12 04302 R Signal Alternator R signal input voltage mV
13 04402 HST TEMP. HST oil temperature sensor voltage mV
See detailed
14 20215 HST PROGRM HST controller software version Number
information
15 40002 R SPEED Right travel speed km/h 5
16 40003 L SPEED Left travel speed km/h 6
17 40004 R SPEED Right HST motor speed sensor frequency Hz
18 40005 L SPEED Left HST motor speed sensor frequency Hz
Display by See detailed
19 40910 S/T SW1 HST controller input signal 1
bit information
bit information
bit information
bit information
23 40914 SOL ON/OFF HST controller output signal 2
bit information
24 40918 D-OUT SW HST controller output signal 1
bit information
25 40921 Mon SW1 Monitor panel input signal 1
bit information
26 40922 Mon SW2 Monitor panel input signal 2
bit information
27 50001 DECEL PEDL Decelerator pedal potentiometer voltage mV
28 50003 DECEL PEDL Decelerator pedal command speed rpm 7
29 50202 FR LEVR 1 Directional potentiometer 1 mV 8
30 50203 FR LEVR 2 Directional potentiometer 2 mV 9
31 50204 FR LEVR Directional lever ratio %
32 50300 S/T LEVR 1 Steering potentiometer 1 mV 10
33 50301 S/T LEVR 2 Steering potentiometer 2 mV 11
34 50302 S/T LEVR Steering lever ratio %
35 50400 BRAKE PEDL Brake pedal potentiometer voltage mV 12
36 50401 BRAKE PEDL Brake pedal ratio %
37 50901 N-SAFTY Neutral safety relay drive voltage mV 13
38 52300 MOTOR Dir Motor command value cc/rev
Right forward pump EPC output current command
39 52400 RF PUMP mA
value
Left forward pump EPC output current command
40 52401 LF PUMP mA
value
20-186 D31/37/39EX, PX-21

(1)
Change
No. Code Item Unit Remarks
in order
Right reverse pump EPC output current command
41 52402 RR PUMP mA
value
Left reverse pump EPC output current command
42 52403 LR PUMP mA
value
43 52404 RF PUMP Right forward pump EPC output value cc/rev
44 52405 LF PUMP Left forward pump EPC output value cc/rev
45 52406 RR PUMP Right reverse pump EPC output value cc/rev
46 52407 LR PUMP Left reverse pump EPC output value cc/rev
Right forward pump EPC output current detection
47 52408 RF PUMP mA 14
value
Left forward pump EPC output current detection
48 52409 LF PUMP mA 15
value
Right reverse pump EPC output current detection
49 52410 RR PUMP mA 16
value
Left reverse pump EPC output current detection
50 52411 LR PUMP mA 17
value
51 52500 HST R SENS HST right circuit pressure sensor voltage mV
52 52501 HST R PRES HST right circuit pressure MPa 18
53 52502 HST L SENS HST left circuit pressure sensor voltage mV
54 52503 HST L PRES HST left circuit pressure MPa 19
55 60000 TRACTION Theoretical drawbar pull ton 20
56 60600 BR HOLD Battery relay drive voltage mV 21
57 70401 BACK ALARM Backup alarm drive voltage mV
58 85001 HST TEMP. HST oil temperature °C 22
★ The items having numbers in the “Change in order” column of the above table can be changed in order by
operating the information switch.
★ Unlike other codes, code [00200] displays the model code and specification code set in the adjustment
moved as shown below.
(a): Model code (D31: 31, D37: 37, D39: 39)
(b): Specification code (PX: 01, EX: 02)
D31/37/39EX, PX-21 20-187

(1)
Examples of display of bit information [40911]: HTS controller input signal 2

★ The display position of the bit information in the (a): (Unused)
“Real-time monitoring mode (Display of only 1 (b): (Unused)
item)” is different from that in the “Dual display (c): (Unused)
monitoring mode (Simultaneous display of 2 (d): (Unused)
items)”. (e): Travel lock switch 2 (NO): Lock
★ The bit information is displayed by [ _ ] for OFF (f): (Unused)
and [o] for ON in the places (a) – (h). (g): (Unused)
★ The state of each item shown below is the condi- (h): (Unused)
tion for turning on the bit.
[40912]: HTS controller input signal 3

[40910]: HTS controller input signal 1 (a): Reverse travel speed setting switch: Decel-
(a): Shift-up switch (NO): ON eration (Left)
(b): Unused) (b): Reverse travel speed setting switch:
(c): Brake pressure switch: ON (Brake released) Acceleration (Right)
(d): HST charge filter clogging switch: ON (Filter (c): Travel lock switch 1 (NO): Lock
clogged) (d): Travel lock switch 1 (NC): Free
(e): Shift-down switch (NC): OFF (e): Buzzer cancel switch: t (Right)
(f): Shift-down switch (NO): ON (f): Buzzer cancel switch: U (Left)
(g): Shift-up switch (NC): OFF (g): Information switch: > (Right)
(h): Service switch: ON (h): Information switch: < (Left)
20-188 D31/37/39EX, PX-21

(1)
[40913]: HTS controller input signal 4 [40918]: HTS controller output signal 1
(a): Shift mode switch: Quick shift mode (Left) (a): (Unused)
(b): (Unused) (b): (Unused)
(c): (Unused) (c): (Unused)
(d): (Unused) (d): Neutral safety relay: ON
(e): (Unused) (e): (Unused)
(f): (Unused) (f): Backup alarm: ON
(g): (Unused) (g): (Unused)
(h): (Unused) (h): Battery relay: ON
[40914]: HTS controller output signal 2 [40921]: Monitor panel input signal 1
(a): 3rd travel speed selection solenoid valve: ON (a): (Unused)
(b): 2nd travel speed selection solenoid valve: ON (b): (Unused)
(c): Parking brake solenoid valve: ON (c): (Unused)
(d): Slow brake solenoid valve: ON (d): (Unused)
(e): (Unused) (e): (Unused)
(f): (Unused) (f): Preheating signal: ON
(g): (Unused) (g): Night light signal: ON
(h): (Unused) (h): Starting switch C signal: ON
D31/37/39EX, PX-21 20-189

(1)
[40922]: Monitor panel input signal 2

(a): (Unused)
(b): Service switch: ON
(c): (Unused)
(d): (Unused)
(e): (Unused)
(f): Engine oil pressure switch: ON
(g): (Unused)
(h): (Unused)
20-190 D31/37/39EX, PX-21

(1)
11. Dual display monitoring mode ii) After inputting the codes, display the
(11-DUAL DISPLAY MONITORING MODE) monitoring screen by operating buzzer
In this mode, 2 monitored items can be dis- cancel switch (4).
played simultaneously. • [U]: Enter input codes.
★ Note that only codes and monitoring infor- ★ If the input codes are normal, the
mation are displayed in this mode since the monitoring screen shown below ap-
usable display columns are limited. (Item pears.
names and units cannot be displayed.)
★ If the input codes are abnormal, the

1) Selecting and executing mode code input screen appears again af-
i) Select “Dual display monitoring mode” ter the screen shown below.
on the mode selection screen.
★ If the mode is selected, code [dR] is
ii) Display the monitoring code input screen
2) Selecting and entering monitored items

i) On the code input screen, input the 5-
digit codes of the items to be monitored
to the upper and lower lines by operat-
ing information switch (5), shift-up
switch (6), and shift-down switch (7).
• [>]: Move cursor to left.
• [<]: Move cursor to right.
D31/37/39EX, PX-21 20-191

(1)
3) Contents of display on monitoring screen

(Figure below shows examples)
(a): Code 1
(b): Information 1
(c): Code 2
(d): Information 2
★ For details, see the “Monitoring mode ta-
ble”.
4) When operating machine in monitoring mode

★ In the ordinary display mode, if the PCCS
lever is in neutral, the speed does not
change, even if shift-up switch (6) or shift-
down switch (7) is operated.
★ If the speed needs to be changed, set the
PCCS lever in the forward or reverse trav-
el position and operate shift-up switch (6)
or shift-down switch (7) while the machine
is traveling.
20-192 D31/37/39EX, PX-21

(1)
TESTING AND ADJUSTING PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM
PREPARATION WORK FOR 2. HST controller

1) Remove the 4 mounting bolts of operator's
TROUBLESHOOTING FOR seat (3) and 2 anchor bolts of the seat belt,
ELECTRIC SYSTEM and then fold operator's seat (3) toward the
dashboard.
★ When carrying out troubleshooting for an electric
circuit related to the monitor panel and HST con-
troller, expose the related connectors according
1. Monitor panel
1) Remove the 4 mounting bolts of dashboard
(1) and fold dashboard (1) toward the opera-
tor's seat.
2) Insert or connect testing T-adapters in or to

connectors CN-ST1, CN-ST2, and CN-ST3
of HST controller (4).
★ If the connectors cannot be disconnect-
ed and connected easily, remove the
controller.
★ Since the connectors are secured with
screws, loosen those screws before dis-
connecting.
2) Insert or connect testing T-adapters in or to ★ When connecting the connectors again,
connectors CN-S03 and CN-S04 of monitor tighten their screws to the specified
3 Screw: 2.82 Nm {0.288 kgm}

panel (2). torque.
D31/37/39EX, PX-21 20-193

(1)
TESTING AND ADJUSTING PM-CLINIC
PM-CLINIC
20-194 D31/37/39EX, PX-21

(1)
Pm-clinic measuring points (1/2)
Reference items for measurement procedure (Page)

1. Engine speed: Measuring engine speed (Page 20-105)
2. Blow-by pressure: Measuring blow-by pressure (Page 20-114)
3. Engine oil pressure: Measuring engine oil pressure (Page 20-115)
4. Boost pressure: Measuring intake air pressure (boost pressure) (Page 20-106)
5. Exhaust temperature: Measuring exhaust temperature (Page 20-108)
D31/37/39EX, PX-21 20-195

(1)
Pm-clinic measuring points (2/2)
6. HST charge circuit pressure: Testing and adjusting HST oil pressure (Page 20-124)
7. Solenoid valve output pressure: Measuring HST solenoid valve output pressure (Page 20-128)
8. Work equipment pump relief pressure: Testing and adjusting work equipment oil pressure (Page 20-141)
9. Work equipment PPC valve output pressure: Measuring work equipment PPC valve output pressure (Page 20-143)
20-196 D31/37/39EX, PX-21

(1)
D31/37/39EX, PX-21 20-197

(1)
20-198 D31/37/39EX, PX-21

(1)
Y Komatsu
Undercarriage Inspection Customer name:
T20606 Address:
Model D39PX-21 Serial# Equip# Work Order No

Location SMR Wet,AR,HD or Dry DRY
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 686.8 706.8
LINK PITCH R
M L L=l/4 RH 686.8 706.8
LH 171.70 176.70
master pin
l
M
RH 171.70 176.70
LH 98.0 89.0
H
RH 98.0 89.0
LINK HEIGHT
New Turned
BUSHING d1
LH 56.0 47.5
New Turned
d
d RH 56.0 47.5
D is the smallest
of d1, d2 and, d3
GROUSER HIGHT LH 53.0 25.0
H
RH 53.0 25.0
CARRIER LH 150.0 126.0
Front
RH 150.0 126.0
D LH 150.0 126.0
Rear
RH 150.0 126.0
LH 19.0 28.0
IDLER Front
RH 19.0 28.0
H
LH 19.0 28.0
Rear
RH 19.0 28.0
1 LH 175.0 150.0
2 LH 175.0 150.0
3 LH 175.0 150.0
4 LH 175.0 150.0
5 LH 175.0 150.0
6 LH 175.0 150.0
7 LH 175.0 150.0
TRACK ROLLER 8 LH 175.0 150.0
9 LH 175.0 150.0
D 10 LH 175.0 150.0
1 RH 175.0 150.0
h2 h1 2 RH 175.0 150.0
3 RH 175.0 150.0
D=2(h1-h2) 4 RH 175.0 150.0
5 RH 175.0 150.0
6 RH 175.0 150.0
7 RH 175.0 150.0
8 RH 175.0 150.0
9 RH 175.0 150.0
1.3 10 RH 175.0 150.0
SPROCKET h1 LH 0.0 6.0
H is the smallest of
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
D31/37/39EX, PX-21 20-199

(1)
Y Komatsu
T20606 Address:

Insp.Date(yyyy/mm/dd) (yyyy/m/d) Wear type IMPACT
LH 686.8 698.8
LINK PITCH R
M L L=l/4 RH 686.8 698.8
LH 171.70 174.70
master pin
l
M
RH 171.70 174.70
LH 98.0 89.0
H
RH 98.0 89.0
LINK HEIGHT
New Turned
BUSHING d1
LH 56.0 50.0
New Turned
d
d RH 56.0 50.0
D is the smallest
of d1, d2 and, d3
H
RH 53.0 25.0
Front
RH 150.0 126.0
D LH 150.0 126.0
Rear
RH 150.0 126.0
LH 19.0 28.0
IDLER Front
RH 19.0 28.0
H
LH 19.0 28.0
Rear
RH 19.0 28.0
1 LH 175.0 150.0
2 LH 175.0 150.0
3 LH 175.0 150.0
4 LH 175.0 150.0
5 LH 175.0 150.0
6 LH 175.0 150.0
7 LH 175.0 150.0
9 LH 175.0 150.0
D 10 LH 175.0 150.0
1 RH 175.0 150.0
h2 h1 2 RH 175.0 150.0
3 RH 175.0 150.0
D=2(h1-h2) 4 RH 175.0 150.0
5 RH 175.0 150.0
6 RH 175.0 150.0
7 RH 175.0 150.0
8 RH 175.0 150.0
9 RH 175.0 150.0
10 RH 175.0 150.0
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
20-200 D31/37/39EX, PX-21

(1)
Y Komatsu
T20606 Address:

Location SMR Wet,AR,HD or Dry WET
LH 686.8 698.8
LINK PITCH R
M L L=l/4 RH 686.8 698.8
LH 171.70 174.70
master pin
l
M
RH 171.70 174.70
LH 98.0 89.0
H
RH 98.0 89.0
LINK HEIGHT
New Turned
BUSHING d1
LH 56.0 47.5
New Turned
d
d RH 56.0 47.5
D is the smallest
of d1, d2 and, d3
H
RH 53.0 25.0
Front
RH 150.0 126.0
D LH 150.0 126.0
Rear
RH 150.0 126.0
LH 19.0 28.0
IDLER Front
RH 19.0 28.0
H
LH 19.0 28.0
Rear
RH 19.0 28.0
1 LH 175.0 150.0
2 LH 175.0 150.0
3 LH 175.0 150.0
4 LH 175.0 150.0
5 LH 175.0 150.0
6 LH 175.0 150.0
7 LH 175.0 150.0
9 LH 175.0 150.0
D 10 LH 175.0 150.0
1 RH 175.0 150.0
h2 h1 2 RH 175.0 150.0
3 RH 175.0 150.0
D=2(h1-h2) 4 RH 175.0 150.0
5 RH 175.0 150.0
6 RH 175.0 150.0
7 RH 175.0 150.0
8 RH 175.0 150.0
9 RH 175.0 150.0
10 RH 175.0 150.0
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
D31/37/39EX, PX-21 20-201

(1)
Y Komatsu
T20606 Address:

LH 686.8 698.8
LINK PITCH R
M L L=l/4 RH 686.8 698.8
LH 171.70 174.70
master pin
l
M
RH 171.70 174.70
LH 98.0 89.0
H
RH 98.0 89.0
LINK HEIGHT
New Turned
BUSHING d1
LH 56.0 50.0
New Turned
d
d RH 56.0 50.0
D is the smallest
of d1, d2 and, d3
H
RH 53.0 25.0
Front
RH 150.0 126.0
D LH 150.0 126.0
Rear
RH 150.0 126.0
LH 19.0 28.0
IDLER Front
RH 19.0 28.0
H
LH 19.0 28.0
Rear
RH 19.0 28.0
1 LH 175.0 150.0
2 LH 175.0 150.0
3 LH 175.0 150.0
4 LH 175.0 150.0
5 LH 175.0 150.0
6 LH 175.0 150.0
7 LH 175.0 150.0
9 LH 175.0 150.0
D 10 LH 175.0 150.0
1 RH 175.0 150.0
h2 h1 2 RH 175.0 150.0
3 RH 175.0 150.0
D=2(h1-h2) 4 RH 175.0 150.0
5 RH 175.0 150.0
6 RH 175.0 150.0
7 RH 175.0 150.0
8 RH 175.0 150.0
9 RH 175.0 150.0
10 RH 175.0 150.0
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
20-202 D31/37/39EX, PX-21

(1)
Y Komatsu
T20606 Address:
Model D31EX-21 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 87.0 80.0
H
RH 87.0 80.0
LINK HEIGHT
New Turned
BUSHING d1
LH 50.0 41.6
New Turned
d
d RH 50.0 41.6
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 170.0 156.0
2 LH 170.0 156.0
3 LH 170.0 156.0
4 LH 170.0 156.0
5 LH 170.0 156.0
6 LH 170.0 156.0
7 LH 170.0 156.0
9 LH 170.0 156.0
D 10 LH 170.0 156.0
1 RH 170.0 156.0
h2 h1 2 RH 170.0 156.0
3 RH 170.0 156.0
D=2(h1-h2) 4 RH 170.0 156.0
5 RH 170.0 156.0
6 RH 170.0 156.0
7 RH 170.0 156.0
8 RH 170.0 156.0
9 RH 170.0 156.0
1.3 10 RH 170.0 156.0
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
D31/37/39EX, PX-21 20-203

(1)
Y Komatsu
T20606 Address:

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 87.0 80.0
H
RH 87.0 80.0
LINK HEIGHT
New Turned
BUSHING d1
LH 50.0 44.5
New Turned
d
d RH 50.0 44.5
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 170.0 156.0
2 LH 170.0 156.0
3 LH 170.0 156.0
4 LH 170.0 156.0
5 LH 170.0 156.0
6 LH 170.0 156.0
7 LH 170.0 156.0
9 LH 170.0 156.0
D 10 LH 170.0 156.0
1 RH 170.0 156.0
h2 h1 2 RH 170.0 156.0
3 RH 170.0 156.0
D=2(h1-h2) 4 RH 170.0 156.0
5 RH 170.0 156.0
6 RH 170.0 156.0
7 RH 170.0 156.0
8 RH 170.0 156.0
9 RH 170.0 156.0
10 RH 170.0 156.0
h1,h2,h3 h3 h2
RH 0.0 6.0
Remarks:
20-204 D31/37/39EX, PX-21

(1)
Y Komatsu
T20606 Address:

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 87.0 80.0
H
RH 87.0 80.0
LINK HEIGHT
New Turned
BUSHING d1
LH 50.0 41.6
New Turned
d
d RH 50.0 41.6
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 170.0 156.0
2 LH 170.0 156.0
3 LH 170.0 156.0
4 LH 170.0 156.0
5 LH 170.0 156.0
6 LH 170.0 156.0
7 LH 170.0 156.0
9 LH 170.0 156.0
D 10 LH 170.0 156.0
1 RH 170.0 156.0
h2 h1 2 RH 170.0 156.0
3 RH 170.0 156.0
D=2(h1-h2) 4 RH 170.0 156.0
5 RH 170.0 156.0
6 RH 170.0 156.0
7 RH 170.0 156.0
8 RH 170.0 156.0
9 RH 170.0 156.0
10 RH 170.0 156.0
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
D31/37/39EX, PX-21 20-205

(1)
Y Komatsu
T20606 Address:

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 87.0 80.0
H
RH 87.0 80.0
LINK HEIGHT
New Turned
BUSHING d1
LH 50.0 44.5
New Turned
d
d RH 50.0 44.5
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 170.0 156.0
2 LH 170.0 156.0
3 LH 170.0 156.0
4 LH 170.0 156.0
5 LH 170.0 156.0
6 LH 170.0 156.0
7 LH 170.0 156.0
9 LH 170.0 156.0
D 10 LH 170.0 156.0
1 RH 170.0 156.0
h2 h1 2 RH 170.0 156.0
3 RH 170.0 156.0
D=2(h1-h2) 4 RH 170.0 156.0
5 RH 170.0 156.0
6 RH 170.0 156.0
7 RH 170.0 156.0
8 RH 170.0 156.0
9 RH 170.0 156.0
1.3 10 RH 170.0 156.0
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
20-206 D31/37/39EX, PX-21

(1)
Y Komatsu
T20606 Address:

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 87.0 80.0
H
RH 87.0 80.0
LINK HEIGHT
New Turned
BUSHING d1
LH 50.0 41.6
New Turned
d
d RH 50.0 41.6
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 170.0 156.0
2 LH 170.0 156.0
3 LH 170.0 156.0
4 LH 170.0 156.0
5 LH 170.0 156.0
6 LH 170.0 156.0
7 LH 170.0 156.0
9 LH 170.0 156.0
D 10 LH 170.0 156.0
1 RH 170.0 156.0
h2 h1 2 RH 170.0 156.0
3 RH 170.0 156.0
D=2(h1-h2) 4 RH 170.0 156.0
5 RH 170.0 156.0
6 RH 170.0 156.0
7 RH 170.0 156.0
8 RH 170.0 156.0
9 RH 170.0 156.0
10 RH 170.0 156.0
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
D31/37/39EX, PX-21 20-207

(1)
Y Komatsu
T20606 Address:

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 87.0 80.0
H
RH 87.0 80.0
LINK HEIGHT
New Turned
BUSHING d1
LH 50.0 44.5
New Turned
d
d RH 50.0 44.5
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 170.0 156.0
2 LH 170.0 156.0
3 LH 170.0 156.0
4 LH 170.0 156.0
5 LH 170.0 156.0
6 LH 170.0 156.0
7 LH 170.0 156.0
9 LH 170.0 156.0
D 10 LH 170.0 156.0
1 RH 170.0 156.0
h2 h1 2 RH 170.0 156.0
3 RH 170.0 156.0
D=2(h1-h2) 4 RH 170.0 156.0
5 RH 170.0 156.0
6 RH 170.0 156.0
7 RH 170.0 156.0
8 RH 170.0 156.0
9 RH 170.0 156.0
10 RH 170.0 156.0
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
20-208 D31/37/39EX, PX-21

(1)
Y Komatsu
T20606 Address:

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 87.0 80.0
H
RH 87.0 80.0
LINK HEIGHT
New Turned
BUSHING d1
LH 50.0 41.6
New Turned
d
d RH 50.0 41.6
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 170.0 156.0
2 LH 170.0 156.0
3 LH 170.0 156.0
4 LH 170.0 156.0
5 LH 170.0 156.0
6 LH 170.0 156.0
7 LH 170.0 156.0
9 LH 170.0 156.0
D 10 LH 170.0 156.0
1 RH 170.0 156.0
h2 h1 2 RH 170.0 156.0
3 RH 170.0 156.0
D=2(h1-h2) 4 RH 170.0 156.0
5 RH 170.0 156.0
6 RH 170.0 156.0
7 RH 170.0 156.0
8 RH 170.0 156.0
9 RH 170.0 156.0
10 RH 170.0 156.0
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
D31/37/39EX, PX-21 20-209

(1)
Y Komatsu
T20606 Address:

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 87.0 80.0
H
RH 87.0 80.0
LINK HEIGHT
New Turned
BUSHING d1
LH 50.0 44.5
New Turned
d
d RH 50.0 44.5
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 170.0 156.0
2 LH 170.0 156.0
3 LH 170.0 156.0
4 LH 170.0 156.0
5 LH 170.0 156.0
6 LH 170.0 156.0
7 LH 170.0 156.0
9 LH 170.0 156.0
D 10 LH 170.0 156.0
1 RH 170.0 156.0
h2 h1 2 RH 170.0 156.0
3 RH 170.0 156.0
D=2(h1-h2) 4 RH 170.0 156.0
5 RH 170.0 156.0
6 RH 170.0 156.0
7 RH 170.0 156.0
8 RH 170.0 156.0
9 RH 170.0 156.0
10 RH 170.0 156.0
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
20-210 D31/37/39EX, PX-21

(1)
Y Komatsu
T20606 Address:

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 87.0 80.0
H
RH 87.0 80.0
LINK HEIGHT
New Turned
BUSHING d1
LH 50.0 41.6
New Turned
d
d RH 50.0 41.6
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 170.0 156.0
2 LH 170.0 156.0
3 LH 170.0 156.0
4 LH 170.0 156.0
5 LH 170.0 156.0
6 LH 170.0 156.0
7 LH 170.0 156.0
9 LH 170.0 156.0
D 10 LH 170.0 156.0
1 RH 170.0 156.0
h2 h1 2 RH 170.0 156.0
3 RH 170.0 156.0
D=2(h1-h2) 4 RH 170.0 156.0
5 RH 170.0 156.0
6 RH 170.0 156.0
7 RH 170.0 156.0
8 RH 170.0 156.0
9 RH 170.0 156.0
10 RH 170.0 156.0
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
D31/37/39EX, PX-21 20-211

(1)
Y Komatsu
T20606 Address:

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 87.0 80.0
H
RH 87.0 80.0
LINK HEIGHT
New Turned
BUSHING d1
LH 50.0 44.5
New Turned
d
d RH 50.0 44.5
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 170.0 156.0
2 LH 170.0 156.0
3 LH 170.0 156.0
4 LH 170.0 156.0
5 LH 170.0 156.0
6 LH 170.0 156.0
7 LH 170.0 156.0
9 LH 170.0 156.0
D 10 LH 170.0 156.0
1 RH 170.0 156.0
h2 h1 2 RH 170.0 156.0
3 RH 170.0 156.0
D=2(h1-h2) 4 RH 170.0 156.0
5 RH 170.0 156.0
6 RH 170.0 156.0
7 RH 170.0 156.0
8 RH 170.0 156.0
9 RH 170.0 156.0
10 RH 170.0 156.0
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
20-212 D31/37/39EX, PX-21

(1)
Y Komatsu
T20606 Address:

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 87.0 80.0
H
RH 87.0 80.0
LINK HEIGHT
New Turned
BUSHING d1
LH 50.0 41.6
New Turned
d
d RH 50.0 41.6
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 170.0 156.0
2 LH 170.0 156.0
3 LH 170.0 156.0
4 LH 170.0 156.0
5 LH 170.0 156.0
6 LH 170.0 156.0
7 LH 170.0 156.0
9 LH 170.0 156.0
D 10 LH 170.0 156.0
1 RH 170.0 156.0
h2 h1 2 RH 170.0 156.0
3 RH 170.0 156.0
D=2(h1-h2) 4 RH 170.0 156.0
5 RH 170.0 156.0
6 RH 170.0 156.0
7 RH 170.0 156.0
8 RH 170.0 156.0
9 RH 170.0 156.0
10 RH 170.0 156.0
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
D31/37/39EX, PX-21 20-213

(1)
Y Komatsu
T20606 Address:

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 87.0 80.0
H
RH 87.0 80.0
LINK HEIGHT
New Turned
BUSHING d1
LH 50.0 44.5
New Turned
d
d RH 50.0 44.5
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 170.0 156.0
2 LH 170.0 156.0
3 LH 170.0 156.0
4 LH 170.0 156.0
5 LH 170.0 156.0
6 LH 170.0 156.0
7 LH 170.0 156.0
9 LH 170.0 156.0
D 10 LH 170.0 156.0
1 RH 170.0 156.0
h2 h1 2 RH 170.0 156.0
3 RH 170.0 156.0
D=2(h1-h2) 4 RH 170.0 156.0
5 RH 170.0 156.0
6 RH 170.0 156.0
7 RH 170.0 156.0
8 RH 170.0 156.0
9 RH 170.0 156.0
10 RH 170.0 156.0
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
20-214 D31/37/39EX, PX-21

(1)
Y Komatsu
T20606 Address:

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 87.0 80.0
H
RH 87.0 80.0
LINK HEIGHT
New Turned
BUSHING d1
LH 50.0 41.6
New Turned
d
d RH 50.0 41.6
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 170.0 156.0
2 LH 170.0 156.0
3 LH 170.0 156.0
4 LH 170.0 156.0
5 LH 170.0 156.0
6 LH 170.0 156.0
7 LH 170.0 156.0
9 LH 170.0 156.0
D 10 LH 170.0 156.0
1 RH 170.0 156.0
h2 h1 2 RH 170.0 156.0
3 RH 170.0 156.0
D=2(h1-h2) 4 RH 170.0 156.0
5 RH 170.0 156.0
6 RH 170.0 156.0
7 RH 170.0 156.0
8 RH 170.0 156.0
9 RH 170.0 156.0
10 RH 170.0 156.0
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
D31/37/39EX, PX-21 20-215

(1)
Y Komatsu
T20606 Address:

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 87.0 80.0
H
RH 87.0 80.0
LINK HEIGHT
New Turned
BUSHING d1
LH 50.0 44.5
New Turned
d
d RH 50.0 44.5
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 170.0 156.0
2 LH 170.0 156.0
3 LH 170.0 156.0
4 LH 170.0 156.0
5 LH 170.0 156.0
6 LH 170.0 156.0
7 LH 170.0 156.0
9 LH 170.0 156.0
D 10 LH 170.0 156.0
1 RH 170.0 156.0
h2 h1 2 RH 170.0 156.0
3 RH 170.0 156.0
D=2(h1-h2) 4 RH 170.0 156.0
5 RH 170.0 156.0
6 RH 170.0 156.0
7 RH 170.0 156.0
8 RH 170.0 156.0
9 RH 170.0 156.0
10 RH 170.0 156.0
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
20-216 D31/37/39EX, PX-21

(1)
Y Komatsu
T20606 Address:

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 87.0 80.0
H
RH 87.0 80.0
LINK HEIGHT
New Turned
BUSHING d1
LH 50.0 41.6
New Turned
d
d RH 50.0 41.6
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 170.0 156.0
2 LH 170.0 156.0
3 LH 170.0 156.0
4 LH 170.0 156.0
5 LH 170.0 156.0
6 LH 170.0 156.0
7 LH 170.0 156.0
9 LH 170.0 156.0
D 10 LH 170.0 156.0
1 RH 170.0 156.0
h2 h1 2 RH 170.0 156.0
3 RH 170.0 156.0
D=2(h1-h2) 4 RH 170.0 156.0
5 RH 170.0 156.0
6 RH 170.0 156.0
7 RH 170.0 156.0
8 RH 170.0 156.0
9 RH 170.0 156.0
10 RH 170.0 156.0
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
D31/37/39EX, PX-21 20-217

(1)
Y Komatsu
T20606 Address:

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 87.0 80.0
H
RH 87.0 80.0
LINK HEIGHT
New Turned
BUSHING d1
LH 50.0 44.5
New Turned
d
d RH 50.0 44.5
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 170.0 156.0
2 LH 170.0 156.0
3 LH 170.0 156.0
4 LH 170.0 156.0
5 LH 170.0 156.0
6 LH 170.0 156.0
7 LH 170.0 156.0
9 LH 170.0 156.0
D 10 LH 170.0 156.0
1 RH 170.0 156.0
h2 h1 2 RH 170.0 156.0
3 RH 170.0 156.0
D=2(h1-h2) 4 RH 170.0 156.0
5 RH 170.0 156.0
6 RH 170.0 156.0
7 RH 170.0 156.0
8 RH 170.0 156.0
9 RH 170.0 156.0
10 RH 170.0 156.0
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
20-218 D31/37/39EX, PX-21

(1)
Y Komatsu
T20606 Address:

LH 686.8 706.8
LINK PITCH R
M L L=l/4 RH 686.8 706.8
LH 171.70 176.70
master pin
l
M
RH 171.70 176.70
LH 98.0 89.0
H
RH 98.0 89.0
LINK HEIGHT
New Turned
BUSHING d1
LH 56.0 47.5
New Turned
d
d RH 56.0 47.5
D is the smallest
of d1, d2 and, d3
H
RH 53.0 25.0
Front
RH 150.0 126.0
D LH 150.0 126.0
Rear
RH 150.0 126.0
LH 19.0 28.0
IDLER Front
RH 19.0 28.0
H
LH 19.0 28.0
Rear
RH 19.0 28.0
1 LH 175.0 150.0
2 LH 175.0 150.0
3 LH 175.0 150.0
4 LH 175.0 150.0
5 LH 175.0 150.0
6 LH 175.0 150.0
7 LH 175.0 150.0
9 LH 175.0 150.0
D 10 LH 175.0 150.0
1 RH 175.0 150.0
h2 h1 2 RH 175.0 150.0
3 RH 175.0 150.0
D=2(h1-h2) 4 RH 175.0 150.0
5 RH 175.0 150.0
6 RH 175.0 150.0
7 RH 175.0 150.0
8 RH 175.0 150.0
9 RH 175.0 150.0
10 RH 175.0 150.0
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
D31/37/39EX, PX-21 20-219

(1)
Y Komatsu
T20606 Address:

LH 686.8 698.8
LINK PITCH R
M L L=l/4 RH 686.8 698.8
LH 171.70 174.70
master pin
l
M
RH 171.70 174.70
LH 98.0 89.0
H
RH 98.0 89.0
LINK HEIGHT
New Turned
BUSHING d1
LH 56.0 50.0
New Turned
d
d RH 56.0 50.0
D is the smallest
of d1, d2 and, d3
H
RH 53.0 25.0
Front
RH 150.0 126.0
D LH 150.0 126.0
Rear
RH 150.0 126.0
LH 19.0 28.0
IDLER Front
RH 19.0 28.0
H
LH 19.0 28.0
Rear
RH 19.0 28.0
1 LH 175.0 150.0
2 LH 175.0 150.0
3 LH 175.0 150.0
4 LH 175.0 150.0
5 LH 175.0 150.0
6 LH 175.0 150.0
7 LH 175.0 150.0
9 LH 175.0 150.0
D 10 LH 175.0 150.0
1 RH 175.0 150.0
h2 h1 2 RH 175.0 150.0
3 RH 175.0 150.0
D=2(h1-h2) 4 RH 175.0 150.0
5 RH 175.0 150.0
6 RH 175.0 150.0
7 RH 175.0 150.0
8 RH 175.0 150.0
9 RH 175.0 150.0
10 RH 175.0 150.0
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
20-220 D31/37/39EX, PX-21

(1)
Y Komatsu
T20606 Address:

LH 686.8 698.8
LINK PITCH R
M L L=l/4 RH 686.8 698.8
LH 171.70 174.70
master pin
l
M
RH 171.70 174.70
LH 98.0 89.0
H
RH 98.0 89.0
LINK HEIGHT
New Turned
BUSHING d1
LH 56.0 47.5
New Turned
d
d RH 56.0 47.5
D is the smallest
of d1, d2 and, d3
H
RH 53.0 25.0
Front
RH 150.0 126.0
D LH 150.0 126.0
Rear
RH 150.0 126.0
LH 19.0 28.0
IDLER Front
RH 19.0 28.0
H
LH 19.0 28.0
Rear
RH 19.0 28.0
1 LH 175.0 150.0
2 LH 175.0 150.0
3 LH 175.0 150.0
4 LH 175.0 150.0
5 LH 175.0 150.0
6 LH 175.0 150.0
7 LH 175.0 150.0
9 LH 175.0 150.0
D 10 LH 175.0 150.0
1 RH 175.0 150.0
h2 h1 2 RH 175.0 150.0
3 RH 175.0 150.0
D=2(h1-h2) 4 RH 175.0 150.0
5 RH 175.0 150.0
6 RH 175.0 150.0
7 RH 175.0 150.0
8 RH 175.0 150.0
9 RH 175.0 150.0
10 RH 175.0 150.0
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
D31/37/39EX, PX-21 20-221

(1)
Y Komatsu
T20606 Address:

LH 686.8 698.8
LINK PITCH R
M L L=l/4 RH 686.8 698.8
LH 171.70 174.70
master pin
l
M
RH 171.70 174.70
LH 98.0 89.0
H
RH 98.0 89.0
LINK HEIGHT
New Turned
BUSHING d1
LH 56.0 50.0
New Turned
d
d RH 56.0 50.0
D is the smallest
of d1, d2 and, d3
H
RH 53.0 25.0
Front
RH 150.0 126.0
D LH 150.0 126.0
Rear
RH 150.0 126.0
LH 19.0 28.0
IDLER Front
RH 19.0 28.0
H
LH 19.0 28.0
Rear
RH 19.0 28.0
1 LH 175.0 150.0
2 LH 175.0 150.0
3 LH 175.0 150.0
4 LH 175.0 150.0
5 LH 175.0 150.0
6 LH 175.0 150.0
7 LH 175.0 150.0
9 LH 175.0 150.0
D 10 LH 175.0 150.0
1 RH 175.0 150.0
h2 h1 2 RH 175.0 150.0
3 RH 175.0 150.0
D=2(h1-h2) 4 RH 175.0 150.0
5 RH 175.0 150.0
6 RH 175.0 150.0
7 RH 175.0 150.0
8 RH 175.0 150.0
9 RH 175.0 150.0
10 RH 175.0 150.0
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
20-222 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING
Points to remember when troubleshooting.................................................................................................. 20-302

Sequence of events in troubleshooting ....................................................................................................... 20-303
Handling of electric equipment and hydraulic component .......................................................................... 20-304
Checks before troubleshooting ................................................................................................................... 20-312
Classification and procedures of troubleshooting ....................................................................................... 20-313
Connector arrangement drawing and electric circuit diagram of each system............................................ 20-316
Connection table for connector pin numbers .............................................................................................. 20-330
T-branch box and T-branch adapter table ................................................................................................... 20-366
Troubleshooting when error code is displayed............................................................................................ 20-401
Troubleshooting of electrical system (E mode) ........................................................................................... 20-601
Troubleshooting of hydraulic and mechanical system (H mode) ................................................................ 20-701
Troubleshooting of engine (S mode)........................................................................................................... 20-801
D31/37/39EX, PX-21 20-301

(5)
TESTTING AND ADJUSTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

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 two 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 water 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 connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and func-
tion.
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 symptoms.
1. When carrying out troubleshooting, do not hurry 5) Other maintenance items can be checked
to disassemble the components. externally, so check any item that is consid-
If components are disassembled immediately ered to be necessary.
any failure occurs:
• Parts that have no connection with the failure 4. Confirming failure
or other unnecessary parts will be disassem- • Confirm the extent of the failure yourself, and
bled. judge whether to handle it as a real failure or
• It will become impossible to find the cause of as a problem with the method of operation,
the failure. etc.
It will also cause a waste of manhours, parts, or a When operating the machine to reenact
oil or grease, and at the same time, will also lose the troubleshooting symptoms, do not
the confidence of the user or operator. carry out any investigation or measure-
For this reason, when carrying out troubleshoot- ment that may make the problem worse.
ing, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in 5. Troubleshooting
accordance with the fixed procedure. • Use the results of the investigation and in-
spection in Items 2 – 4 to narrow down the
2. Points to ask user or operator causes of failure, then use the troubleshoot-
1) Have any other problems occurred apart ing flowchart to locate the position of the fail-
from the problem that has been reported? ure exactly.
2) Was there anything strange about the a The basic procedure for troubleshooting
machine before the failure occurred? is as follows.
3) Did the failure occur suddenly, or were there 1) Start from the simple points.
problems with the machine condition before 2) Start from the most likely points.
this? 3) Investigate other related parts or
4) Under what conditions did the failure occur? information.
5) Had any repairs been carried out before the
failure? 6. Measures to remove root cause of failure
When were these repairs carried out? • Even if the failure is repaired, if the root
6) Has the same kind of failure occurred cause of the failure is not repaired, the same
before? failure will occur again.
To prevent this, always investigate why the
3. Check before troubleshooting problem occurred. Then, remove the root
1) Check the oil level cause.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
4) Check the stroke of the control valve spool.
20-302 D31/37/39EX, PX-21

(1)
TESTTING AND ADJUSTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
D31/37/39EX, PX-21 20-303

(1)
TESTTING AND ADJUSTING HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT
HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC

COMPONENT
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 hydrau-
lic 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, connec-
tors 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, dur-
ing 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 (defective
contact between male and female)
Problems with defective contact are likely
to occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces. The
corroded or oxidized contact surfaces may
become shiny again (and contact may
become normal) by connecting and discon-
necting 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 excessive
force brought to bear on the wiring, the
plating at the joint will peel and cause
improper connection or breakage.
20-304 D31/37/39EX, PX-21

(5)
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 solder-
ing 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 structure),
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 con-
nector, the pins will be short-circuited by
the water, so if any water gets in, immedi-
ately dry the connector or take other appro-
priate 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 exces-
sive 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 wa-
ter from the compressed air completely
before cleaning with compressed air.
D31/37/39EX, PX-21 20-305

(5)
3. Removing, installing, and drying connectors

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

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

clip, pull the connector in a parallel di-
rection 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 disassembled
for a long time, it is particularly
easy for improper contact to occur,
so always cover the connector.
20-306 D31/37/39EX, PX-21

(5)
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 connec-
tor.
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 cor-
rectly, and then insert it securely. For
connectors with the lock stopper, push
in the connector until the stopper 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 addi-
tion, if the wiring harness is
misaligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be correct-
ed easily, remove the clamp and
adjust the position.
• If the connector clamp has been
removed, be sure to return it to its
original position. Check also that
there are no loose clamps.
D31/37/39EX, PX-21 20-307

(5)
3) Heavy duty wire connector (DT 8-pole, 12- • Disconnection • 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
20-308 D31/37/39EX, PX-21

(5)
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 follows.
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 defec-
tive contact, so remove all oil and
water from the compressed air be-
fore 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-
nector, blow it with contact restorer
and reassemble.
D31/37/39EX, PX-21 20-309

(5)
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 con-
tacts with your hand.
4) During rainy weather, do not leave the con-
troller 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 connectors
connected to the controller. Fit an arc weld-
ing 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 connec-
tors before going on to the next step.
a If the power is turned ON with the con-
nectors still disconnected, unneces-
sary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related wir-
ing 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 probably
defective contact in that circuit.
20-310 D31/37/39EX, PX-21

(5)
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. Disas-
sembly and maintenance of hydraulic equip-
ment 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 enter-
ing. 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 dis-
posal.
4. Do not let any dirt or dust get in during refill-

ing 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.
D31/37/39EX, PX-21 20-311

(5)
TESTING AND ADJUSTING HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT
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 con-
taminants 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 car-
ried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
contro l valve, et c.) 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 cannot
remove, so it is an extremely effective device.
20-311-1 D31/37/39EX, PX-21

(5)
TESTTING AND ADJUSTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING

Judgement
Item Action
value
1. Check fuel level, type of fuel — Add fuel
Lubricating oil,
2. Check for impurities in fuel — Clean, drain

3. Check engine oil level (oil pan oil level), type of oil — Add oil
coolant
4. Check coolant level — Add coolant

5. Check air cleaner for clogging — Clean or replace
6. Check hydraulic oil level, type of oil — Add oil
7. Check hydraulic filter and HST charge filter — Replace
equipment
8. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace

Electrical
9. Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace

10. Check for looseness, corrosion of starting motor terminal, wiring — Tighten or replace
mechanical
equipment
Hydraulic,
11. Check for abnormal noise, smell — Repair

12. Check for oil leakage — Repair
13. Carry out air bleeding — Bleed air
14. Check battery voltage (engine stopped) 20 – 30V Replace
15. Check battery electrolyte level — Add or replace
Electrics, electrical equipment
16. Check for discolored, burnt, exposed wiring — Replace

17. Check for missing wiring clamps, hanging wiring — Repair
18. Check for water leaking on wiring (be particularly careful attention to — Disconnect
water leaking on connectors or terminals) connector and dry
19. Check for blown, corroded fusible links and fuses — Replace
20. Check alternator voltage (engine running at 1/2 throttle or above) After Replace
running for
several
minutes :
27.5 – 29.5V
21. Check operating sound of battery relay — Replace
(when switch is turned ON/OFF)
20-312 D31/37/39EX, PX-21

(1)
TESTTING AND ADJUSTING CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING

Classification of troubleshooting
Mode Contents
Error code Troubleshooting when error code is displayed
E-mode Troubleshooting for electric system
H-mode Troubleshooting for hydraulic and mechanical system
S-mode Troubleshooting for engine unit
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 monitor panel:
If an action code is displayed on the monitor panel, display the error code in the error code display mode
(for the electrical system and the mechanical system) of the monitor panel (EMMS).
Carry out troubleshooting under the displayed error code.
a Each error code “flashes” when the trouble corresponding to it is detected. Even if an error code “lights
up” when the starting switch is turned ON, the trouble corresponding to that error code may not have
been repaired (Some troubles can be detected by simply turning the starting switch ON).
a If an error code is recorded, be sure to perform the operation for reproducing it to see if the trouble cor-
responding to it has been repaired (For the method of reproducing the error code, see the troubleshoot-
ing under the error code).
2. Procedure for troubleshooting to be taken when error code is recorded:
If an action code is not displayed on the monitor panel, check for an error code in the error code display
mode (for the electrical system and the mechanical system) of the monitor panel (EMMS).
If an error code is recorded, carry out troubleshooting under it.
a Each error code “flashes” when the trouble corresponding to it is detected. Even if an error code “lights
up” when the starting switch is turned ON, the trouble corresponding to that error code may not have
been repaired (Some troubles can be detected by simply turning the starting switch ON).
a If an error code is recorded, be sure to perform the operation for reproducing it to see if the trouble cor-
responding to it has been repaired (For the method of reproducing the error code, see the troubleshoot-
ing under the error code).
3. Procedure of troubleshooting to be taken when action code is not displayed and error code is not
recorded:
If an error code is not recorded in the monitor panel (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 troubleshooting
related to that phenomenon in the ”E mode“, “H mode”, or “S mode”.
D31/37/39EX, PX-21 20-313

(1)
Phenomena looking like troubles and troubleshooting
Troubleshooting
No. Phenomenon looking like trouble
Error code E-mode H-mode S-mode
Phenomena related to action code or error code
1 Action codes are displayed on monitor panel. Check error codes.
2 Error codes are displayed in error code display mode. q
Phenomena related to engine
3 Engine does not start easily (It always takes time to start) S-1
4 Engine does not crank E-1(1) S-2 a)
Engine cranks but exhaust smoke
5 E-1(2) S-2 b)
Engine does not start does not come out
Exhaust smoke comes out but engine
6 S-2 c)
does not start
7 Engine speed does not rise sharply (Follow-up performance is low) S-3
8 Engine stops during operation S-4
9 Engine rotation is abnormal (Engine hunts) S-5
10 Output is insufficient (Power is low) S-6
11 Exhaust gas color is bad (Incomplete combustion) S-7
12 Oil is consumed much (or exhaust gas color is bad) S-8
13 Oil becomes dirty quickly S-9
14 Fuel is consumed much S-10
15 Coolant contains oil (or it blows back or reduces) S-11
16 Engine oil pressure caution lamp lights up (Oil pressure lowers) S-12
17 Oil level rises (Water or fuel is mixed in oil) S-13
18 Water temperature rises too high (Overheating) S-14
19 Abnormal sound comes out S-15
20 Vibration is excessive S-16
21 Engine is not preheated normally (Manual preheating mechanism) E-2
22 Engine does not stop E-3
Phenomena related to HST
Right and left travel systems do not operate forward and in reverse
23 H-1
(No travel systems operate)
Right or left travel system does not operate forward and in reverse
24 H-2
(Only right or left travel system does not operate)
Right or left travel system does not operate forward or in reverse
25 H-3
(Only 1 system does not operate)
26 Speed or power of travel is low H-4 S-6
27 Gear is not shifted H-5
28 Large shock is made when machine stops traveling H-6
29 Machine deviates largely during travel H-7
30 Hydraulic drift of travel is large H-8
31 Engine stalls or engine speed lowers extremely during travel H-9 S-4
20-314 D31/37/39EX, PX-21

(1)
Troubleshooting
No. Phenomenon looking like trouble
Error code E-mode H-mode S-mode
32 Abnormal sound comes out from around HST pump and motor H-10
33 Work equipment dose not operate at all H-11
34 Speed or power of whole work equipment is low H-12
35 Speed or power of lifting blade is low H-13
36 Speed or power of tilting blade is low H-14
37 Speed or power of angling blade is low H-15
38 Time lag in lifting blade is large H-16
39 Hydraulic drift of lifting blade is large H-17
40 Hydraulic drift of tilting blade is large H-18
Abnormal sound comes out from around work equipment pump and
41 H-19
control valve
42 HST oil temperature (Hydraulic oil temperature) rises too high E-7(3) H-20
Phenomena related to monitor panel (Operator mode: Ordinary screen)
43 When starting switch is turned ON, any item does not light up E-4
When starting switch is turned ON, all items light up and none of
44 E-5
them goes off
45 Charge level caution flashes while engine is running E-6
46 Emergency warning items flash while engine is running E-7
47 Preheating pilot lamp does not light up during preheating operation E-8
48 Engine coolant thermometer is abnormal E-9
49 HST oil thermometer is abnormal E-10
50 Fuel level gauge is abnormal E-11
51 Reverse travel speed indicator is abnormal E-12
52 Gear speed, set travel speed, and shift mode indicator is abnormal E-13
53 Multi-information section is abnormal E-14
54 Caution lamp does not flash or does not go off E-15
55 Caution buzzer does not sound or does not stop E-16
56 Reverse travel speed setting switch does not function E-17
57 Shift mode switch does not function E-18
58 Buzzer cancel switch does not function E-19
59 Information switch does not function E-20
Phenomena related to monitor panel (Service mode: Special function screen)
60 System is not set in service mode or is not set out of service mode E-21
Other phenomena
61 Backup alarm does not sound E-22
62 Headlamp or rear lamp does not light up E-23
63 Canopy heater does not operate [Canopy specification] E-24
64 Air conditioner does not operate [Cab specification] E-25
Windshield wiper and windshield washer do not operate [Cab speci-
65 E-26
fication]
D31/37/39EX, PX-21 20-315

(1)
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC
TESTTING AND ADJUSTING CIRCUIT DIAGRAM OF EACH SYSTEM

CIRCUIT DIAGRAM OF EACH SYSTEM
Connectors list
a The addresses roughly show the places of the connectors in the 3-dimensional connectors arrangement
drawing and the electric circuit diagram of each system.
Address
Connector No. of
Type Name of device Stereo-
No. pins M-circuit H-circuit
gram
250 Terminal 1 Starting switch (Terminal B) N-4 A-2 H-9
255 Terminal 1 Starting switch (Terminal R1) N-3 A-2 -
256 Terminal 1 Starting switch (Terminal R2) N-4 - -
260 Terminal 1 Starting switch (Terminal BR) N-5 A-2 H-9
270 Terminal 1 Starting switch (Terminal ACC) N-5 B-2 I-9
280 Terminal 1 Starting switch (Terminal C) N-6 A-2 -
CN1 DT 2 Intermediate connector AA-8 D-7 -
CN2 DT 6 Intermediate connector Z-7 E-7 K-7
CN3 DT 6 Intermediate connector Z-7 E-7 K-6
CN4 DT 2 Starting motor safety relay (Terminals S and R) D-5 C-8
CN5 DT 12 Intermediate connector D-6 G-4 G-6
CN11 SHINAGAWA 6 Neutral and parking relay I-2 J-1 K-4
CN12 DT 2 HST oil temperature sensor J-2 - L-4
CN13 DT 2 Fuel level sensor K-4 L-2 -
CN14 DT 2 Intermediate connector K-4 - L-3
CN15 DT 2 Fuel system air bleeding pump J-2 K-2 -
CN16 DT 6 Intermediate connector K-3 - K-2
CN17 DTHD 1 Spare power supply connector B-2 - -
CN20 DT 2 Engine coolant temperature sensor AC-9 G-9 -
CN21 090II 2 Horn B-3 - -
CN22 DT 2 Intermediate connector B-4 - -
CN23 X 1 Air conditioner compressor [Cab specification] Y-4 - -
CN26 DT 3 Neutral and parking limit switch 1 U-8 - E-1
CN26B DT 3 Neutral and parking limit switch 2 U-8 - D-1
CN27 DT 6 Intermediate connector S-9 - A-8
CN33 DT 4 Intermediate connector C-9, K-7 K-5, K-6 -
CN34 YAZAKI 2 Intermediate connector D-9, K-6 - -
CN38 KANSEI 3 Shift-up switch T-9 - A-8
CN39 KANSEI 3 Shift-down switch T-9 - A-8
CN45 DT 12 Intermediate connector W-7 - F-9
CN51 DT 2 Headlamp (Right) [Canopy specification] A-9 L-5 -
CN52 DT 2 Headlamp (Left) [Canopy specification] B-9 L-5 -
CN53 DT 2 Rear lamp [Canopy specification] B-9 L-6 -
CN54 SHINAGAWA 6 Lighting relay I-1 J-1 -
CN60 PA 9 Radio [Cab and Japanese specification] J-8 - -
Radio with cassette player [Cab and North America/
CN61 PA 9 J-8 - -
EU specification]
CN62 KES1 2 Rear windshield washer motor [Cab specification] I-9 - -
CN63 KES1 2 Front windshield washer motor [Cab specification] J-8 - -
CN64 M 6 Rear wiper switch [Cab specification] G-9 - -
CN65 M 6 Front wiper switch [Cab specification] G-9 - -
CN66 M 2 Rear wiper circuit breaker [Cab specification] G-9 - -
20-316 D31/37/39EX, PX-21

(1)
Address
Connector No. of
gram
CN68 M 6 Front wiper circuit breaker [Cab specification] F-8 - -
CN69 KES0 4 Rear wiper motor [Cab specification] I-9 - -
CN70 M 2 Rear speaker (Left) [Cab specification] I-8 - -
CN71 M 2 Rear speaker (Right) [Cab specification] H-9 - -
CN72 KES1 2 Room lamp [Cab specification] H-9 - -
CN73 DT 2 Rear lamp [Cab specification] H-9 K-7 -
CN74 DT 2 Headlamp (Left) [Cab specification] H-9 K-7 -
CN75 DT 2 Headlamp (Right) [Cab specification] E-8 K-6 -
CN76 AMP 12 Air conditioner control panel [Cab specification] J-8 - -
CN77 AMP 16 Air conditioner control panel [Cab specification] J-8 - -
CN78 M 2 Cigarette lighter [Cab specification] K-5 - -
CN80 SWP 16 Air conditioner unit [Cab specification] K-5 - -
CN81 DT 4 Air conditioner unit [Cab specification] K-6 - -
CN82 X 2 Air conditioner condenser [Cab specification] K-6 - -
CN92 DT 4 Intermediate connector K-3 - -
CN-BP1 DT 3 Brake pedal potentiometer Q-1 - E-1
Brake oil pressure switch (HST charge oil pressure
CN-BS DT 2 Q-1 - E-1
switch)
CN-BUZ KES1 3 Buzzer cancel switch Q-7 - J-9
CN-CA DT 3 CAN terminal resistance W-6 K-8 A-1
CN-CA2 DT 3 CAN terminal resistance O-2 A-4 H-9
CN-CB M 2 Caution buzzer P-2 A-4 -
CN-CUR KES1 3 Information switch P-2 - J-9
CN-D3 SWP 2 Diode Y-2 G-9
CN-D4 SWP 8 Assembled-type diode T-1 - B-1
CN-DP1 DT 3 Decelerator pedal potentiometer P-1 - F-1
CN-EL DT 8 PCCS lever (Directional/steering/gear shift lever) V-8 - B-9
CN-EN DT 2 Engine speed sensor AC-2 - L-6
CN-FG Terminal 1 Floor ground P-8 H-5 F-8
CN-EP DT 3 Fuel control lever potentiometer U-2 - E-9
CN-FS X 4 Personal computer connecting terminal W-5 - A-2
CN-FWL KES1 4 Working lamp switch O-7 B-1 -
CN-H1 L 2 Fusible link (Fuse constant power supply) K-6 I-1 L-8
CN-H2 L 2 Fusible link (Fuse switch power supply) K-7 I-1 L-8
CN-H3 L 2 Fusible link (Cab power supply) K-7 - L-8
CN-HS KES1 4 Heater switch [Canopy specification] Q-8 - -
CN-KS Terminal 6 Starting switch N-6 A-3 H-9
CN-LF DT 2 HST pump left forward EPC valve AF-3 - D-9
CN-LP DT 3 HST pump left circuit pressure sensor AD-2 - C-9
CN-LR DT 2 HST pump left reverse EPC valve AE-3 - D-9
CN-LRS DT 4 Left HST motor speed sensor AJ-6 - K-2
CN-MTS KES1 4 Shift mode switch N-7 - I-9
CN-P1 DT 12 Intermediate connector C-5 D-6 H-7
CN-P2 DT 4 Intermediate connector D-5 - J-7
CN-P3 DT 12 Intermediate connector C-4 D-3 H-7
CN-P4 DT 4 Intermediate connector D-5 D-1 I-7
CN-PB DT 3 Brake pedal limit switch Q-1 - D-1
Disconnection detecting resistor (Right motor speed
CN-R1 DT 2 AI-9 - L-2
sensor circuit)
Disconnection detecting resistor (Right motor speed
CN-R2 DT 2 AH-9 - K-2
sensor circuit)
CN-REV KES1 3 Reverse travel speed setting switch N-7 - I-9
D31/37/39EX, PX-21 20-317

(1)
Address
Connector No. of
gram
CN-RF DT 2 HST pump right forward EPC valve AF-3 - D-9
CN-RH Terminal 1 Electrical intake air heater Y-6 I-9
CN-RP DT 3 HST pump right circuit pressure sensor AD-9 - E-9
CN-RR DT 2 HST pump right reverse EPC valve AF-4 - E-9
CN-RRS DT 4 Right HST motor speed sensor AG-9 - K-2
CN-S03 070 20 Monitor panel O-2 A-7 G-9
CN-S04 070 12 Monitor panel N-3 A-5 G-9
CN-S1 DT 2 2nd travel speed selection solenoid valve R-1 - C-1
CN-S2 DT 2 3rd travel speed selection solenoid valve R-1 - C-1
CN-S3 DT 2 Slow brake solenoid valve R-1 - C-1
CN-S4 DT 2 Parking brake solenoid valve Q-1 - C-1
CN-S24 Terminal 6 Service switch O-2 A-3 H-9
CN-ST1 DRC26 24 HST controller Q-9 I-8 A-8
CN-ST2 DRC26 40 HST controller R-9 J-8 A-6
CN-ST3 DRC26 40 HST controller S-9 J-8 A-4
CN-T1 Terminal 1 Starting motor (Terminal B) Y-3 C-9 -
CN-T2 Terminal 1 Starting motor (Terminal C) Y-4 D-8 -
CN-T3 Terminal 1 Starting motor safety relay (Terminal B) C-4 B-8 -
CN-T4 Terminal 1 Starting motor safety relay (Terminal C) B-4 B-8 -
CN-T5 Terminal 1 Heater relay (Terminal S) AB-8 H-7 -
CN-T6 Terminal 1 Heater relay (Terminal L) Y-7 I-7 -
CN-T7 Terminal 1 Battery relay (Terminal B) I-2 H-1 J-9
CN-T8 Terminal 1 Battery relay (Terminal M) I-2 H-1 J-9
CN-T9 Terminal 1 Battery relay (Negative (-) terminal) K-3 H-1 J-8
CN-T10 Terminal 1 Fender ground H-1 L-3 J-7
CN-T12 Terminal 1 Heater relay (Terminal B) AB-8 I-7 -
CN-T13 Terminal 1 Battery relay (Position (+) terminal) K-3 H-1 K-8
CN-T15 Terminal 1 Alternator (Terminal B) Y-6 E-8 -
CN-T16 Terminal 1 Alternator (Terminal R) Y-5 E-8 K-7
CN-T17 Terminal 1 Engine stop solenoid (+) Z-2 H-9 -
CN-T18 Terminal 1 Engine stop solenoid (-) AA-1 H-9 -
CN-T19 Terminal 1 Engine oil pressure switch AB-1 F-9 -
CN-T20 Terminal 1 Engine ground AC-1 H-8 -
CN-T34 Terminal 1 HST charge filter clogging switch K-5 - L-4
CN-T35 Terminal 1 Fender ground S-1 J-4 F-7
CN-T36 Terminal 1 Floor ground P-1 H-4 -
CN-T37 Terminal 1 Horn switch P-8 - -
CN-T38 Terminal 1 Horn switch P-8 - -
CN-T39 Terminal 1 Backup alarm K-4 - L-3
CN-T40 Terminal 1 Backup alarm K-4 - L-3
FB-1 - - Fuse box (1) G-1 H-6 G-3
FB-2 - - Fuse box (2) G-1 G-6 G-3
FB-3 - - Fuse box (3) H-9 - -
20-318 D31/37/39EX, PX-21

(1)
Connector Location Stereogram
20-320 D31/37/39EX, PX-21

(1)
D31/37/39EX, PX-21 20-321

(1)
20-322 D31/37/39EX, PX-21

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D31/37/39EX, PX-21 20-323

(1)
20-324 D31/37/39EX, PX-21

(1)
D31/37/39EX, PX-21 20-325

(1)
Monitor Panel System Circuit Diagram (M Circuit)
20-326 D31/37/39EX, PX-21

(1)
a This circuit diagram is made by excerpting the monitor panel system, engine preheating/starting/charging/
stopping system, light system, and communication network system from the general electric circuit diagram
(“Connector No. and pin No.” from each branching/merging point indicate the ends of branch or source of
merging within the parts of the same wiring harness).
D31/37/39EX, PX-21 20-327

(1)
HST Control System Circuit Diagram (H Ciruit)
20-328 D31/37/39EX, PX-21

(1)
a This circuit diagram is made by excerpting the HST controller system from the general electric circuit dia-
gram (“Connector No. and pin No.” from each branching/merging point indicate the ends of branch or
source of merging within the parts of the same wiring harness).
D31/37/39EX, PX-21 20-329

(1)
TESTTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

(Rev. 2007.10)
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.
20-330 D31/37/39EX, PX-21

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D31/37/39EX, PX-21 20-331

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20-332 D31/37/39EX, PX-21

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D31/37/39EX, PX-21 20-333

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20-334 D31/37/39EX, PX-21

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D31/37/39EX, PX-21 20-335

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20-336 D31/37/39EX, PX-21

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D31/37/39EX, PX-21 20-337

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20-338 D31/37/39EX, PX-21

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D31/37/39EX, PX-21 20-339

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20-340 D31/37/39EX, PX-21

(5)
D31/37/39EX, PX-21 20-341

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20-342 D31/37/39EX, PX-21

(5)
D31/37/39EX, PX-21 20-343

(5)
20-344 D31/37/39EX, PX-21

(5)
D31/37/39EX, PX-21 20-345

(5)
20-346 D31/37/39EX, PX-21

(5)
D31/37/39EX, PX-21 20-347

(5)
20-348 D31/37/39EX, PX-21

(5)
D31/37/39EX, PX-21 20-349

(5)
20-350 D31/37/39EX, PX-21

(5)
D31/37/39EX, PX-21 20-351

(5)
20-352 D31/37/39EX, PX-21

(5)
D31/37/39EX, PX-21 20-353

(5)
20-354 D31/37/39EX, PX-21

(5)
D31/37/39EX, PX-21 20-355

(5)
20-356 D31/37/39EX, PX-21

(5)
D31/37/39EX, PX-21 20-357

(5)
20-358 D31/37/39EX, PX-21

(5)
D31/37/39EX, PX-21 20-359

(5)
20-360 D31/37/39EX, PX-21

(5)
D31/37/39EX, PX-21 20-361

(5)
20-362 D31/37/39EX, PX-21

(5)
D31/37/39EX, PX-21 20-363

(5)
20-364 D31/37/39EX, PX-21

(5)
D31/37/39EX, PX-21 20-365

(5)
TESTTING AND ADJUSTING T-BRANCH BOX AND T-BRANCH ADAPTER TABLE
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE

(Rev. 2007.8)
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal col-
umn 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
799-601-3510 Adapter for BENDIX (MS) 5 MS-5S 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
20-366 D31/37/39EX, PX-21

(5)
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
D31/37/39EX, PX-21 20-367

(5)
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.
20-368 D31/37/39EX, PX-21

(5)
TROUBLESHOOTING WHEN ERROR CODE IS
DISPLAYED
Error Codes Table ....................................................................................................................................... 20-403
Information in troubleshooting table ............................................................................................................ 20-406
Error code [6091NX] (HST charge filter element: Clogging) ....................................................................... 20-409
Error code [AB00MA] (Alternator: Malfunction)........................................................................................... 20-410
Error code [B@BAZG] (Engine oil: Lowering of oil pressure) ..................................................................... 20- 411
Error code [B@BCNS] (Coolant: Overheating)........................................................................................... 20-412
Error code [B@CRNS] (HST oil: Overheating) ........................................................................................... 20-413
Error code [B@CRZG] (HST oil: Lowering of oil pressure)......................................................................... 20-414
Error code [D110KB] (Battery relay: Short circuit)....................................................................................... 20-416
Error code [D130KA] (Safety relay: Disconnection) .................................................................................... 20-418
Error code [D130KB] (Safety relay: Short circuit) ....................................................................................... 20-420
Error code [DAFRKR] (Monitor controller CAN communication:
Defective communication (Abnormality in objective component system))............................................. 20-422
Error code [DAJ0KK] (HST controller: Lowering of source voltage (Input)) ................................................ 20-424
Error code [DAJ0KT] (HST controller: Internal defect of controller) ............................................................ 20-426
Error code [DAJ5KK] (HST controller sensor power supply output: Lowering of source voltage (Input)) ... 20-428
Error code [DD12KA] (Shift-up switch: Disconnection) ............................................................................... 20-432
Error code [DD12KB] (Shift-up switch: Short circuit)................................................................................... 20-434
Error code [DD13KA] (Shift-down switch: Disconnection) .......................................................................... 20-436
Error code [DD13KB] (Shift-down switch: Short circuit) .............................................................................. 20-438
Error code [DD14KB] (Travel lock SW1: Short circuit)................................................................................ 20-440
Error code [DDDCKB] (Reverse travel speed switch: Short circuit)............................................................ 20-442
Error code [DDP6KB] (Brake pressure switch: Short circuit) ...................................................................... 20-444
Error code [DDQ2KA] (Travel lock SW1: Disconnection) ........................................................................... 20-446
Error code [DDU1FS] (Parking brake ON-OFF switch: Stick) ..................................................................... 20-448
Error code [DDU1KA] (Parking brake ON-OFF switch: Disconnection)...................................................... 20-450
Error code [DDU1KB] (Parking brake ON-OFF switch: Short circuit) ......................................................... 20-452
Error code [DDU1KY] (Parking brake ON-OFF switch: Short circuit with power supply line) ..................... 20-454
Error code [DDU1L4] (Parking brake ON-OFF switch: Disagreement of ON and OFF signals) ................. 20-456
Error code [DGS1KX] (Hydraulic tank oil temperature sensor: Out of input signal range).......................... 20-458
Error code [DHH5KA] (LH pump pressure sensor: Disconnection) ............................................................ 20-460
Error code [DHH5KB] (LH pump pressure sensor: Short circuit) ................................................................ 20-462
Error code [DHH6KA] (RH pump pressure sensor: Disconnection)............................................................ 20-464
Error code [DHH6KB] (RH pump pressure sensor: Short circuit) ............................................................... 20-466
Error code [DK10KA] (Throttle angle sensor: Disconnection)..................................................................... 20-468
Error code [DK10KB] (Throttle angle sensor: Short circuit) ........................................................................ 20-470
Error code [DK12KA] (Deceleration sensor: Disconnection) ...................................................................... 20-472
Error code [DK12KB] (Deceleration sensor: Short circuit) .......................................................................... 20-474
Error code [DK30KA] (Steering angle sensor: Disconnection).................................................................... 20-476
Error code [DK30KB] (Steering angle sensor: Short circuit) ....................................................................... 20-478
Error code [DK30KX] (Steering angle sensor: Out of input signal range) ................................................... 20-480
Error code [DK30KZ] (Steering angle sensor: Disconnection or short circuit) ............................................ 20-481
Error code [DK30L8] (Steering angle sensor: Disagreement of analog signals)......................................... 20-482
Error code [DK31KA] (Steering angle sensor 2: Disconnection)................................................................. 20-484
Error code [DK31KB] (Steering angle sensor 2: Short circuit) .................................................................... 20-486
Error code [DK40KA] (Brake angle sensor: Disconnection) ....................................................................... 20-488
Error code [DK40KB] (Brake angle sensor: Short circuit) ........................................................................... 20-490
Error code [DK55KX] (Directional potentiometer: Out of input signal range) .............................................. 20-492
Error code [DK55KZ] (Directional potentiometer: Disconnection or short circuit) ....................................... 20-493
Error code [DK55L8] (Directional potentiometer: Disagreement of analog signals).................................... 20-494
D31/37/39EX, PX-21 20-401

(1)
TROUBLESHOOTING
Error code [DK56KA] (Directional potentiometer 1: Disconnection)............................................................ 20-496

Error code [DK56KB] (Directional potentiometer 1: Short circuit) ............................................................... 20-498
Error code [DK57KA] (Directional potentiometer 2: Disconnection)............................................................ 20-500
Error code [DK57KB] (Directional potentiometer 2: Short circuit) ............................................................... 20-502
Error code [DLE2KA] (Engine speed sensor: Disconnection)..................................................................... 20-504
Error code [DLE2KB] (Engine speed sensor: Short circuit) ........................................................................ 20-506
Error code [DLM0KX] (Motor speed sensor: Out of input signal range)...................................................... 20-508
Error code [DLM1KA] (Left HST motor speed sensor: Disconnection) ....................................................... 20-510
Error code [DLM1KB] (Left HST motor speed sensor: Short circuit)........................................................... 20-512
Error code [DLM1MA] (Left HST motor speed sensor: Malfunction)........................................................... 20-514
Error code [DLM2KA] (Right HST motor speed sensor: Disconnection)..................................................... 20-516
Error code [DLM2KB] (Right HST motor speed sensor: Short circuit) ........................................................ 20-518
Error code [DLM2MA] (Right HST motor speed sensor: Malfunction) ........................................................ 20-520
Error code [DN21FS] (Center brake limit switch: Fixing) ............................................................................ 20-522
Error code [DV00KB] (Buzzer: Short circuit) ............................................................................................... 20-524
Error code [DV20KB] (Backup alarm buzzer: Short circuit) ........................................................................ 20-526
Error code [DW28KA] (2nd gear speed solenoid valve: Disconnection) ..................................................... 20-528
Error code [DW28KB] (2nd gear speed solenoid valve: Short circuit) ........................................................ 20-530
Error code [DW29KA] (3rd gear speed solenoid valve: Disconnection)...................................................... 20-532
Error code [DW29KB] (3rd gear speed solenoid valve: Short circuit) ......................................................... 20-534
Error code [DW4BKA] (Parking brake solenoid valve: Disconnection) ....................................................... 20-536
Error code [DW4BKB] (Parking brake solenoid valve: Short circuit)........................................................... 20-538
Error code [DW7EKA] (Slow brake solenoid valve: Disconnection)............................................................ 20-540
Error code [DW7EKB] (Slow brake solenoid valve: Short circuit) ............................................................... 20-542
Error code [DXA4KA] (LH pump F-EPC solenoid valve: Disconnection) .................................................... 20-544
Error code [DXA4KB] (LH pump F-EPC solenoid valve: Short circuit)........................................................ 20-546
Error code [DXA5KA] (LH pump R-EPC solenoid valve: Disconnection).................................................... 20-548
Error code [DXA5KB] (LH pump R-EPC solenoid valve: Short circuit) ....................................................... 20-550
Error code [DXA6KA] (RH pump F-EPC solenoid valve: Disconnection) ................................................... 20-552
Error code [DXA6KB] (RH pump F-EPC solenoid valve: Short circuit) ....................................................... 20-554
Error code [DXA7KA] (RH pump R-EPC solenoid valve: Disconnection) ................................................... 20-556
Error code [DXA7KB] (RH pump R-EPC solenoid valve: Short circuit)....................................................... 20-558
20-402 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING ERROR CODES TABLE
ERROR CODES TABLE

Action Warning Warning
Error code Defective part Trouble Controller
code lamp buzzer
6091NX HST charge filter element Clogging Mechanical — q q
AB00MA Alternator Malfunction Mechanical — q
B@BAZG Engine oil Lowering of oil pressure Mechanical — q q
B@BCNS Coolant Overheating Mechanical — q q
B@CRNS HST oil Overheating Mechanical — q q
B@CRZG HST oil Lowering of oil pressure Mechanical — q q
D110KB Battery relay Short circuit HST — q q
D130KA Safety relay Disconnection HST E02 q q
D130KB Safety relay Short circuit HST E02 q q
Defective communication
Monitor controller CAN commu-
DAFRKR (Abnormality in objective Monitor CALL E03 q q
nication
component)
Lowering of source voltage
DAJ0KK HST controller HST CALL E04 q q
(Input)
DAJ0KT HST controller Internal defect of controller HST CALL E03 q q
HST controller sensor power Lowering of source voltage
DAJ5KK HST CALL E04 q q
supply output (Input)
DD12KA Shift-up switch Disconnection HST E02 q q
DD12KB Shift-up switch Short circuit HST E02 q q
DD13KA Shift-down switch Disconnection HST E02 q q
DD13KB Shift-down switch Short circuit HST E02 q q
DD14KB Travel lock switch 1 Short circuit HST CALL E03 q q
DDDCKB Reverse travel speed switch Short circuit HST E01 q q
DDP6KB Brake pressure switch Fixing HST E01 q q
DDQ2KA Travel lock switch 1 Disconnection HST CALL E03 q q
DDU1FS Parking brake ON-OFF switch Short circuit HST CALL E03 q q
Short circuit with power
DDU1KA Parking brake ON-OFF switch HST CALL E03 q q
supply line
Disagreement of ON/OFF
DDU1KB Parking brake ON-OFF switch HST CALL E03 q q
signals
DDU1KY Parking brake ON-OFF switch HST CALL E03 q q
supply line
Disagreement of ON/OFF
DDU1L4 Parking brake ON-OFF switch HST CALL E03 q q
signals
Hydraulic tank oil temperature
DGS1KX Out of input signal range HST —
sensor
DHH5KA LH pump pressure sensor Disconnection HST E01 q q
DHH5KB LH pump pressure sensor Short circuit HST E01 q q
DHH6KA RH pump pressure sensor Disconnection HST E01 q q
DHH6KB RH pump pressure sensor Short circuit HST E01 q q
DK10KA Throttle angle sensor Disconnection HST E02 q q
DK10KB Throttle angle sensor Short circuit HST E02 q q
DK12KA Deceleration sensor Disconnection HST E02 q q
DK12KB Deceleration sensor Short circuit HST E02 q q
DK30KA Steering angle sensor Disconnection HST CALL E03 q q
DK30KB Steering angle sensor Short circuit HST CALL E03 q q
D31/37/39EX, PX-21 20-403

(1)

code lamp buzzer
DK30KX Steering angle sensor Out of input signal range HST CALL E04 q q
DK30KZ Steering angle sensor Disconnection or Short circuit HST CALL E04 q q
Disagreement of analog
DK30L8 Steering angle sensor HST CALL E03 q q
signals
DK31KA Steering angle sensor 2 Disconnection HST CALL E03 q q
DK31KB Steering angle sensor 2 Short circuit HST CALL E03 q q
DK40KA Brake angle sensor Disconnection HST CALL E03 q q
DK40KB Brake angle sensor Short circuit HST CALL E03 q q
DK55KX Directional potentiometer Out of input signal range HST CALL E04 q q
DK55KZ Directional potentiometer Disconnection or short circuit HST CALL E04 q q
Disagreement of analog
DK55LB Directional potentiometer HST CALL E03 q q
signals
DK56KA Directional potentiometer 1 Disconnection HST CALL E03 q q
DK56KB Directional potentiometer 1 Short circuit HST CALL E03 q q
DK57KA Directional potentiometer 2 Disconnection HST CALL E03 q q
DK57KB Directional potentiometer 2 Short circuit HST CALL E03 q q
DLE2KA Engine speed sensor Disconnection HST CALL E03 q q
DLE2KB Engine speed sensor Short circuit HST CALL E03 q q
DLM0KX Motor speed sensor Out of input signal range HST CALL E03 q q
DLM1KA Left HST motor speed sensor Disconnection HST E01
DLM1KB Left HST motor speed sensor Short circuit HST E01
DLM1MA Left HST motor speed sensor Malfunction HST E01
DLM2KA Right HST motor speed sensor Disconnection HST E01
DLM2KB Right HST motor speed sensor Short circuit HST E01
DLM2MA Right HST motor speed sensor Malfunction HST E01
DN21FS Center brake limit switch Fixing HST CALL E03 q q
DV00KB Buzzer Short circuit Monitor —
DV20KB Backup alarm buzzer Short circuit HST E01 q q
DW28KA 2nd speed solenoid valve Disconnection HST E02 q q
DW28KB 2nd speed solenoid valve Short circuit HST E02 q q
DW29KA 3rd speed solenoid valve Disconnection HST E02 q q
DW29KB 3rd speed solenoid valve Short circuit HST E02 q q
DW4BKA Parking brake solenoid valve Disconnection HST CALL E04 q q
DW4BKB Parking brake solenoid valve Short circuit HST CALL E04 q q
DW7EKA Slow brake solenoid valve Disconnection HST CALL E04 q q
DW7EKB Slow brake solenoid valve Short circuit HST CALL E04 q q
DXA4KA LH pump F-EPC solenoid valve Disconnection HST CALL E03 q q
DXA4KB LH pump F-EPC solenoid valve Short circuit HST CALL E03 q q
DXA5KA LH pump R-EPC solenoid valve Disconnection HST CALL E03 q q
DXA5KB LH pump R-EPC solenoid valve Short circuit HST CALL E03 q q
20-404 D31/37/39EX, PX-21

(1)

code lamp buzzer
DXA6KA RH pump F-EPC solenoid valve Disconnection HST CALL E03 q q
DXA6KB RH pump F-EPC solenoid valve Short circuit HST CALL E03 q q
DXA7KA RH pump R-EPC solenoid valve Disconnection HST CALL E03 q q
DXA7KB RH pump R-EPC solenoid valve Short circuit HST CALL E03 q q
a “Controller” in the table indicates classification of the controller in charge of system check, monitor panel,
and code.
Monitor: Error code of electric system checked by monitor panel
HST: Error code of electric system checked by HST controller
Mechanical: Error code of mechanical system
D31/37/39EX, PX-21 20-405

(1)
TROUBLESHOOTING INFORMATION IN TROUBLESHOOTING TABLE
INFORMATION IN TROUBLESHOOTING TABLE
Action code Error code

Display on Display on Trouble Trouble in machine
panel panel
Contents of
Condition at the time when the monitor panel or controller detects the trouble
trouble
Action of The action taken by the monitor panel or controller to protect the system or devices when the monitor
controller panel or controller detects the trouble
Problem that
The problem that appears on the machine as a result of the action taken by the monitor panel or control-
appears on
ler (shown above)
machine
Related infor-
Information related to the detected trouble or troubleshooting
mation
Cause Standard value in normal state/Remarks on troubleshooting
<Contents of description>
• Standard value in normal state to judge possible causes
1
• Remarks on judgment
<Troubles in wiring harness>

• Disconnection
Connector is connected imperfectly or wiring harness is broken.
• Grounding fault
2 Wiring harness which is not connected to chassis ground circuit is in contact with
Possible causes and standard
chassis ground circuit.

• Short circuit with power source
value in normal state
Wiring harness which is not connected to power source (24 V) circuit is in contact
with power source (24 V) circuit.
Possible causes of trouble
• Short circuit
(Given numbers are refer-
3 Independent wiring harnesses are in contact with each other abnormally.
ence numbers, which do
not indicate priority)
<Precautions for troubleshooting>
1) Method of indicating connector No. and handling of T-adapter
Insert or connect T-adapter as explained below for troubleshooting, unless other-
wise specified.
4 • If connector No. has no marks of “male” and “female”, disconnect connector and
insert T-adapters in both male side and female side.
• If connector No. has marks of “male” and “female”, disconnect connector and
connect T-adapter to only male side or female side.
2) Entry order of pin Nos. and handling of circuit tester leads
Connect positive (+) lead and negative (–) lead of circuit tester as explained below
for troubleshooting, unless otherwise specified.
5
• Connect positive (+) lead to pin No. or harness entered on front side.
• Connect negative (–) lead to pin No. or harness entered on rear side.
20-406 D31/37/39EX, PX-21

(1)
Related Circuit Diagram
This is a circuit diagram of the part related to troubleshooting.
• Connector No.: Shows the “Type-Number of pin” and “Color”.

• Arrow ( ): Roughly shows the location on the machine.
D31/37/39EX, PX-21 20-407

(1)
TROUBLESHOOTING 6091NX
Error code [6091NX] (HST charge filter element: Clogging)

Action code Error Code
Trouble HST charge filter element: Clogging (Mechanical system)
— 6091NX
Contents of
• When the HST oil temperature is above 50°C, the HST charge filter clogging switch operates.
trouble
• Flashes the HST filter clogging caution lamp.
Action of
• Flashes the warning lamp and sounds the warning buzzer (Function of caution lamp).
controller
• If the cause of the failure disappears, the system resets itself.
Problem that
appears on • If the machine is operated as it is, the HST hydraulic equipment may be damaged.
machine
• The input state (ON/OFF) from the HST charge filter clogging switch can be checked in the monitoring
Related
mode. (Code: 40910-S/T SW1, 4th from left)
information
• Method of reproducing error code: Start the engine and raise HST oil temperature to 50°C.

standard value in normal state
Possible causes and
Clogging of HST charge

A phenomenon seems to have caused clogging of HST charge filter. Find and stop
1 filter
it and repair the damaged part.
(When system is normal)
Defective HST filter clog-

Carry out troubleshooting for E-mode, EMERGENCY CAUTION ITEM FLASHES
2 ging caution lamp sys-
WHILE ENGINE IS RUNNING, HST filter clogging caution lamp system.
tem
D31/37/39EX, PX-21 20-409

(1)
TROUBLESHOOTING AB00MA
Error code [AB00MA] (Alternator: Malfunction)

Trouble Alternator: Malfunction (Mechanical system)
— AB00MA
Contents of
• While the engine is running, the battery charge caution is turned ON.
trouble
Action of • Flashes the battery charge caution lamp.
controller • If the cause of the failure disappears, the system resets itself.
Problem that
appears on • If the machine is operated as it is, the battery may not be charged.
machine
• The battery voltage (Volt) and generating condition of the alternator (Volt) can be checked in the moni-
Related
toring mode. (Code: 03200-BATTERY, Code: 04302-R Signal)
information
• Method of reproducing error code: Start the engine.

Possible causes and
Defective charge of bat-

A phenomenon seems to have caused defective charge of the battery. Find and
1 tery
stop it and repair the damaged part.
Defective battery charge Carry out troubleshooting for E-mode, CAUTION ITEM
2
caution lamp system (BATTERY CHARGE CAUTION LAMP) FLASHES WHILE ENGINE IS RUNNING.
20-410 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING B@BAZG
Error code [B@BAZG] (Engine oil: Lowering of oil pressure)

Trouble Engine oil: Lowering of oil pressure (Mechanical system)
— B@BAZG
Contents of
• While the engine is running, the engine oil pressure caution is turned ON.
trouble
• Flashes the engine oil pressure caution lamp.
Action of
controller
Problem that
appears on • If the machine is operated as it is, the engine may be damaged.
machine
• The input state (ON/OFF) from the engine oil pressure switch can be checked in the monitoring mode.
Related
(Code: 40922-Mon SW2, 6th from left)
information

Possible causes and
Lowering of engine oil

A phenomenon seems to have caused lowering of the engine oil pressure.
1 pressure
Find and stop it and repair the damaged part.
Defective engine oil

2 pressure caution lamp
WHILE ENGINE IS RUNNING, Engine oil pressure caution lamp system.
system
D31/37/39EX, PX-21 20-411

(1)
TROUBLESHOOTING B@BCNS
Error code [B@BCNS] (Coolant: Overheating)

Trouble Coolant: Overheating (Mechanical system)
— B@BCNS
Contents of
• While the engine is running, the engine coolant temperature caution is turned ON.
trouble
• Flashes the engine coolant temperature caution lamp.
Action of
controller
Problem that
appears on • If the machine is operated as it is, the engine may be damaged.
machine
• The input state (Coolant temperature, voltage) from the engine coolant temperature sensor can be
Related
checked in the monitoring mode. (Code: 04102-ENG. TEMP., Code: 04106-ENG. TEMP.)
information

Possible causes and
Overheating of engine
A phenomenon seems to have caused overheating of the engine coolant. Find and
1 coolant
stop it and repair the damaged part.
Defective engine cool-

2 ant temperature caution
WHILE ENGINE IS RUNNING, Engine coolant temperature caution lamp system.
lamp system
20-412 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING B@CRNS
Error code [B@CRNS] (HST oil: Overheating)

Trouble HST oil: Overheating (Mechanical system)
— B@CRNS
Contents of
• While the engine is running, the HST oil temperature caution is turned ON.
trouble
• Flashes the HST oil temperature caution lamp.
Action of
controller
Problem that
• If the machine is operated as it is, the HST hydraulic equipment or work equipment hydraulic equip-
appears on
ment may be damaged.
machine
• The input state (Voltage, oil temperature) from the HST oil temperature sensor can be checked in the
Related
monitoring mode. (Code: 004402-HST TEMP, Code: 85001-HST TEMP.)
information

Possible causes and
Overheating of HST oil A phenomenon seems to have caused overheating of the HST oil. Find and stop it
1
(When system is normal) and repair the damaged part.
Defective HST oil tem-

2 perature caution lamp
WHILE ENGINE IS RUNNING, HST oil temperature caution lamp system.
system
D31/37/39EX, PX-21 20-413

(1)
TROUBLESHOOTING B@CRZG
Error code [B@CRZG] (HST oil: Lowering of oil pressure)

Trouble HST oil: Lowering of oil pressure (Mechanical system)
— B@CRZG
Contents of • While the engine is running and the parking brake is released, the brake oil pressure switch is turned
trouble OFF and the charge pressure lowers.
• Flashes the HST charge pressure caution lamp.
Action of
controller
Problem that
• If the machine is operated as it is, the HST hydraulic equipment or work equipment hydraulic equip-
appears on
ment may be damaged.
machine
• The input state (ON/OFF) from the HST charge pressure switch (brake oil pressure switch) can be
Related checked in the monitoring mode. (Code: 40910-S/T SW1, 3rd from left)
information • Method of reproducing error code: Start the engine, set the parking brake lever in the FREE position,
and release the brake pedal.

Possible causes and
Lowering of HST charge

A phenomenon seems to have caused lowering of the HST charge pressure. Find
1 pressure (When system
and stop it and repair the damaged part.
is normal)
Defective HST charge

2 pressure caution lamp
WHILE ENGINE IS RUNNING, HST charge pressure caution lamp system.
system
20-414 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING D110KB
Error code [D110KB] (Battery relay: Short circuit)

Trouble Battery relay: Short circuit (HST controller system)
— D110KB
Contents of
• When the signal is output to the battery relay circuit, an abnormal current flows.
trouble
• Stops outputting the signal to the battery relay circuit.
Action of
• Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
controller
turned OFF.
• A problem may occur in writing data into the (non-volatile memory) of the controller.
Problem that
• The initial adjustment values, error records, saved loads, etc. become abnormal because of memory
appears on
trouble.
machine
• Internal defect of controller [DAJOKT] is displayed, too.
• The output state (ON/OFF, voltage) to the battery relay can be checked in the monitoring mode.
Related
(Code: 40918-D-OUT SW, 8th from left, Code: 60600-BR HOLD)
information
• Method of reproducing error code: Set the starting switch in the OFF position, then in the ON position.

a Prepare with starting switch OFF (and disconnect CN-T9), then carry out
troubleshooting without turning starting switch.
Defective battery relay
1 Battery relay Continuity/Resistance

(Internal short circuit)
CN-T13 – CN-T9 There is continuity
Possible causes and
Between CN-T13 and chassis ground Min. 1 Mz

Grounding fault of wiring a Prepare with starting switch OFF, then carry out troubleshooting without turning
harness starting switch.
2
(Contact with grounding a Between CN-ST3 (female) (8) – CN-T13 or CN-KS
circuit) Resistance Min. 1 Mz
(260) wiring harness and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
3 Defective HST controller CN-ST3 Starting switch Voltage
Between (4) and
ON 20 – 30V
chassis ground
20-416 D31/37/39EX, PX-21

(1)
Circuit diagram related to driving battery relay
D31/37/39EX, PX-21 20-417

(1)
TROUBLESHOOTING D130KA
Error code [D130KA] (Safety relay: Disconnection)

Trouble Safety relay: Disconnection (HST controller system)
E02 D130KA
Contents of
• When the ground circuit of the neutral safety relay is disconnected, 24 V is not generated.
trouble
• Flashes the warning lamp and sounds the warning buzzer.
Action of
controller
turned OFF.
Problem that
• If the engine has been stopped, it cannot be started (Disconnection).
appears on
• The engine can be started, regardless of the position of the parking brake lever (Grounding fault).
machine
• The output state (ON/OFF, voltage) to the neutral safety relay can be checked in the monitoring mode.
Related (Code: 40918-D-OUT SW, 4th from left, Code: 50901-N-SAFTY)
information • Method of reproducing error code: Turn the starting switch ON and set the parking brake lever in the
FREE position.

a Prepare with starting switch OFF, then carry out troubleshooting with starting switch
OFF and ON.
Defective starting switch Starting switch Resistance
1
(Internal disconnection) CN-KS
OFF Min. 1 Mz
Between 250 and 270 ON Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Defective neutral starting switch.
2 safety relay(Internal CN11 (male) Resistance
disconnection)
Between (1) and (2) 200 – 400 z
Possible causes and
Disconnection in wiring starting switch.

harness (Disconnec-
Wiring harness between CN-ST2 (female) (8) and
3 tion in wiring harness Resistance Max. 1 z
CN11 (female) (2)
or defective contact in
connector) Wiring harness between CN11 (female) (1) and
Resistance Max. 1 z
CN-KS (270)
starting switch.
Grounding fault of wir-
Between CN-ST2 (female) (8) – CN11 (female) (2)
4 ing harness (Contact Resistance Min. 1 Mz
wiring harness and chassis ground
with ground circuit)
Between CN11 (female) (1) – CN-KS (270) or
Resistance Min. 1 Mz
FB1-5 inlet wiring harness and chassis ground
Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
Defective HST control- CN-ST2 Parking brake lever Voltage
5
ler
Between (8) and FREE 20 – 30 V
chassis ground LOCK Max. 1 V
20-418 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING D130KA
Circuit diagram related to neutral safety relay
D31/37/39EX, PX-21 20-419

(1)
Error code [D130KB] (Safety relay: Short circuit)

Trouble Safety relay: Short circuit (HST controller system)
E02 D130KB
Contents of
• When the ground circuit of the neutral safety relay is disconnected, an abnormal current flows.
trouble
Action of • Stops disconnecting the ground circuit of the neutral safety relay circuit.
controller • Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
turned OFF.
Problem that
appears on • If the engine has been stopped, it cannot be started.
machine
• The output state (ON/OFF, voltage) to the neutral safety relay can be checked in the monitoring mode.
(Code: 40918-D-OUT SW, 4th from left, Code: 50901-N-SAFTY)
Related • Method of reproducing error code: Turn the starting switch ON and set the parking brake lever in the
information LOCK position.
• This error code detects abnormality on the primary side (coil side) of the neutral safety relay but does
not detect abnormality on the secondary side (contact side).

Defective neutral safety starting switch.
1 relay
CN11 (male) Resistance

200 – 400 z
Possible causes and
Between (1) and (2)

Short circuit with a Prepare with starting switch OFF, then turn starting switch ON and carry out
power source in wiring troubleshooting.
2
harness (Contact with Between CN-ST2 (female) (8) – CN11 (female) (2) wir-
Voltage Max. 1 V
24 V circuit) ing harness and chassis ground
troubleshooting.
Defective HST CN-ST2 Parking brake lever Voltage
3
controller
Between (8) and chassis FREE 20 – 30 V
ground LOCK Max. 1 V
20-420 D31/37/39EX, PX-21

(1)
Circuit diagram related to neutral safety relay
D31/37/39EX, PX-21 20-421

(1)
TROUBLESHOOTING DAFRKR
Error code [DAFRKR] (Monitor controller CAN communication:

Defective communication (Abnormality in objective component system))
Action code Error Code Monitor controller CAN communication: Defective communication
Trouble
E02 DAFRKR (Abnormality in objective component system) (Monitor panel system)
tContents of
• The monitor panel cannot recognize the HST controller in the CAN communication circuit.
trouble
Action of
• Limits the functions partly.
controller
Problem that
• Once the machine is stopped and started again, its travel speed is limited to 50%.
appears on
• The monitor panel cannot display the information.
machine
Related
• Method of reproducing error code: Turn the starting switch ON.
information

starting switch.
Disconnection in wiring
Wiring harness between CN-S04 (female) (1), (2) – CN-
harness (Disconnection
ST2 (female) (32) or CN-CA2 (female) (A) or CN-CA Resistance Max. 1 z
1 in wiring harness or
(female) (A)
defective contact in con-
nector) Wiring harness between CN-S04 (female) (3), (4) – CN-
ST2 (female) (22) or CN-CA2 (female) (B) or CN-CA Resistance Max. 1 z
(female) (B)
starting switch.
Short circuit with Between CN-S04 (female) (1), (2) – CN-ST2 (female)
chassis ground in wir- (32) or CN-CA2 (female) (A) or CN-CA (female) (A) or Resistance Min. 1 M z
2
ing harness (Contact CN45 (female) (3) wiring harness and chassis ground
Possible causes and
with ground circuit) Between CN-S04 (female) (3), (4) – CN-ST2 (female)
(22) or CN-CA2 (female) (B) or CN-CA (female) (B) or Resistance Min. 1 M z
CN45 (female) (10) wiring harness and chassis ground
starting switch.
Short circuit with Between CN-S04 (female) (1), (2) – CN-ST2 (female)
power source in wiring (32) or CN-CA2 (female) (A) or CN-CA (female) (A) or Voltage Max. 1 V
3
harness (Contact with CN45 (female) (3) wiring harness and chassis ground
24 V circuit) Between CN-S04 (female) (3), (4) – CN-ST2 (female)
(22) or CN-CA2 (female) (B) or CN-CA (female) (B) or Voltage Max. 1 V
CN45 (female) (10) wiring harness and chassis ground
starting switch.
Defective CAN termi-
4 CN-CA
nal resistor (male)
Resistance
Between (1) and (2) 100 z – 140 z

Defective monitor If none of causes 1 – 4 is the cause of the trouble, the monitor panel or HST control-
5 panel or HST ler may be defective (Troubleshooting cannot be carried out since the defect is in the
controller monitor panel or HST controller).
20-422 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING DAFRKR
Circuit diagram related to CAN communication
D31/37/39EX, PX-21 20-423

(1)
TROUBLESHOOTING DAJ0KK
Error code [DAJ0KK] (HST controller: Lowering of source voltage (Input))
Action code Error code HST controller: Lowering of source voltage (Input)
Trouble
CALL E04 DAJ0KK (HST controller system)
Contents of
• The source voltage of the HST controller is below 17 V.
trouble
Action of
controller
Problem that • Once the machine is stopped, it cannot start again.
appears on • The monitor panel may not display normally.
machine • The relays and solenoids may not be driven and the system may not operate normally.
• The state of the power supply (voltage) of the HST controller can be checked in the monitoring mode.
Related
• (Code: 03200-BATTERY)
information

Defective fusible link If the fusible link is broken, the circuit probably has a grounding fault, etc.
1
(CN-H2) (See cause 4.)
2 Defective fuse (FB1-3) If the fuse is broken, the circuit probably has a grounding fault, etc. (See cause 4.)
starting switch.
Disconnection in wiring Wiring harness between CN-ST3 (female) (1), (2), (11),
Resistance Max. 1 z
harness (Disconnection (12), (22) and FB1-3 outlet
3 in wiring harness or Wiring harness between FB1-3 inlet and CN-H2 (male)
Resistance Max. 1 z
defective contact in con- (2)
Possible causes and
nector) Wiring harness between CN-H2 (male) (1) and CN-T8 Resistance Max. 1 z
Wiring harness between CN-ST3 (female) (21), (31),
Resistance Max. 1 z
(32), (33) and chassis ground
starting switch.
Short circuit with Between CN-ST3 (female) (1), (2), (11), (12), (22) –
Resistance Min. 1 M z
chassis ground in wir- FB1-3 outlet wiring harness and chassis ground
4
ing harness (Contact Between FB1-3 inlet – CN-H2 (male) (2) or other
with ground circuit) related circuit wiring harness and chassis ground
Between CN-H2 (male) (1) – CN-T8 or other related cir-
cuit wiring harness and chassis ground
starting switch.
Defective HST
5 CN-ST3 Voltage
controller
Between (1), (2), (11), (12), (22) and
20 – 30 V
(21), (31), (32), (33)
20-424 D31/37/39EX, PX-21

(1)
Circuit diagram related to HST controller power supply
D31/37/39EX, PX-21 20-425

(1)
TROUBLESHOOTING DAJ0KT
Error code [DAJ0KT] (HST controller: Internal defect of controller)
User Code Error code Failure HST controller: Internal defect of controller
Trouble
CALL E04 DAJ0KT phenomenon (HST controller system)
Contents of
• The information in the ROM (non-volatile memory) of the HST controller is abnormal.
trouble
Action of • Limits the functions partly (depending on the defective part in the HST controller).
turned OFF.
Problem that • Once the machine is stopped and started again, its travel speed is limited to 50% (regardless of the
appears on defective part in the HST controller).
machine • Some functions do not work normally (depending on the defective part in the HST controller).
Related
information

Execute the adjustment mode. If the error code lights up (to indicated restoration),
Defective adjustment of
1 the system is normal.

HST controller
• Adjustment code: 0002-BODY TYPE
Possible causes and
Troubleshooting cannot be carried out since the defect is in the HST controller.
2 Defective HST controller
(If there is not a visible trouble, the controller may be used as it is.)
If error code [D110KB] is displayed or if the monitor is turned OFF just after the start-
Defective holding of
3 ing switch is turned OFF, the battery relay may not be held normally. In this case,
battery relay
carry out troubleshooting for error code [D110KB], too.
Wiring harness between CN-ST3 (female) (4) and CN-
4 in wiring harness or Resistance Max. 1 z
T13 or CN-KS (260)
nector)
20-426 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING DAJ0KT
Circuit diagram related to driving battery relay
D31/37/39EX, PX-21 20-427

(1)
Error code [DAJ5KK] (HST controller sensor power supply output: Lowering of source
voltage (Input))
Action code Error Code HST controller sensor power supply output: Lowering of source volt-
Trouble
CALL E04 DAJ5KK age (Input) (HST controller system)
• The voltage of the 5 V power supply circuit of the HST controller is below 4.5 V or above 5.5 V.
Failure content
• An abnormal current flows in the 5 V power supply circuit of the HST controller.
• Turns the output of the 5 V power supply circuit OFF
Action of
controller
turned OFF.
Action of • Once the machine is stopped, it cannot start again.
controller • The system may not operate normally.
• If this trouble occurs, the respective error codes of the pressure sensors, potentiometers, and speed
Related
sensors supplied with power from the 5 V power supply are also displayed and recorded.
information

a Turn starting switch OFF and disconnect connector, then turn starting switch ON
Defective directional and carry out troubleshooting.
potentiometer Directional potentiometer
Defective steering poten- CN-EL connector
Steering potentiometer
tiometer
Defective fuel control Fuel control lever potenti-
CN-FP connector
lever potentiometer ometer
Defective decelerator Decelerator pedal potenti-
Disconnect devices shown
pedal potentiometer CN=DP1 connector

at right in order. ometer
Defective brake pedal
Possible causes and
1 When one of them is dis- Brake pedal potentiometer CN-BP1 connector

potentiometer
Defective left HST pump connected, if error code Left HST pump pressure
lights up CN-LP connector
pressure sensor sensor
Defective right HST (to display restoration),
that device has defect in it. Right HST pump pressure
pump pressure sensor CN-RP connector
sensor
Defective left HST motor
speed sensor Left HST motor speed
CN-LRS connector
Defective right HST sensor
motor speed sensor Right HST motor speed
CN-RRS connector
sensor
starting switch.
Short circuit with chas-
sis ground in wiring har- Between CN-ST1 (female) (22) – CN-EL (female) (4),
2 (5) or CN-FP (female) (C) or CN-DP1 (female) (C) or
ness (Contact with
ground circuit) CN-BP1 (female) (C) or CN-LP (female) (B) or CN-RP Resistance Min. 1 Mz
(female) (B) or CN-LRS (female) (1) or CN-RRS
(female) (1) wiring harness and chassis ground
20-428 D31/37/39EX, PX-21

(1)

troubleshooting.
Short circuit with Between CN-ST1 (female) (22) – CN-EL (female) (4),
Possible causes and
(5) or CN-FP (female) (C) or CN-DP1 (female) (C) or

power source in wiring
3 CN-BP1 (female) (C) or CN-LP (female) (B) or CN-RP Voltage Max. 1 V
harness (Contact with (female) (B) or CN-LRS (female) (1) or CN-RRS
24 V circuit)3. (female) (1) wiring harness and chassis ground
If the wiring harness has a short circuit with the power source, each sensor may be
broken. Accordingly, check each sensor after repairing the wiring harness.
Defective HST troubleshooting.
4
controller CN-ST1 Voltage
Between (22) and (21) 4.5 – 5.5 V
D31/37/39EX, PX-21 20-429

(1)
Circuit diagram related to 5 V power supply of HST controller
20-430 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING DD12KA
Error code [DD12KA] (Shift-up switch: Disconnection)

Trouble Shift-up switch: Disconnection (HST controller system)
E02 DD12KA
Contents of
• The 2 systems of the shift-up switch are turned OFF (opened) simultaneously.
trouble
Action of • Recognizes that the shift-up switch is not pressed.
turned OFF.
Problem that
appears on • The gear cannot be shifted up in the quick shift mode.
machine
• The NO signal of the 2 systems of the switch is for sensing operations and the NC signal is for sensing
errors.
Related
• The input state (ON/OFF) from the shift-up switch can be checked in the monitoring mode.
information
(Code: 40910-S/T SW1, 1st from left: NO, 7th: NC)
• Method of reproducing error code: Turn the starting switch ON and shift up the gear.

starting switch.
Defective shift-up switch Shift-up switch

1 CN38 (male)
(Internal disconnection) OFF (Released) ON (Pressed)
Between (2) and (3) Max. 1 z Min. 1 Mz
Between (2) and (1) Min. 1 Mz Max. 1 z
starting switch.
Disconnection in wiring Wiring harness between CN-ST1 (female) (12) and

harness (Disconnection Resistance Max. 1 z
CN38 (female) (3)
Possible causes and
defective contact in con- Wiring harness between CN-ST1 (female) (23) and
Resistance Max. 1 z
nector) CN38 (female) (1)
Resistance Max. 1 z
CN38 (female) (2)
Short circuit with power starting switch.
source in wiring harness Between CN-ST1 (female) (12) – CN38 (female) (3) wir-
3 Voltage Max. 1 V
(Contact with 24 V cir- ing harness and chassis ground
cuit) Between CN-ST1 (female) (23) – CN38 (female) (1) wir-
Voltage Max. 1 V
ing harness and chassis ground
starting switch.
Shift-up switch
4 Defective HST controller CN-ST1
OFF (Released) ON (Pressed)
Between (12) and (4) Max. 1 V 5 – 11V
Between (23) and (4) 5 – 11V Max. 1 V
20-432 D31/37/39EX, PX-21

(1)
Circuit diagram related to shift-up switch and shift-down switch
D31/37/39EX, PX-21 20-433

(1)
TROUBLESHOOTING DD12KB
Error code [DD12KB] (Shift-up switch: Short circuit)

Trouble Shift-up switch: Short circuit (HST controller system)
E02 DD12KB
Contents of
• The 2 systems of the shift-up switch are turned ON (closed) simultaneously.
trouble
Action of • Recognizes that the shift-up switch is not pressed.
turned OFF.
Problem that
• The gear cannot be shifted up in the quick shift mode.
appears on
• The travel speed cannot be increased in the variable shift mode.
machine
errors.
Related
information

starting switch.

1 CN38 (male)
(Internal short circuit) OFF (Released) ON (Pressed)
Max. 1 z
Between (2) and (3) Min. 1 Mz

Possible causes and
Short circuit with starting switch.
chassis ground in wir- Between CN-ST1 (female) (12) – CN38 (female) (3) wir-
2 Resistance Min. 1 Mz
ing harness (Contact ing harness and chassis ground
with ground circuit) Between CN-ST1 (female) (23) – CN38 (female) (1) wir-
troubleshooting.
Defective HST Shift-up switch

3 CN-ST1
controller OFF (Released) ON (Pressed)
Between (12) and (4) Max. 1 V 5 – 11 V
Between (23) and (4) 5 – 11 V Max. 1 V
20-434 D31/37/39EX, PX-21

(1)
Circuit diagram related to shift-up switch and shift-down switch
D31/37/39EX, PX-21 20-435

(1)
Error code [DD13KA] (Shift-down switch: Disconnection)
User Code Error Code

Trouble Shift-down switch: Disconnection (HST controller system)
E02 DD13KA
Contents of
• The 2 systems of the shift-down switch are turned OFF (opened) simultaneously.
trouble
Action of • Recognizes that the shift-down switch is not pressed.
turned OFF.
Problem that
• The gear cannot be shifted down in the quick shift mode.
appears on
• The travel speed cannot be decreased in the variable shift mode.
machine
errors.
Related
• The input state (ON/OFF) from the shift-down switch can be checked in the monitoring mode.
information
(Code: 40910-S/T SW1, 5th from left: NC, 6th: NO)
• Method of reproducing error code: Turn the starting switch ON and shift down the gear.

starting switch.
Defective shift-down Shift-down switch
1 switch (Internal discon- CN39 (female)
OFF (Released) ON (Pressed)
nection)
Between (2) and (3) Max. 1 z Min. 1 Mz
a Disconnection in wiring harness (Disconnection in wiring harness or defective
contact in connector)
Disconnection in wir-

ing harness (Discon- Resistance Max. 1 z
CN39 (male) (3)
Possible causes and
2 nection in wiring
harness or defective Resistance Max. 1 z
CN39 (male) (1)
Resistance Max. 1 z
CN39 (male) (2)
Short circuit with troubleshooting.
power source in wiring Between CN-ST1 (female) (24) – CN39 (male) (3) wir-
3 Voltage Max. 1 V
harness (Contact with ing harness and chassis ground
24 V circuit) Between CN-ST1 (female) (18) – CN39 (male) (1) wir-
Voltage Max. 1 V
troubleshooting.
Defective HST Shift-down switch

4 Shift-down switch
Between (24) and (4) Max. 1 V 5 – 11
Between (18) and (4) 5 – 11 Max. 1 V
20-436 D31/37/39EX, PX-21

(1)
Circuit diagram related to shift-down switch and shift-down switch
D31/37/39EX, PX-21 20-437

(1)
Error code [DD13KB] (Shift-down switch: Short circuit)

Trouble Shift-down switch: Short circuit (HST controller system)
E02 DD13KB
Contents of
• The 2 systems of the shift-up switch are turned ON (closed) simultaneously.
trouble
Action of • Recognizes that the shift-down switch is not pressed.
turned OFF.
Problem that
• The gear cannot be shifted down in the quick shift mode.
appears on
• The travel speed cannot be decreased in the variable shift mode.
machine
errors.
Related
information

starting switch.

1 CN39 (female)
(Internal short circuit) OFF (Released) ON (Pressed)
Max. 1 z
Between (2) and (3) Min. 1 Mz

Possible causes and
chassis ground in wir- Between CN-ST1 (female) (24) – CN39 (male) (3) wir-
with ground circuit) Between CN-ST1 (female) (18) – CN39 (male) (1) wir-
troubleshooting.
Defective HST Shift-up switch

3 CN-ST1
Between (24) and (4) Max. 1 V 5 – 11 V
Between (18) and (4) 5 – 11 V Max. 1 V
20-438 D31/37/39EX, PX-21

(1)
Circuit diagram related to shift-down switch and shift-down switch
D31/37/39EX, PX-21 20-439

(1)
Error code [DD14KB] (Travel lock SW1: Short circuit)

Trouble Travel lock SW1: Short circuit (HST controller system)
CALL E03 DD14KB
Contents of
• The 2 systems of the travel lock switch 1 are turned ON (closed) simultaneously.
trouble
• Recognizes that the travel lock lever is in the FREE position.
Action of
controller
turned OFF.
Problem that
appears on
• The engine cannot be started.
machine
errors.
Related
• The input state (ON/OFF) from the travel lock switch 1 can be checked in the monitoring mode.
information
(Code: 40912-S/T SW, 3rd from left: NO, 4th: NC)
• Method of reproducing error code: Turn the starting switch ON and operate the parking brake lever.

starting switch.
Defective travel lock Parking brake lever
1 switch 1 CN26 (male)
FREE (Upper) LOCK (Lower)
Between (A) and (B) Max. 1 z Min. 1 Mz
Between (A) and (C) Min. 1 Mz Max. 1 z

Possible causes and
chassis ground in wir- Between CN-ST2 (female) (5) – CN26 (female) (B) wir-
with ground circuit) Between CN-ST2 (female) (15) – CN26 (female) (C)
troubleshooting.
Parking brake lever
CN-ST1, CN-ST2
Defective HST con- FREE (Upper) LOCK (Lower)
3
troller Between CN-ST2 (5) and
Max. 1 V 5 – 11 V
CN-ST1 (10)
Between CN-ST2 (15) and
5 – 11 V Max. 1 V
CN-ST1 (10)
20-440 D31/37/39EX, PX-21

(1)
Circuit diagram related to travel lock switch 1
D31/37/39EX, PX-21 20-441

(1)
TROUBLESHOOTING DDDCKB
Error code [DDDCKB] (Reverse travel speed switch: Short circuit)

Trouble Reverse travel speed switch: Short circuit (HST controller system)
E01 DDDCKB
Contents of
• The 2 systems of the reverse travel speed setting switch are turned ON (closed) simultaneously.
trouble
• Recognizes that the reverse travel speed setting switch is in the neutral position.
Action of
controller
turned OFF.
Problem that
appears on • The reverse travel speed cannot be set high or low.
machine
• The input state (ON/OFF) from the reverse travel speed setting switch can be checked in the monitor-
Related infor- ing mode. (Code: 40912-S/T SW, 1st from left: Increase speed, 2nd: Decrease speed)
mation • Method of reproducing error code: Turn the starting switch ON and operate the reverse travel speed
setting switch.

starting switch.
Reverse travel speed set-
CN-REV (male) Resistance
Defective reverse travel ting switch
1 speed setting switch Center Min. 1 Mz
(Internal short circuit) Between (1) and (2)
Increase speed (Right) Max. 1 z
Min. 1 Mz
Center
Between (1) and (3)
Decrease speed (Left) Max. 1 z
Possible causes and
Short circuit with chassis starting switch.
ground in wiring harness Between CN-ST2 (female) (25) – CN-REV (female) (2)
(Contact with ground cir- wiring harness and chassis ground
cuit) Between CN-ST2 (female) (35) – CN-REV (female) (3)
troubleshooting.
Reverse travel speed
CN-ST1, CN-ST2 Voltage
setting switch
Defective HST
3 Center 5 – 11 V
controller Between CN-ST2 (25) and
CN-ST1 (10) Increase speed (Right) Max. 1 V
Between CN-ST2 (35) and Center 5 – 11 V
CN-ST1 (10) Decrease speed (Left) Max. 1 V
20-442 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING DDDCKB
Circuit diagram related to reverse speed set switch
D31/37/39EX, PX-21 20-443

(1)
TROUBLESHOOTING DDP6KB
Error code [DDP6KB] (Brake pressure switch: Short circuit)

Trouble Brake pressure switch: Short circuit (HST controller system)
E01 DDP6KB
Contents of • When the starting switch is turned ON, the signal from the HST charge pressure switch (brake oil pres-
trouble sure switch) is connected to the ground.
• None in particular.
Action of
controller
turned OFF.
Problem that
appears on • Even if the HST charge pressure lowers, the charge pressure caution of the monitor is not turned ON.
machine
• The input state (ON/OFF) from the brake oil pressure switch can be checked in the monitoring mode.
Related
(Code: 40910-S/T SW1, 3rd from left)
information

a Prepare with starting switch OFF, then hold starting switch OFF or start engine and
carry out troubleshooting (When starting engine, set parking brake lever in FREE
Defective HST charge position).
1 pressure switch CN-BS (male) Engine Resistance

Stopped Min. 1 Mz
Possible causes and
Between (1) and (2)

Running Max. 1 z
Short circuit with chassis a Prepare with starting switch OFF, then carry out troubleshooting without turning
ground in wiring harness starting switch.
2
(Contact with ground cir- Between CN-ST1 (female) (11) – CN-BS (female) (2)
cuit) Resistance Min. 1 Mz
a Prepare with starting switch OFF, then hold starting switch ON or start engine and
carry out troubleshooting (When starting engine, release brake pedal).
CN-ST1 Engine Voltage
Stopped
5 – 11 V
Between (11) and (4) (With starting switch ON)
Running Max. 1 V
20-444 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING DDP6KB
Circuit diagram related to HST charge pressure switch
D31/37/39EX, PX-21 20-445

(1)
TROUBLESHOOTING DDQ2KA
Error code [DDQ2KA] (Travel lock SW1: Disconnection)

Trouble Travel lock SW1: Disconnection (HST controller system)
CALL E03 DDQ2KA
Contents of
• The 2 systems of the travel lock switch 1 are turned OFF (opened) simultaneously.
trouble
• Recognizes that the travel lock lever is in the FREE position.
Action of
controller
turned OFF.
Problem that
appears on • Once the machine is stopped and started again, its travel speed is limited to 50%.
machine
errors.
Related
• The input state (ON/OFF) from the travel lock switch 1 can be checked in the monitoring mode. (Code:
information
40912-S/T SW, 3rd from left: NO, 4th: NC)
• Method of reproducing error code: Turn the starting switch ON and operate the parking brake lever.

starting switch.

CN26 (male)
1 switch 1 (Internal short FREE (Upper) LOCK (Lower)
circuit) Between (A) and (B) Max. 1 z Min. 1 Mz
Defective installation of
Between (A) and (C) Max. 1 z
travel lock switch
Defective installation Travel lock switch 1 may be installed defectively. Check it directly (See TESTING
2
of travel lock switch AND ADJUSTING).
starting switch.
Disconnection in wir-
Resistance Max. 1 z
Possible causes and
ing harness (Discon- CN26 (female) (B)

3 nection in wiring
CN26 (female) (C)
Resistance Max. 1 z
CN26 (female) (A)
Short circuit with troubleshooting.
power source in wiring Between CN-ST2 (female) (5) – CN26 (female) (B) wir-
4 Voltage Max. 1 V
harness (Contact with ing harness and chassis ground
24 V circuit) Between CN-ST2 (female) (15) – CN26 (female) (C)
Voltage Max. 1 V
troubleshooting.
Parking brake lever
CN-ST1, CN-ST2
Defective HST FREE (Upper) LOCK (Lower)
5
controller Between CN-ST2 (5) and
Max. 1 V 5 – 11 V
CN-ST1 (10)
5 – 11 V Max. 1 V
CN-ST1 (10)
20-446 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING DDQ2KA
Circuit diagram related to travel lock switch 1
D31/37/39EX, PX-21 20-447

(1)
TROUBLESHOOTING DDU1FS
Error code [DDU1FS] (Parking brake ON-OFF switch: Stick)

Trouble Parking brake ON-OFF switch: Stick (HST controller system)
CALL E03 DDU1FS
• The output circuit to the slow brake solenoid valve is outputting normally.
Contents of When the signal of travel lock switch 1 is in the LOCK position and the pressing ratio of the brake pedal
trouble is below 60%, the slow brake output monitor signal (signal of travel lock switch 2) is turned OFF
(opened).
Action of • Limits the functions partly.
turned OFF.
Problem that
machine
• The output state (ON/OFF) to the slow brake solenoid valve can be checked in the monitoring mode.
(Code: 40914-SOL ON/OFF)
Related infor- • The input state (ON/OFF) of the slow brake output monitor signal (travel lock switch 2) can be checked
mation in the monitoring mode. (Code: 40911-S/T SW2, 5th from left: NO)
• Method of reproducing error code: Turn the starting switch ON, set the parking brake lever in the LOCK
position, and release the brake pedal.

starting switch.
Possible causes and
Parking brake lever

Defective travel lock CN26B (male)
1
switch 2 (Internal defect) FREE (Upper) LOCK (Lower)
Travel lock switches 1 and 2 may be installed defectively. Check them directly (See
2 travel lock switches 1
TESTING AND ADJUSTING).
and 2
20-448 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING DDU1FS
Circuit diagram related to travel lock switch 2, brake pedal limit switch, and slow brake solenoid valve
D31/37/39EX, PX-21 20-449

(1)
TROUBLESHOOTING DDU1KA
Error code [DDU1KA] (Parking brake ON-OFF switch: Disconnection)

Trouble Parking brake ON-OFF switch: Disconnection (HST controller system)
CALL E03 DDU1KA
• No current flows in the output circuit to the slow brake solenoid valve.
Contents of
• When the signal of travel lock switch 1 is in the LOCK position, the slow brake output monitor signal
trouble
(signal of travel lock switch 2) is turned OFF (opened).
Action of con- • Operates the HST brake, limiting the functions partly.
troller • Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
turned OFF.
Problem that
machine
(Code: 40914-SOL ON/OFF, 4th from left)
Related • The input state (ON/OFF) of the slow brake output monitor signal (travel lock switch 2) can be checked
information in the monitoring mode. (Code: 40911-S/T SW2, 5th from left: NO)
• Method of reproducing error code: Turn the starting switch ON and set the parking brake lever in the
LOCK position.

starting switch.

1 CN26B (male)
Possible causes and

2 travel lock switches 1 and
2
CN26B (female) (C)
nector) Wiring harness between CN-ST3 (female) (37) and
Resistance Max. 1 z
CN26B (female) (A)
20-450 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING DDU1KA
D31/37/39EX, PX-21 20-451

(1)
TROUBLESHOOTING DDU1KB
Error code [DDU1KB] (Parking brake ON-OFF switch: Short circuit)
Usr Code Action code

Trouble Parking brake ON-OFF switch: Short circuit (HST controller system)
CALL E03 DDU1KB
• When the signal of travel lock switch 1 is in the LOCK position and the pressing ratio of the brake pedal
Contents of
is below 60%, the slow brake output monitor signal (signal of travel lock switch 2) is turned ON
trouble
(closed).
Action of con- • Limits the functions partly.
troller • Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
turned OFF.
Problem that
machine
position, and press the brake pedal fully.

starting switch.
Parking brake lever

CN26B (male)
Defective travel lock FREE (Upper) LOCK (Lower)
Possible causes and
1
switch 2 (Internal defect) Between (A) and (B) Max. 1 z Min. 1 Mz
Between (A), (B), (C) and
Min. 1 Mz Min. 1 Mz
chassis ground
ground in wiring harness Between CN-ST3 (female) (37) – CN26B (female) (A)
(Contact with ground cir- wiring harness and chassis ground
cuit) Between CN-ST3 (female) (9) – CN26B (female) (C)
20-452 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING DDU1KB
D31/37/39EX, PX-21 20-453

(1)
TROUBLESHOOTING DDU1KY
Error code [DDU1KY] (Parking brake ON-OFF switch: Short circuit with power supply line)
Action code Error code Parking brake ON-OFF switch: Short circuit with power supply line
Trouble
CALL E03 DDU1KY (HST controller system)
Contents of
• When the signal of travel lock switch 1 is in the FREE position, the slow brake output monitor signal
trouble
(signal of travel lock switch 2) is turned ON (closed).
Action of • Operates the HST brake, limiting the functions partly.
turned OFF.
Problem that
machine
The output state (ON/OFF) to the slow brake solenoid valve can be checked in the monitoring mode.
Related The input state (ON/OFF) of the slow brake output monitor signal (travel lock switch 2) can be checked in
information the monitoring mode. (Code: 40911-S/T SW2, 5th from left: NO)
Method of reproducing error code: Turn the starting switch ON and set the parking brake lever in the
FREE position.

starting switch.
Possible causes and

1 CN26B (male)
2
harness (Contact with Between CN-ST3 (female) (9) – CN26B (female) (C)
Voltage Max. 1 V
24 V circuit) wiring harness and chassis ground
20-454 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING DDU1KY
D31/37/39EX, PX-21 20-455

(1)
TROUBLESHOOTING DDU1L4
Error code [DDU1L4] (Parking brake ON-OFF switch: Disagreement of ON and OFF
signals)
User Code Error code Parking brake ON-OFF switch: Disagreement of ON and OFF signals
Trouble
CALL E03 DDU1L4 (HST controller system)
• The output circuit to the slow brake solenoid valve is outputting normally and the signal of travel lock
switch 1 is in the LOCK position.
Contents of • When the pressing ratio of the brake pedal is below 60%, the slow brake output monitor signal (signal
trouble of travel lock switch 2) is turned ON (closed).
• When the pressing ratio of the brake pedal is above 60%, the slow brake output monitor signal (signal
of travel lock switch 2) is turned OFF (opened).
Action of
controller
turned OFF.
Problem that
machine
Related infor- • The input state (ON/OFF) of the slow brake output monitor signal (travel lock switch 2) can be checked
mation in the monitoring mode. (Code: 40912-S/T SW2, 5th from left: NO)
position, and release the brake pedal or press it fully.

starting switch.
Parking brake lever

CN26B (male)
Defective travel lock FREE (Upper) LOCK (Lower)
Possible causes and
1
switch 2 (Internal defect) Between (A) and (B) Max. 1 z Min. 1 Mz
Between (A), (B), (C) and
Min. 1 Mz Min. 1 Mz
chassis ground
Short circuit with chas- starting switch.
sis ground in wiring har- Between CN-ST3 (female) (9) – CN26B (female) (C)
ness (Contact with wiring harness and chassis ground
ground circuit) Between CN-ST3 (female) (37) – CN26B (female) (A)
20-456 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING DDU1L4
D31/37/39EX, PX-21 20-457

(1)
TROUBLESHOOTING DGS1KX
Error code [DGS1KX] (Hydraulic tank oil temperature sensor: Out of input signal range)
Action code Error code Failure Hydraulic tank oil temperature sensor: Out of input
Trouble
— DGS1KX phenomenon signal range (HST controller system)
Contents of
• The input voltage from the HST oil temperature sensor is below 0.3 V.
trouble
Action of
controller
turned OFF.
Problem that
• If this trouble occurs, the HST oil thermometer of the monitor panel indicates the maximum level, the
appears on
HST oil overheating caution lamp flashes, and the warning buzzer sounds.
machine
• The input state (voltage, oil temperature) from the HST oil temperature sensor can be checked in the
Related
monitoring mode. (Code: 004402-HST TEMP, Code: 85001-HST TEMP)
information
• ¥ Method of reproducing error code: Turn the starting switch ON.

starting switch.
Defective HST oil tem-
CN12 (male) HST oil temperature Resistance

1 perature sensor
(Internal short circuit) Between (1) and (2) 3.5 k – 90 kz
Possible causes and
Between (1) and chassis 10 – 100 °C

Min. 1 Mz
ground
Short circuit with chas- a Prepare with starting switch OFF, then carry out troubleshooting without turning
sis ground in wiring har- starting switch.
2
ness (Contact with Short circuit with chassis ground in wiring harness
ground circuit) Resistance Min. 1 Mz
(Contact with ground circuit)
troubleshooting.
CN-ST1 HST oil temperature Voltage
Between (9) and (21) 10 – 100 °C 2.0 – 4.8 V
20-458 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING DGS1KX
Circuit diagram related to HST oil pressure sensor
D31/37/39EX, PX-21 20-459

(1)
TROUBLESHOOTING DHH5KA
Error code [DHH5KA] (LH pump pressure sensor: Disconnection)

Trouble LH pump pressure sensor: Disconnection (HST controller system)
E01 DHH5KA
Contents of
• The input voltage from the LH pump pressure sensor is below 0.3 V.
trouble
Action of
controller
turned OFF.
Problem that
• The auto shift-down/up function may not work.
appears on
• The LH pump oil pressure may not be monitored in the monitoring mode.
machine
• If the 5 V circuit (B) and ground circuit (A) of the pressure sensor are connected inversely, the pressure
sensor will be broken. Accordingly, take extreme care when checking.
Related infor-
• The input state (voltage) from the LH pump pressure sensor can be checked in the monitoring mode.
mation
(Code: 52502-HST L SENS)
• Method of reproducing error code: Turn the starting switch ON or start the engine.

Defective sensor power
1 If error code [DAJ5KK] is displayed, carry out troubleshooting for it first.
supply system
troubleshooting.
CN-LP Voltage
Defective LH pump pres-
Between (B) and (A) Power supply 4.5 – 5.5 V
2 sure sensor
(Internal defect) Between (C) and (A) Signal 0.4 – 0.6 V
The pressure sensor voltage is measured with the wiring harness connected.
Accordingly, if the voltage is abnormal, check the wiring harness and controller, too,
for another cause of the trouble, and then judge.

Possible causes and
starting switch.
Disconnection in wiring Wiring harness between CN-ST1 (female) (22) and CN-
LP (female) (B)
defective contact in con- Wiring harness between CN-ST1 (female) (21) and CN-
Resistance Max. 1 z
nector) LP (female) (A)
Resistance Max. 1 z
LP (female) (C)
4
ness (Contact with Between CN-ST1 (female) (14) – CN-LP (female) (C)
troubleshooting.
5 Defective HST controller CN-ST1 Voltage
Between (22) and (21) Power supply 4.5 – 5.5 V
Between (14) and (21) Signal 0.4 – 0.6 V
20-460 D31/37/39EX, PX-21

(1)
Circuit diagram related to LH pump pressure sensor
D31/37/39EX, PX-21 20-461

(1)
TROUBLESHOOTING DHH5KB
Error code [DHH5KB] (LH pump pressure sensor: Short circuit)
Action code Error code Failure LH pump pressure sensor: Short circuit
Trouble
E01 DHH5KB phenomenon (HST controller system)
Contents of
• The input voltage from the LH pump pressure sensor is above 4.5 V.
trouble
• Controls the machine with the pressure signal received just before the trouble occurs until the machine
is stopped.
Action of • Controls the machine, assuming the pump pressure to be 9.81 MPa {100 kg/cm2}, once the machine is
controller stopped.
turned OFF.
Problem that
appears on
• The LH pump oil pressure may not be monitored in the monitoring mode.
machine
a If the 5 V circuit (B) and ground circuit (A) of the pressure sensor are connected inversely, the pressure
Related
• The input state (voltage) from the LH pump pressure sensor can be checked in the monitoring mode.
information
(Code: 52502-HST L SENS)

supply system
a Prepare with starting switch OFF, then turn starting switch ON or start engine and
carry out troubleshooting.
CN-LP Voltage
Defective LH pump pres-

2 sure sensor
Possible causes and
(Internal defect) Between (C) and (A) Signal 0.4 – 0.6 V

Short circuit with power a Prepare with starting switch OFF, then turn starting switch ON and carry out
source in wiring harness troubleshooting.
3
(Contact with 24 V cir- Between CN-ST1 (female) (14) – CN-LP (female) (C)
cuit) Voltage Max. 1 V
20-462 D31/37/39EX, PX-21

(1)
Circuit diagram related to LH pump pressure sensor
D31/37/39EX, PX-21 20-463

(1)
Error code [DHH6KA] (RH pump pressure sensor: Disconnection)

Trouble RH pump pressure sensor: Disconnection (HST controller system)
E01 DHH6KA
Contents of
• The input voltage from the RH pump pressure sensor is below 0.3 V.
trouble
Action of
controller
turned OFF.
Problem that
appears on
• The RH pump oil pressure may not be monitored in the monitoring mode.
machine
a If the 5 V circuit (B) and ground circuit (A) of the pressure sensor are connected inversely, the pressure
Related
• The input state (voltage) from the RH pump pressure sensor can be checked in the monitoring mode.
information
(Code: 52500-HST R SENS)

supply system
troubleshooting.
CN-RP Voltage
Defective RH pump
2 pressure sensor (Internal
defect) Between (C) and (A) Signal 0.4 – 0.6 V

Possible causes and
starting switch.
RP (female) (B)
Resistance Max. 1 z
nector) RP (female) (A)
Resistance Max. 1 z
RP (female) (C)
4
ness (Contact with Between CN-ST1 (female) (20) – CN-RP (female) (C)
troubleshooting.
20-464 D31/37/39EX, PX-21

(1)
Circuit diagram related to RH pump pressure sensor
D31/37/39EX, PX-21 20-465

(1)
Error code [DHH6KB] (RH pump pressure sensor: Short circuit)

Trouble RH pump pressure sensor: Short circuit (HST controller system)
E01 DHH6KB
Contents of
• The input voltage from the RH pump pressure sensor is above 4.5 V.
trouble
• Controls the machine with the pressure signal received just before the trouble occurs until the machine
is stopped.
Action of • Controls the machine, assuming the pump pressure to be 9.81 MPa {100 kg/cm2}, once the machine is
controller stopped.
turned OFF.
Problem that
appears on
• The RH pump oil pressure may not be monitored in the monitoring mode.
machine
• If the 5 V circuit (B) and ground circuit (A) of the pressure sensor are connected inversely, the pressure
Related
• The input state (voltage) from the RH pump pressure sensor can be checked in the monitoring mode.
information
(Code: 52500-HST R SENS)

supply system
troubleshooting.
CN-RP Voltage
Defective RH pump
2 pressure sensor (Internal
Possible causes and
defect) Between (C) and (A) Signal 0.4 – 0.6 V

3
(Contact with 24 V Between CN-ST1 (female) (20) – CN-RP (female) (C)
circuit) Voltage Max. 1 V
4 Defective HST controller CN-T1 Voltage
20-466 D31/37/39EX, PX-21

(1)
Circuit diagram related to RH pump pressure sensor
D31/37/39EX, PX-21 20-467

(1)
TROUBLESHOOTING DK10KA
Error code [DK10KA] (Throttle angle sensor: Disconnection)

Trouble Throttle angle sensor: Disconnection (HST controller system)
E02 DK10KA
Contents of
• The input voltage from the fuel control lever potentiometer is below 0.3 V.
trouble
• Controls the machine with the position signal received just before the trouble occurs until the machine
is stopped.
Action of
• Controls the machine, assuming the fuel control lever to be at the high idling position, once the
controller
machine is stopped.
turned OFF.
Problem that
appears on • When the fuel control lever (throttle) is set low, the machine cannot absorb full power.
machine
• The input state (voltage) from the fuel control lever potentiometer can be checked in the monitoring
Related
mode. (Code: 03002-FUEL DIAL)
information
• Method of reproducing error code: Turn the starting switch ON and operate the fuel control lever.

supply system
starting switch.
CN-FP (male) Resistance
Defective fuel control
Between (A) and (C) 4.0 – 6.0 kz
2 lever potentiometer
(Internal defect) 0.5 – 4.5 kz
Between (B) and (A)
(Between LOW and HIGH)
0.5 – 4.5 kz
Between (B) and (C)
Possible causes and
(Between LOW and HIGH)

FP (female) (C)
nector) Wiring harness between CN-ST1 (female) (8) and CN-
Resistance Max. 1 z
FP (female) (B)
4
ness (Contact with Between CN-ST1 (female) (8) – CN-FP (female) (B)
troubleshooting.
20-468 D31/37/39EX, PX-21

(1)
Circuit diagram related to fuel control lever potentiometer
D31/37/39EX, PX-21 20-469

(1)
TROUBLESHOOTING DK10KB
Error code [DK10KB] (Throttle angle sensor: Short circuit)

Trouble Throttle angle sensor: Short circuit (HST controller system)
E02 DK10KB
Contents of
• The input voltage from the fuel control lever potentiometer is above 4.5 V.
trouble
is stopped.
Action of
• Controls the machine, assuming the fuel control lever to be at the high idling position, once the
controller
machine is stopped.
turned OFF.
Problem that
appears on • When the fuel control lever (throttle) is set low, the machine cannot absorb full power.
machine
• The input state (voltage) from the fuel control lever potentiometer can be checked in the monitoring
Related
mode. (Code: 03002-FUEL DIAL)
information
• Method of reproducing error code: Turn the starting switch ON and operate the fuel control lever.

supply system
starting switch.
Defective fuel control CN-FP (male) Resistance
2 lever potentiometer
(Internal defect)
Between (B) and (A) (Between LOW and HIGH)

Possible causes and
Between (B) and (C) (Between LOW and HIGH)

Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting without turning
harness (Disconnection starting switch.
Resistance Max. 1 z
nector) FP (female) (A)
Short circuit with power troubleshooting.
4 source in wiring harness
(Contact with 24 V circuit) Between CN-ST1 (female) (8) – CN-FP (female) (B) wir- Voltage Max. 1 V
troubleshooting.
20-470 D31/37/39EX, PX-21

(1)
Circuit diagram related to fuel control lever potentiometer
D31/37/39EX, PX-21 20-471

(1)
Error code [DK12KA] (Deceleration sensor: Disconnection)

Trouble Deceleration sensor: Disconnection (HST controller system)
E02 DK12KA
Contents of
• The input voltage from the decelerator pedal potentiometer is below 0.3 V.
trouble
Action of is stopped.
controller • Controls the machine, assuming the decelerator pedal stroke to be 0, once the machine is stopped.
turned OFF.
Problem that
appears on • When the decelerator pedal is pressed, the machine does not stop (on a flat place).
machine
• The input state (voltage) from the decelerator pedal potentiometer can be checked in the monitoring
Related
mode. (Code: 50001-DESEL PEDAL)
information
• Method of reproducing error code: Turn the starting switch ON and press the decelerator pedal.

supply system
starting switch.
CN-DP1 (male) Resistance
Defective decelerator
2 pedal potentiometer
Between (B) and (A)
(Between release and stroke end)
0.5 – 4.5 kz
Between (B) and (C)
Possible causes and

DP1 (female) (C)
Resistance Max. 1 z
DP1 (female) (B)
4
(Contact with ground cir- Between CN-ST1 (female) (2) – CN-DP1 (female) (B)
troubleshooting.
20-472 D31/37/39EX, PX-21

(1)
Circuit diagram related to decelerator pedal potentiometer
D31/37/39EX, PX-21 20-473

(1)
Error code [DK12KB] (Deceleration sensor: Short circuit)

Trouble Deceleration sensor: Short circuit (HST controller system)
E02 DK12KB
Contents of
• The input voltage from the decelerator pedal potentiometer is above 4.5 V.
trouble
controller • Controls the machine, assuming the decelerator pedal stroke to be 0, once the machine is stopped.
turned OFF.
Problem that
appears on • When the decelerator pedal is pressed, the machine does not stop (on a flat place).
machine
• The input state (voltage) from the decelerator pedal potentiometer can be checked in the monitoring
Related
mode. (Code: 50001-DESEL PEDAL)
information
• Method of reproducing error code: Turn the starting switch ON and press the decelerator pedal.
Cause Standard value in normalcy and references for troubleshooting

supply system
starting switch.
CN-DP1 (male) Resistance
Defective decelerator
2 pedal potentiometer
Between (B) and (A)
standard value in normalcy
0.5 – 4.5 kz
Presumed cause and
Between (B) and (C)

harness (Disconnec- starting switch.
3 tion in wiring harness
or defective contact in Wiring harness between CN-ST1 (female) (21) and CN- Resistance Max. 1 z
DP1 (female) (A)
connector)
4
harness (Contact with Between CN-ST1 (female) (2) – CN-DP1 (female) (B)
Voltage Max. 1 V
troubleshooting.
Defective HST control- CN-ST1 Voltage
5
ler
20-474 D31/37/39EX, PX-21

(1)
Circuit diagram related to decelerator pedal potentiometer
D31/37/39EX, PX-21 20-475

(1)
Error code [DK30KA] (Steering angle sensor: Disconnection)

Trouble Steering angle sensor: Disconnection (HST controller system)
CALL E03 DK30KA
Contents of
• The input voltage from the steering potentiometer 1 is above 4.5 V.
trouble
Action of • Controls the machine with the signal of the steering potentiometer 2, limiting the functions partly.
turned OFF.
Problem that
machine
• The input state (voltage) from the steering potentiometer 1 can be checked in the monitoring mode.
Related (Code: 50300-S/T LEVER 1)
information • Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (in the
steering direction).

supply system
starting switch.
CN-EL (male) Resistance
Defective steering
Between (5) and (8) 3.2 kz ± 20%
2 potentiometer
(Internal defect) 1 – 6 kz
Between (7) and (5)
(Between right and left ends)
6 – 1 kz
Between (7) and (8)
Possible causes and

harness (Disconnec-
EL (female) (8)
connector) Wiring harness between CN-ST1 (female) (19) and CN-
Resistance Max. 1 z
EL (female) (7)
4
harness (Contact with Between CN-ST1 (female) (19) – CN-EL (female) (7)
Voltage Max. 1 V
troubleshooting.
Defective HST CN-ST1 Voltage
5
controller
20-476 D31/37/39EX, PX-21

(1)
Circuit diagram related to directional potentiometer and steering potentiometer
D31/37/39EX, PX-21 20-477

(1)
Error code [DK30KB] (Steering angle sensor: Short circuit)

Trouble Steering angle sensor: Short circuit (HST controller system)
CALL E03 DK30KB
Contents of
• The input voltage from the steering potentiometer 1 is below 0.3 V.
trouble
turned OFF.
Problem that
machine

supply system
starting switch.
Defective steering poten- Between (5) and (8) 3.2 kz ± 20%
2
tiometer (Internal defect) 1 – 6 kz
Between (7) and (5)

Possible causes and
6 – 1 kz
Between (7) and (8)
harness (Disconnec-
EL (female) (5)
connector)
4
(Contact with ground cir- Between CN-ST1 (female) (19) – CN-EL (female) (7)
troubleshooting.
20-478 D31/37/39EX, PX-21

(1)
D31/37/39EX, PX-21 20-479

(1)
TROUBLESHOOTING DK30KX
Error code [DK30KX] (Steering angle sensor: Out of input signal range)
Action code Error code Steering angle sensor: Out of input signal range
Trouble
CALL 04 DK30KX (HST controller system)
Contents of • In steering potentiometer systems 1 and 2, either of error codes [DK30KA] and [DK30KB] and either of
trouble error codes [DK31KA] and [DK31KB] are turned ON simultaneously.
Action of • Controls the machine with the position signal received just before the trouble occurs until the machine
controller is stopped.
turned OFF.
Problem that
appears on • Once the machine is stopped, it cannot start again.
machine
• The input state (voltage) from the steering potentiometers 1 and 2 can be checked in the monitoring
Related mode. (Code: 50300-S/T LEVER 1, Code: 50301-S/T LEVER 2)

Possible causes and
Carry out troubleshooting for error codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
20-480 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING DK30KZ
Error code [DK30KZ] (Steering angle sensor: Disconnection or short circuit)
Action code Error code Failure Steering angle sensor: Disconnection or short circuit
Trouble
CALL E04 DK30KZ phenomenon (HST controller system)
• When the starting switch is turned ON, either of steering potentiometer systems 1 and 2 is abnormal,
Contents of
and then either of error codes [DK30KA] and [DK30KB] and either of error codes [DK31KA] and
trouble
[DK31KB] are turned ON simultaneously in those systems.
turned OFF.
Problem that
machine

Possible causes and
D31/37/39EX, PX-21 20-481

(1)
TROUBLESHOOTING DK30L8
Error code [DK30L8] (Steering angle sensor: Disagreement of analog signals)
Action code Error code Steering angle sensor: Disagreement of analog signals
Trouble
CALL E03 DK30L8 (HST controller system)
Contents of • The total of both signal voltages of steeing potentiometer systems 1 and 2 is below 4.41 V or above
trouble 5.59 V.
Action of
• Controls the machine with the potentiometer which is outputting normal signals.
controller
turned OFF.
Problem that
machine

Possible causes and
20-482 D31/37/39EX, PX-21

(1)
Error code [DK31KA] (Steering angle sensor 2: Disconnection)

Trouble Steering angle sensor 2: Disconnection (HST controller system)
CALL E03 DK31KA
Contents of
• The input voltage from the steering potentiometer 2 is above 4.5 V.
trouble
Action of
controller
Problem that
appears on • The engine speed cannot be controlled.
machine

supply system
starting switch.
Defective steering poten-
Between (5) and (8) 3.2 kz ± 20%
2 tiometer 2 (Internal
defect) 6 – 1 kz
Between (6) and (5)

Possible causes and
1 – 6 kz
Between (6) and (8)
Resistance Max. 1 z
nector) EL (female) (8)
(Contact with 24 V circuit) Between CN-ST1 (female) (7) – CN-EL (female) (6) wir-
Voltage Max. 1 V
troubleshooting.
20-484 D31/37/39EX, PX-21

(1)
D31/37/39EX, PX-21 20-485

(1)
Error code [DK31KB] (Steering angle sensor 2: Short circuit)

Trouble Steering angle sensor 2: Short circuit (HST controller system)
CALL E03 DK31KB
Contents of
• The input voltage from the steering potentiometer 2 is below 0.3 V.
trouble
turned OFF.
Problem that
machine

supply system
starting switch.
Defective steering
Between (5) and (8) 3.2 kz ± 20%
2 potentiometer 2
(Internal defect) 6 – 1 kz
Between (6) and (5)
Possible causes and standard
1 – 6 kz
Between (6) and (8)
value in normal state

harness (Disconnec-
Wiring harness between NC-ST1 (female) (22) and CN-
EL (female) (5)
connector) Wiring harness between NC-ST1 (female) (7) and CN-
Resistance Max. 1 z
EL (female) (6)
sis ground in wiring starting switch.
4
harness (Contact with Between CN-ST1 (female) (7) – CN-EL (female) (6) wir-
ground circuit) ing harness and chassis ground
troubleshooting.
5
ler
20-486 D31/37/39EX, PX-21

(1)
D31/37/39EX, PX-21 20-487

(1)
Error code [DK40KA] (Brake angle sensor: Disconnection)
Action code Error code Failure Brake angle sensor: Disconnection

Trouble
CALL E03 DK40KA phenomenon (HST controller system)
Contents of
• The input voltage from the brake pedal potentiometer is below 0.3 V.
trouble
controller • Controls the machine, assuming the brake pedal stroke to be 0, once the machine is stopped.
turned OFF.
Problem that
machine
• The input state (voltage) from the brake pedal potentiometer can be checked in the monitoring mode.
Related
(Code: 50400-BRAKE PEDAL)
information
• Method of reproducing error code: Turn the starting switch ON and press the brake pedal.

supply system
starting switch.
CN-BP1 (male) Resistance
2 potentiometer
Between (B) and (A)
0.5 – 4.5 kz
Between (B) and (C)
Possible causes and

harness (Disconnec-
BP1 (female) (C)
Resistance Max. 1 z
BP1 (female) (B)
sis ground in wiring starting switch.
4
harness (Contact with Between CN-ST1 (female) (3) – CN-BP1 (female) (B)
ground circuit) wiring harness and chassis ground
troubleshooting.
5
ler
20-488 D31/37/39EX, PX-21

(1)
Circuit diagram related to brake pedal potentiometer
D31/37/39EX, PX-21 20-489

(1)
Error code [DK40KB] (Brake angle sensor: Short circuit)

Trouble Brake angle sensor: Short circuit (HST controller system)
CALL E03 DK40KB
Contents of
• The input voltage from the brake pedal potentiometer is above 4.5 V.
trouble
controller • Controls the machine, assuming the brake pedal stroke to be 0, once the machine is stopped.
turned OFF.
Problem that
machine
• The input state (voltage) from the brake pedal potentiometer can be checked in the monitoring mode.
Related
(Code: 50400-BRAKE PEDAL)
information
• Method of reproducing error code: Turn the starting switch ON and press the brake pedal.

supply system
starting switch.
CN-BP1 (male) Resistance
2 potentiometer (Internal
defect) 0.5 – 4.5 kz
Between (B) and (A)

0.5 – 4.5 kz
Possible causes and
Between (B) and (C)

BP1 (female) (A)
connector)
4
harness (Contact with Between CN-ST1 (female) (3) – CN-BP1 (female) (B)
Voltage Max. 1 V
troubleshooting.
5
ler
20-490 D31/37/39EX, PX-21

(1)
Circuit diagram related to brake pedal potentiometer
D31/37/39EX, PX-21 20-491

(1)
TROUBLESHOOTING DK55KX
Error code [DK55KX] (Directional potentiometer: Out of input signal range)
Action code Error code Directional potentiometer: Out of input signal range
Trouble
CALL E04 DK55KX (HST controller system)
Contents of • In directional potentiometer systems 1 and 2, either of error codes [DK56KA] and [DK56KB] and either
trouble of error codes [DK57KA] and [DK57KB] are turned ON simultaneously.
turned OFF.
Problem that
machine
• The input state (voltage) from the directional potentiometers 1 and 2 can be checked in the monitoring
Related mode. (Code: 50202-FR LEVER 1, Code: 50203-FR LEVER 2)
information • Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (in the F/R
direction).

Possible causes and
20-492 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING DK55KZ
Error code [DK55KZ] (Directional potentiometer: Disconnection or short circuit)
Action code Error code Directional potentiometer: Disconnection or short circuit

Trouble
CALL E04 DK55KZ (HST controller system)
• When the starting switch is turned ON, either of directional potentiometer systems 1 and 2 is abnormal,
Contents of
and then either of error codes [DK56KA] and [DK56KB] and either of error codes [DK57KA] and
trouble
[DK57KB] are turned ON simultaneously in those systems.
turned OFF.
Problem that
machine
direction).

Possible causes and
D31/37/39EX, PX-21 20-493

(1)
TROUBLESHOOTING DK55L8
Error code [DK55L8] (Directional potentiometer: Disagreement of analog signals)
Action code Error code Directional potentiometer: Disagreement of analog signals

Trouble
CALL E03 DK55L8 (HST controller system)
Contents of • The total of both signal voltages of directional potentiometer systems 1 and 2 is below 4.41 V or above
trouble 5.59 V.
Action of
• Controls the machine with the potentiometer which is outputting normal signals.
controller
turned OFF.
Problem that
machine
Cause Standard value in normalcy and references for troubleshooting

Possible causes and
20-494 D31/37/39EX, PX-21

(1)
Error code [DK56KA] (Directional potentiometer 1: Disconnection)

Trouble Directional potentiometer 1: Disconnection (HST controller system)
CALL E03 DK56KA
Contents of
• The input voltage from the directional potentiometer 1 is above 4.5 V.
trouble
Action of • Controls the machine with the signal of the directional potentiometer 2, limiting the functions partly.
turned OFF.
Problem that
machine
• The input state (voltage) from the directional potentiometer 1 can be checked in the monitoring mode.
Related (Code: 50202-FR LEVER 1)
direction).

supply system
starting switch.
Defective directional
Between (4) and (1) 3.2 kz ± 20%
2 potentiometer 1
Between (3) and (4)
(Between forward and reverse ends)

5.5 – 5.5 kz
Possible causes and
Between (3) and (1)

EL (female) (1)
connector)
4
harness (Contact with Between CN-ST1 (female) (13) – CN-EL (female) (3)
Voltage Max. 1 V
troubleshooting.
5
ler
Between (22) and (21) Power supply 4.5 – 5.5 kV
Between (13) and (21) Signal 0.3 – 4.5 kV
20-496 D31/37/39EX, PX-21

(1)
D31/37/39EX, PX-21 20-497

(1)
Error code [DK56KB] (Directional potentiometer 1: Short circuit)

Trouble Directional potentiometer 1: Short circuit (HST controller system)
CALL E03 DK56KB
Contents of
• The input voltage from the directional potentiometer 1 is below 0.3 V.
trouble
turned OFF.
Problem that
machine
The input state (voltage) from the directional potentiometer 1 can be checked in the monitoring mode.
Related (Code: 50202-FR LEVER)
information Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (in the F/R
direction).

supply system
starting switch.
Between (4) and (1) 3.2 kz ± 20%
2 potentiometer 1 (Internal
Between (3) and (4
1.5 – 5.5 kz
Between (3) and (1)
Possible causes and

EL (female) (4)
Resistance Max. 1 z
EL (female) (3)
4
(Contact with ground cir- Between CN-ST1 (female) (13) – CN-EL (female) (3)
troubleshooting.
20-498 D31/37/39EX, PX-21

(1)
D31/37/39EX, PX-21 20-499

(1)
Error code [DK57KA] (Directional potentiometer 2: Disconnection)

Trouble Directional potentiometer 2: Disconnection (HST controller system)
CALL E03 DK57KA
Contents of
• The input voltage from the directional potentiometer 2 is above 4.5 V.
trouble
turned OFF.
Problem that
machine
The input state (voltage) from the directional potentiometer 2 can be checked in the monitoring mode.
information Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (in the F/R
direction).

supply system
starting switch.
Between (4) and (1) 3.2 kz ± 20%
Between (2) and (4)
1.5 – 5.5 kz
Between (2) and (1)
Possible causes and
Resistance Max. 1 z
nector) EL (female) (1)
troubleshooting.
Between CN-ST1 (female) (22) – CN-EL (female) (4) or
4 source in wiring harness Voltage Max. 1 V
other related circuit wiring harness and chassis ground
(Contact with 24 V circuit)
Between CN-ST1 (female) (1) – CN-EL (female) (2) wir-
Voltage Max. 1 V
troubleshooting.
20-500 D31/37/39EX, PX-21

(1)
D31/37/39EX, PX-21 20-501

(1)
Error code [DK57KB] (Directional potentiometer 2: Short circuit)

Trouble Directional potentiometer 2: Short circuit (HST controller system)
CALL E03 DK57KB
Contents of
• The input voltage from the directional potentiometer 2 is below 0.5 V.
trouble
turned OFF.
Problem that
machine
• The input state (voltage) from the directional potentiometer 2 can be checked in the monitoring mode.
direction).

supply system
starting switch.
Between (4) and (1) 3.2 kz ± 20%
Between (2) and (4)
1.5 – 5.5 kz
Between (2) and (1)
Possible causes and

EL (female) (4)
Resistance Max. 1 z
EL (female) (2)
4
(Contact with ground cir- Between CN-ST1 (female) (1) – CN-EL (female) (2) wir-
Prepare with starting switch OFF, then turn starting switch ON and carry out trouble-
shooting.
20-502 D31/37/39EX, PX-21

(1)
D31/37/39EX, PX-21 20-503

(1)
TROUBLESHOOTING DLE2KA
Error code [DLE2KA] (Engine speed sensor: Disconnection)

Trouble Engine speed sensor: Disconnection (HST controller system)
CALL E03 DLE2KA
Contents of
• No signals are input from the engine speed sensor.
trouble
turned OFF.
Problem that
appears on
• The gear shift operation is not controlled normally.
machine
• The input state (rpm, frequency) from the engine speed sensor can be checked in the monitoring
Related
mode. (Code: 01002-ENG SPEED, Code: 01007-ENG SPEED)
information

starting switch.
Defective engine speed
1 sensor (Internal discon- CN-EN (male) Resistance
nection) Between (1) and (2) 400 – 1,000 z
Between (1), (2) and chassis ground Min. 1 Mz
Possible causes and
harness (Disconnec-
EN (female) (1)
Resistance Max. 1 z
EN (female) (2)
3
harness (Contact with Between CN-ST2 (female) (40) – CN-EN (female) (1)
Voltage Max. 1 V
starting switch.
Defective HST control- CN-ST2 (female) Resistance
4
ler
Between (40) and (29) 400 – 1,000 z
Between (40) and chassis ground Min. 1 Mz
20-504 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING DLE2KA
Circuit diagram related to engine speed sensor and alternator R signal
D31/37/39EX, PX-21 20-505

(1)
TROUBLESHOOTING DLE2KB
Error code [DLE2KB] (Engine speed sensor: Short circuit)

Trouble Engine speed sensor: Short circuit (HST controller system)
CALL E03 DLE2KB
Contents of
• When the alternator voltage is above 20 V, no signals are input from the engine speed sensor.
trouble
turned OFF.
Problem that
appears on
• The gear shift operation is not controlled normally.
machine
• The input state (rpm, frequency) from the engine speed sensor can be checked in the monitoring
mode. (Code: 01002-ENG SPEED, Code: 01007-ENG SPEED)
Related
• The changing state (voltage) from the alternator can be checked in the monitoring mode.
information
(Code: 04302-R signal)

starting switch.
Defective engine speed
1 sensor (Internal short cir- CN-EN (male) Resistance
cuit) Between (1) and (2) 400 – 1000 z
2 See TESTING AND ADJUSTING, Adjusting engine speed sensor.
engine speed sensor
Possible causes and
3
(Contact with ground cir- Between CN-ST2 (female) (40) – CN-EN (female) (1)
starting switch.
4 Defective HST controller CN-ST2 (female) Resistance
Between (40) and (29) 400 – 1000 z
source in alternator R troubleshooting.
5
signal system (Contact Between CN-ST1 (15) – CN-T16 wiring harness and
with 24 V circuit) Voltage Max. 10 V
chassis ground
20-506 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING DLE2KB
Circuit diagram related to engine speed sensor and alternator R signal
D31/37/39EX, PX-21 20-507

(1)
TROUBLESHOOTING DLM0KX
Error code [DLM0KX] (Motor speed sensor: Out of input signal range)

Trouble Motor speed sensor: Out of input signal range (HST controller system)
CALL E03 DLM0KX
Contents of • In the right and left HST motor speed sensor systems, either of error codes [DLM1KA] and [DLM1KB]
trouble and either of error codes [DLM2KA] and [DLM2KB] are turned ON simultaneously.
turned OFF.
Problem that
appears on
• The machine deviates during travel.
machine
• The input state (speed, frequency) from the right and left HST motor speed sensor can be checked in
the monitoring mode. (Code: 40003-L SPEED, Code: 40005-L SPEED, Code: 40002-R SPEED,
Related
Code: 40004-R)
information
• Method of reproducing error code: Start the engine and operate the PCCS lever (in the forward or
reverse direction).

Possible causes and
Carry out troubleshooting for error codes [DLM1KA], [DLM1KB], [DLM2KA], and [DLM2KB].
20-508 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING DLM1KA
Error code [DLM1KA] (Left HST motor speed sensor: Disconnection)

Trouble Left HST motor speed sensor: Disconnection (HST controller system)
E01 DLM1KA
Contents of
• Disconnection is detected in the left HST motor speed sensor circuit.
trouble
• Stops the straight travel correction control.
Action of
controller
turned OFF.
Problem that
appears on • The machine deviates during travel.
machine
• The input state (speed, frequency) from the left HST motor speed sensor can be checked in the moni-
Related toring mode. (Code: 40003-L SPEED, Code: 40005-L SPEED)
information • Method of reproducing error code: Start the engine and operate the PCCS lever (in the forward or
reverse direction).

supply system
a Prepare with starting switch OFF, then start engine and drive machine to carry out
troubleshooting.
CN-LRS Voltage
Power supply (When
Defective left HST motor Between (1) and (2) 4.5 – 5.5 V
machine is stopped)
2 speed sensor (Internal
defect) Signal (When machine 0 V i o 4.5 – 5.0 V
Between (3) and (2)
travels at constant speed) (Constant period)
The speed sensor voltage is measured with the wiring harness connected. Accord-
ingly, if the voltage is abnormal, check the wiring harness and controller, too, for
another cause of the trouble, and then judge.

Possible causes and
starting switch.
Defective resistor for
3 detecting disconnection CN-R1 (male) Resistance
(Internal short circuit) Between (1) and (2) Resistance
Between (1) and (2) 610 – 630 z
starting switch.
LRS (female) (1) or CN-R1 (female) (2)
Resistance Max. 1 z
nector) LRS (female) (2)
Resistance Max. 1 z
LRS (female) (3) or CN-R1 (female) (1)
5 Defective HST controller Between CN-ST1 (22) and Power supply (When
4.5 – 5.5 V
CN-ST2 (39) machine is stopped)
Between CN-ST2 (20) and Signal (When machine 0 V i o 4.5 – 5.0 V
CN-ST2 (39) travels at constant speed) (Constant period)
20-510 D31/37/39EX, PX-21

(1)
Circuit diagram related to left HST motor speed sensor
D31/37/39EX, PX-21 20-511

(1)
TROUBLESHOOTING DLM1KB
Error code [DLM1KB] (Left HST motor speed sensor: Short circuit)
Action code Error code Left HST motor speed sensor: Short circuit
Trouble
E01 DLM1KB (HST controller system)
Contents of
• The travel command is output, but no signals are input from the left HST motor speed sensor.
trouble
Action of
controller
turned OFF.
Problem that
machine
toring mode. (Code: 40003-L SPEED, Code: 40005-L SPEED)
Related
reverse direction).
information
• If the error cannot be reproduced, the cause is not a sensor trouble but defective air bleeding after
assembly/modification or wrong detection during start at low temperature. In this case, the sensor
does not need to be replaced.

supply system
troubleshooting.
CN-LRS Voltage
Power supply (When
Defective left HST motor Between (1) and (2) 4.5 – 5.5 V
machine is stopped)
2 speed sensor
(Internal defect) Signal (When machine 0 V i o 4.5 – 5.0 V
Between (3) and (2)
The left HST motor speed sensor may be adjusted defectively. Check it directly (See
3 left HST motor speed
Possible causes and
sensor
4
(Contact with ground cir- Between CN-ST2 (female) (20) – CN-LRS (female) (3)
cuit) Resistance Max. 1 z
troubleshooting.
Short circuit with power Between CN-ST1 (female) (22) – CN-LRS (female) (1)
5 source in wiring harness or other related circuit wiring harness and chassis Voltage Max. 1 V
(Contact with 24 V circuit) ground
Between CN-ST2 (female) (20) – CN-LRS (female) (3)
Voltage Max. 1 V
troubleshooting.
4.5 – 5.5 V
When the current flows in the HST pump EPC valve, if the motor does not rotate
7 Defective HST parts
because of internal fixing, etc., this error code may be turned ON.
20-512 D31/37/39EX, PX-21

(1)
D31/37/39EX, PX-21 20-513

(1)
TROUBLESHOOTING DLM1MA
Error code [DLM1MA] (Left HST motor speed sensor: Malfunction)

Trouble Left HST motor speed sensor: Malfunction (HST controller system)
E01 DLM1MA
Contents of
• Signals are input from the left HST motor speed sensor, but the pulses are generated very irregularly.
trouble
Action of
controller
turned OFF.
Problem that
machine
toring mode. (Code: 40003-L SPEED, Code: 40005-L SPEED)
Related
reverse direction).
information

troubleshooting.
CN-LRS Voltage
Possible causes and
Defective left HST motor

1 speed sensor Power supply (When
(Internal defect) Between (1) and (2) 4.5 – 5.5 V
machine is stopped)
Signal (When machine 0 V i o 4.5 – 5.0 V
Between (3) and (2)
The left HST motor speed sensor may be adjusted defectively. Check it directly
2 left HST motor speed
(See TESTING AND ADJUSTING).
sensor
Defective left HST motor The left HST motor may have a defect in it (breakage of revolution sensor).
3
(Internal defect) Check it directly.
20-514 D31/37/39EX, PX-21

(1)
D31/37/39EX, PX-21 20-515

(1)
Error code [DLM2KA] (Right HST motor speed sensor: Disconnection)
Action code Error code Right HST motor speed sensor: Disconnection
Trouble
E01 DLM2KA (HST controller system)
Contents of
• Disconnection is detected in the right HST motor speed sensor circuit.
trouble
Action of
controller
turned OFF.
Problem that
machine
• The input state (speed, frequency) from the right HST motor speed sensor can be checked in the mon-
Related itoring mode. (Code: 40002-R SPEED, Code: 40004-R SPEED)
information • Method of reproducing error code: Start the engine and operate the PCCS lever (in the forward or
reverse direction).

supply system
troubleshooting.
CN-RRS Voltage
Power supply (When
Defective right HST Between (1) and (2) 4.5 – 5.5 V
machine is stopped)
2 motor speed sensor
Between (3) and (2)

Possible causes and
Defective resistor for starting switch.
3 detecting disconnection
CN-R2 (male) Resistance
Between (1) and (2) 610 – 630 z
starting switch.
RRS (female) (1) or CN-R2 (female) (2)
Resistance Max. 1 z
nector) RRS (female) (2)
Resistance Max. 1 z
RRS (female) (3) or CN-R2 (female) (1)
troubleshooting.
4.5 – 5.5 V
20-516 D31/37/39EX, PX-21

(1)
Circuit diagram related to right HST motor speed sensor
D31/37/39EX, PX-21 20-517

(1)
Error code [DLM2KB] (Right HST motor speed sensor: Short circuit)

Trouble Right HST motor speed sensor: Short circuit (HST controller system)
E01 DLM2KB
Contents of
• The travel command is output, but no signals are input from the right HST motor speed sensor.
trouble
Action of
controller
turned OFF.
Problem that
machine
itoring mode. (Code: 40002-R SPEED, Code: 40004-R SPEED)
Related
reverse direction).
information

supply system
troubleshooting.
CN-RRS Voltage
Power supply (When
Defective right HST Between (1) and (2) 4.5 – 5.5 V
machine is stopped)
2 motor speed sensor
Between (3) and (2)
The right HST motor speed sensor may be adjusted defectively. Check it directly
3 right HST motor speed
Possible causes and

sensor
4
(Contact with ground cir- Between CN-ST2 (female) (20) – CN-RRS (female) (3)
troubleshooting.
Between CN-ST1 (female) (22) – CN-RRS (female) (1) or
5 source in wiring harness Voltage Max. 1 V
other related circuit wiring harness and chassis ground
(Contact with 24 V circuit)
Between CN-ST2 (female) (30) – CN-RRS (female) (3)
Voltage Max. 1 V
troubleshooting.
4.5 – 5.5 V
When the current flows in the HST pump EPC valve, if the motor does not rotate
7 Defective HST parts
because of internal fixing, etc., this error code may be turned ON.
20-518 D31/37/39EX, PX-21

(1)
D31/37/39EX, PX-21 20-519

(1)
Error code [DLM2MA] (Right HST motor speed sensor: Malfunction)

Trouble Right HST motor speed sensor: Malfunction (HST controller system)
E01 DLM2MA
Contents of
• Signals are input from the right HST motor speed sensor, but the pulses are generated very irregularly.
trouble
Action of
controller
turned OFF.
Problem that
machine
itoring mode. (Code: 40002-R SPEED, Code: 40004-R SPEED)
Related
reverse direction).
information

troubleshooting.
CN-RRS Voltage
Possible causes and
Defective right HST

1 motor speed sensor Power supply (When
(Internal defect) Between (1) and (2) 4.5 – 5.5 V
machine is stopped)
Signal (When machine 0 V i o 4.5 – 5.0 V
Between (3) and (2)
The right HST motor speed sensor may be adjusted defectively. Check it directly
2 right HST motor speed
sensor
Defective right HST The right HST motor may have a defect in it (breakage of revolution sensor). Check
3
motor (Internal defect) it directly.
20-520 D31/37/39EX, PX-21

(1)
D31/37/39EX, PX-21 20-521

(1)
TROUBLESHOOTING DN21FS
Error code [DN21FS] (Center brake limit switch: Fixing)

Trouble Center brake limit switch: Fixing (HST controller system)
CALL E03 DN21FS
Contents of • When the signal of travel lock switch 1 is in the FREE position and the slow brake output monitor signal
trouble (signal of travel lock switch 2) is turned OFF (opened), the system recognizes that the brake pedal is
100% pressed.
turned OFF.
Problem that
machine
(Code: 40914-SOL ON/OFF)
• Method of reproducing error code: Turn the starting switch ON, set the parking brake lever in the FREE
position, and press the brake pedal fully.

starting switch.
Possible causes and
Defective center brake Brake pedal

1 limit switch (Internal CN-PB (male)
Released Pressed
defect)
Defective installation of The center brake limit switch may be installed defectively. Check it directly (See
2
center brake limit switch TESTING AND ADJUSTING).
Defective installation of The brake potentiometer may be installed defectively. Check it directly (See TEST-
3
brake potentiometer ING AND ADJUSTING).
20-522 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING DN21FS
D31/37/39EX, PX-21 20-523

(1)
TROUBLESHOOTING DV00KB
Error code [DV00KB] (Buzzer: Short circuit)

Trouble Buzzer: Short circuit (Monitor panel system)
— DV00KB
Contents of
• When the caution buzzer circuit is output to the ground, an abnormal current flows.
trouble
• Stops outputting to the ground circuit of the caution buzzer circuit.
Action of
controller
turned OFF.
Problem that
• The caution buzzer does not sound when the starting switch is turned ON, an emergency warning item
appears on
becomes abnormal, or action code [E02], [CALL E03], or [CALL E04] is displayed.
machine
Related
information

Defective warning buzzer starting switch.
1
(Internal short circuit) CN-CB (male) Resistance
Possible causes and
Between (1) and (2) 1.2 Mz

(Contact with 24 V circuit) Between CN-S03 (female) (18) – CN-CB (female) (2)
Voltage Max. 1 V
troubleshooting.
3 Defective monitor panel CN-S03 Caution buzzer Voltage
Between (18) and chassis Stopped 20 – 30 V
ground Operated (Sounded) Max. 1 V
Circuit diagram related to warning buzzer
20-524 D31/37/39EX, PX-21

(1)
Error code [DV20KB] (Backup alarm buzzer: Short circuit)

Trouble Backup alarm buzzer: Short circuit (HST controller system)
E01 DV20KB
Contents of
• When the signal is output to the back alarm buzzer circuit, an abnormal current flows.
trouble
• Stops outputting to the back alarm buzzer circuit.
Action of
controller
turned OFF.
Problem that
appears on • The back alarm buzzer does not sound when the machine travels in reverse.
machine
• The output state (ON/OFF) to the backup alarm buzzer can be checked in the monitoring mode.
Related (Code: 40918-D-OUT SW, 6th from left)
reverse direction).


1
(Contact with ground cir- Wiring harness between CN-ST3 (female) (18) and
Possible causes and

CN14 (female) (1)
troubleshooting.
2 Defective controller CN-ST3 PCCS lever Voltage
Between (18) and chassis Neutral Max. 1 V
ground Reverse 20 – 30 V
Troubleshooting cannot be carried out since the defect is in the backup alarm buzzer.
Defective backup alarm
3 (If neither of above causes 1 and 2 is the cause of the trouble, the travel alarm is
buzzer (Internal defect)
judged defective.)
20-526 D31/37/39EX, PX-21

(1)
Circuit diagram related to backup alarm buzzer
D31/37/39EX, PX-21 20-527

(1)
TROUBLESHOOTING DW28KA
Error code [DW28KA] (2nd gear speed solenoid valve: Disconnection)

Trouble 2nd gear speed solenoid valve: Disconnection (HST controller system)
E02 DW28KA
Contents of
• When the signal is output to the 2nd gear speed solenoid valve circuit, no current flows.
trouble
Action of • Stops outputting to the 2nd gear speed solenoid valve circuit.
turned OFF.
Problem that
appears on
machine
• The output state (ON/OFF) to the 2nd gear speed solenoid valve can be checked in the monitoring
Related mode. (Code: 40914-SOL ON/OFF, 2nd from left)
information • Method of reproducing error code: Turn the starting switch START, shift the gear (select the 2nd gear
speed), and operate the travel control lever (in the forward or reverse direction).

Defective 2nd gear starting switch.
1 speed solenoid valve
CN-S1 (male) Resistance
(Internal disconnection)
Between (1) and (2) 40 – 60 z
Possible causes and
S1 (female) (1)
Resistance Max. 1 z
S1 (female) (2)
(Contact with 24 V circuit) Between CN-ST3 (female) (17) – CN-S1 (female) (1) Voltage Max. 1 V
starting switch.
CN-ST3 (female) Resistance
Between (17) and (3) 40 – 60 z
20-528 D31/37/39EX, PX-21

(1)
Circuit diagram related to 2nd gear speed solenoid valve
D31/37/39EX, PX-21 20-529

(1)
TROUBLESHOOTING DW28KB
Error code [DW28KB] (2nd gear speed solenoid valve: Short circuit)

Trouble 2nd gear speed solenoid valve: Short circuit (HST controller system)
E02 DW28KB
Contents of
• When the signal is output to the 2nd gear speed solenoid valve circuit, abnormal current flows.
trouble
Action of • Stops outputting to the 2nd gear speed solenoid valve circuit.
turned OFF.
Problem that
appears on
machine
• The output state (ON/OFF) to the 2nd gear speed solenoid valve can be checked in the monitoring
Related mode. (Code: 40914-SOL ON/OFF, 2nd from left)
information • Method of reproducing error code: Turn the starting switch START, shift the gear (select the 2nd gear

starting switch.
Defective 2nd gear
1 speed solenoid valve CN-S1 (male) Resistance
(Internal disconnection) Between (1) and (2) 40 – 60 z

Possible causes and
Defective assembled- CN-D4 (male) Resistance (Continuity)

2 type diode
(Internal short circuit) Between (1) and (5) Min. 1 Mz (No continuity)
3
(Contact with ground cir- Between CN-ST3 (female) (17) – CN-S1 (female) (1)
starting switch.
Between (17) and (3) 40 – 60 z
20-530 D31/37/39EX, PX-21

(1)
Circuit diagram related to 2nd gear speed solenoid valve
D31/37/39EX, PX-21 20-531

(1)
Error code [DW29KA] (3rd gear speed solenoid valve: Disconnection)

Trouble 3rd gear speed solenoid valve: Disconnection (HST controller system)
E02 DW29KA
Contents of
• When the signal is output to the 3rd gear speed solenoid valve circuit, no current flows.
trouble
Action of • Stops outputting to the 3rd gear speed solenoid valve circuit.
turned OFF.
Problem that
appears on The travel speed does not rise to high-speed range.
machine
• The output state (ON/OFF) to the 3rd gear speed solenoid valve can be checked in the monitoring
Related mode. (Code: 40914-SOL ON/OFF, 1st from left)
information • Method of reproducing error code: Turn the starting switch START, shift the gear (select the 3rd gear

Defective 3rd gear speed starting switch.
1 solenoid valve
Between (1) and (2) 40 – 60 z
Possible causes and
harness
2 (Disconnection in wiring Resistance Max. 1 z
S2 (female) (1)
harness or defective con-
tact in connector) Wiring harness between CN-ST3 (female) (3) and CN-
Resistance Max. 1 z
S2 (female) (2)
(Contact with 24 V circuit) Between CN-ST3 (female) (7) – CN-S2 (female) (1) wir- Voltage Max. 1 V
starting switch.
Between (7) and (3) 40 – 60 z
20-532 D31/37/39EX, PX-21

(1)
Circuit diagram related to 3rd gear speed solenoid valve
D31/37/39EX, PX-21 20-533

(1)
Error code [DW29KB] (3rd gear speed solenoid valve: Short circuit)

Trouble 3rd gear speed solenoid valve: Short circuit (HST controller system)
E02 DW29KB
Contents of
• When the signal is output to the 3rd gear speed solenoid valve circuit, abnormal current flows.
trouble
Action of • Stops outputting to the 3rd gear speed solenoid valve circuit.
turned OFF.
Problem that
appears on • The travel speed does not rise to high-speed range.
machine
• The output state (ON/OFF) to the 3rd gear speed solenoid valve can be checked in the monitoring
Related mode. (Code: 40914-SOL ON/OFF, 1st from left)
information • Method of reproducing error code: Turn the starting switch START, shift the gear (select the 3rd gear

starting switch.
Defective 3rd gear speed
1 solenoid valve CN-S2 (male) Resistance

Possible causes and
Defective assembled- starting switch.

2 type diode
CN-D4 (male) Resistance (Continuity)
Between (2) and (6) Min. 1 Mz (No continuity)
3
(Contact with ground cir- Between CN-ST3 (female) (3) – CN-S2 (female) (1) wir-
starting switch.
Between (7) and (3) 40 – 60 z
20-534 D31/37/39EX, PX-21

(1)
Circuit diagram related to 3rd gear speed solenoid valve
D31/37/39EX, PX-21 20-535

(1)
TROUBLESHOOTING DW4BKA
Error code [DW4BKA] (Parking brake solenoid valve: Disconnection)

Trouble Parking brake solenoid valve: Disconnection (HST controller system)
CALL E04 DW4BKA
Contents of
• When the signal is output to the parking brake solenoid valve circuit, no current flows.
trouble
Action of • Stops outputting to the parking brake solenoid valve circuit.
turned OFF.
Problem that
• If the machine has been traveling, it stops.
appears on
• If the machine has been stopped, it cannot start.
machine
• The output state (ON/OFF) to the parking brake solenoid valve can be checked in the monitoring
Related mode. (Code: 40914-SOL ON/OFF, 3rd from left)
FREE position.

Defective parking brake starting switch.
1 solenoid valve
Between (1) and (2) 40 – 60 z
Possible causes and
harness
S4 (female) (1)
harness or defective con-
tact in connector) Wiring harness between CN-ST3 (female) (3) and CN-
Resistance Max. 1 z
S4 (female) (2)
(Contact with 24 V circuit) Between CN-ST3 (female) (27) – CN-S4 (female) (1) Voltage Max. 1 V
starting switch.
Between (27) and (3) 40 – 60 z
20-536 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING DW4BKA
Circuit diagram related to parking brake solenoid valve
D31/37/39EX, PX-21 20-537

(1)
TROUBLESHOOTING DW4BKB
Error code [DW4BKB] (Parking brake solenoid valve: Short circuit)

Trouble Parking brake solenoid valve: Short circuit (HST controller system)
CALL E04 DW4BKB
Contents of
• When the signal is output to the parking brake solenoid valve circuit, abnormal current flows.
trouble
Action of • Stops outputting to the parking brake solenoid valve circuit.
turned OFF.
Problem that
• If the machine has been traveling, it stops.
appears on
• If the machine has been stopped, it cannot start.
machine
• The output state (ON/OFF) to the parking brake solenoid valve can be checked in the monitoring
Related mode. (Code: 40914-SOL ON/OFF, 3rd from left)
FREE position.

starting switch.
Defective parking brake

Possible causes and

2 type diode
3
(Contact with ground cir- Between CN-ST3 (female) (27) – CN-S4 (female) (1)
starting switch.
Between (27) and (3) 40 – 60 z
20-538 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING DW4BKB
Circuit diagram related to parking brake solenoid valve
D31/37/39EX, PX-21 20-539

(1)
TROUBLESHOOTING DW7EKA
Error code [DW7EKA] (Slow brake solenoid valve: Disconnection)

Trouble Slow brake solenoid valve: Disconnection (HST controller system)
CALL E04 DW7EKA
Contents of
• When the signal is output to the slow brake solenoid valve circuit, no current flows.
trouble
Action of • Stops outputting to the slow brake solenoid valve circuit.
turned OFF.
Problem that
machine
Related (Code: 40914-SOL ON/OFF, 4th from left)
information • Method of reproducing error code: Turn the starting switch ON, set the parking brake lever in the FREE

Defective slow brake starting switch.
1 solenoid valve (Internal
disconnection)
Between (1) and (2) 40 – 60 z
Defective travel lock starting switch.
2 switch 2
CN26B (male) Travel lock lever Resistance
Between (A) and (B) FREE (Upper) Max. 1 z
Defective brake pedal starting switch.
3 limit switch
CN-PB (male) Brake pedal Resistance
Between (A) and (B) Released Max. 1 z
Possible causes and
starting switch.
Disconnection in wiring Resistance Max. 1 z
CN26B (female) (A)
Wiring harness between CN26B (female) (B) and CN-
PB (female) (A)
nector) Wiring harness between CN-PB (female) (B) and CN-S3
Resistance Max. 1 z
(female) (1)
Resistance Max. 1 z
S3 (female) (2)
troubleshooting.
Between CN-ST3 (female) (37) – CN26B (female) (A)
Short circuit with power Voltage Max. 1 V
(Contact with 24 V circuit) Between CN26B (female) (B) – CN-PB (female) (A) wir- Voltage Max. 1 V
Between CN-PB (female) (B) – CN-S3 (female) (1) wir-
Voltage Max. 1 V
starting switch.
Between (37) and (3) 40 – 60 z
20-540 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING DW7EKA
standard value in normal state Cause Standard value in normal state/Remarks on troubleshooting
Possible causes and
7 travel lock switches 1 and
2
The brake potentiometer or brake limit switch may be installed defectively. Check
8 brake pedal potentiome-
them directly (See TESTING AND ADJUSTING).
ter or brake limit switch
D31/37/39EX, PX-21 20-541

(1)
TROUBLESHOOTING DW7EKB
Error code [DW7EKB] (Slow brake solenoid valve: Short circuit)

Trouble Slow brake solenoid valve: Short circuit (HST controller system)
CALL E04 DW7EKB
Contents of
• When the signal is output to the slow brake solenoid valve circuit, an abnormal current flows.
trouble
Action of • Stops outputting to the slow brake solenoid valve circuit.
turned OFF.
Problem that
machine
Related (Code: 40914-SOL ON/OFF, 4th from left)
information • Method of reproducing error code: Turn the starting switch ON, set the parking brake lever in the FREE

starting switch.
Defective slow brake
2 type diode
Defective travel lock
starting switch.
3 switch 2
CN26B (male) Resistance
Possible causes and

Between (A), (B) and chassis ground Min. 1 Mz
Defective brake pedal starting switch.
4 limit switch
CN-PB (male) Resistance
Between (A), (B) and chassis ground Min. 1 Mz
starting switch.
Short circuit with chassis Between CN-ST3 (female) (37) – CN26B (female) (A)
ground in wiring harness wiring harness and chassis ground
5
(Contact with ground cir- Between CN26B (female) (B) – CN-PB (female) (A) wir-
Between CN-PB (female) (B) – CN-S3 (female) (1) wir-
starting switch.
Between (37) and (3) 40 – 60 z
20-542 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING DW7EKB
D31/37/39EX, PX-21 20-543

(1)
TROUBLESHOOTING DXA4KA
Error code [DXA4KA] (LH pump F-EPC solenoid valve: Disconnection)
Action code Error code LH pump F-EPC solenoid valve: Disconnection

Trouble
CALL E03 DXA4KA (HST controller system)
Contents of
• When the signal is output to the LH pump F-EPC solenoid valve circuit, no current flows.
trouble
• Stops outputting to the LH pump F-EPC solenoid valve circuit.
Action of
• Stops outputting to the RH pump F-EPC solenoid valve circuit, too.
controller
turned OFF.
Problem that • If the machine has been traveling forward, it stops.
appears on • If the machine has been stopped, it cannot start forward.
machine • Once the machine is stopped, its travel speed is limited to 50%.
• The output state (command current, sensed current) to the LH pump F-EPC solenoid valve can be
Related checked in the monitoring mode. (Code: 52401-LF PUMP, Code: 52409-LF PUMP)
information • Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (in the for-
ward direction).

Defective LH pump starting switch.
1 F-EPC solenoid valve
CN-LF (male) Resistance
Between (1) and (2) 5 – 15 z
Possible causes and
LF (female) (1)
Resistance Max. 1 z
LF (female) (2)
(Contact with 24 V circuit) Between CN-ST3 (female) (5) – CN-LF (female) (1) wir- Voltage Max. 1 V
starting switch.
Between (3) and (13) 5 – 15 z
20-544 D31/37/39EX, PX-21

(1)
Circuit diagram related to LH pump F-EPC solenoid valve
D31/37/39EX, PX-21 20-545

(1)
TROUBLESHOOTING DXA4KB
Error code [DXA4KB] (LH pump F-EPC solenoid valve: Short circuit)
Action code Error code LH pump F-EPC solenoid valve: Short circuit
Trouble
CALL E03 DXA4KB (HST controller system)
Contents of
• When the signal is output to the LH pump F-EPC solenoid valve circuit, an abnormal current flows.
trouble
• Stops outputting to the LH pump F-EPC solenoid valve circuit.
Action of
controller
turned OFF.
• The output state (command current, sensed current) to the LH pump F-EPC solenoid valve can be
Related checked in the monitoring mode. (Code: 52401-LF PUMP, Code: 52409-LF PUMP)
ward direction).

starting switch.
Defective LH pump
CN-LF (male) Resistance

(Internal short circuit) Between (1) and (2) 5 – 15 z
Possible causes and

2
(Contact with ground cir- Between CN-ST3 (female) (5) – CN-LF (female) (1) wir-
starting switch.
Between (5) and (13) 5 – 15 z
20-546 D31/37/39EX, PX-21

(1)
Circuit diagram related to LH pump F-EPC solenoid valve
D31/37/39EX, PX-21 20-547

(1)
Error code [DXA5KA] (LH pump R-EPC solenoid valve: Disconnection)
Action code Error code LH pump R-EPC solenoid valve: Disconnection

Trouble
Contents of
• When the signal is output to the LH pump R-EPC solenoid valve circuit, no current flows.
trouble
• Stops outputting to the LH pump R-EPC solenoid valve circuit.
Action of
• Stops outputting to the RH pump R-EPC solenoid valve circuit, too.
controller
turned OFF.
Problem that • If the machine has been traveling in reverse, it stops.
appears on • If the machine has been stopped, it cannot start in reverse.
• The output state (command current, sensed current) to the LH pump R-EPC solenoid valve can be
Related checked in the monitoring mode. (Code: 52403-LR PUMP, Code: 52411-LR PUMP)
reverse direction).

Defective LH pump starting switch.
1 R-EPC solenoid valve
CN-LR (male) Resistance
Between (1) and (2) 5 – 15 z
Possible causes and
LR (female) (1)
Resistance Max. 1 z
LR (female) (2)
(Contact with 24 V circuit) Between CN-ST3 (female) (6) – CN-LR (female) (1) wir- Voltage Max. 1 V
starting switch.
Between (6) and (13) 5 – 15 z
20-548 D31/37/39EX, PX-21

(1)
Circuit diagram related to LH pump R-EPC solenoid valve
D31/37/39EX, PX-21 20-549

(1)
Error code [DXA5KB] (LH pump R-EPC solenoid valve: Short circuit)
Action code Error code LH pump R-EPC solenoid valve: Short circuit
Trouble
Contents of
• When the signal is output to the LH pump R-EPC solenoid valve circuit, an abnormal current flows.
trouble
• Stops outputting to the LH pump R-EPC solenoid valve circuit.
Action of
controller
turned OFF.
• The output state (command current, sensed current) to the LH pump R-EPC solenoid valve can be
Related checked in the monitoring mode. (Code: 52403-LR PUMP, Code: 52411-LR PUMP)
reverse direction).

starting switch.
Defective LH pump
CN-LR (male) Resistance

Possible causes and

2
(Contact with ground cir- Between CN-ST3 (female) (6) – CN-LR (female) (1) wir-
starting switch.
Between (6) and (13) 5 – 15 z
20-550 D31/37/39EX, PX-21

(1)
Circuit diagram related to LH pump R-EPC solenoid valve
D31/37/39EX, PX-21 20-551

(1)
Error code [DXA6KA] (RH pump F-EPC solenoid valve: Disconnection)
Action code Error code RH pump F-EPC solenoid valve: Disconnection

Trouble
Contents of
• When the signal is output to the RH pump F-EPC solenoid valve circuit, no current flows.
trouble
• Stops outputting to the RH pump F-EPC solenoid valve circuit.
Action of
• Stops outputting to the FH pump F-EPC solenoid valve circuit, too.
controller
turned OFF.
• The output state (command current, sensed current) to the RH pump F-EPC solenoid valve can be
Related checked in the monitoring mode. (Code: 52400-RF PUMP, Code: 52408-RF PUMP)
ward direction).

Defective RH pump starting switch.
CN-RF (male) Resistance
Between (1) and (2) 5 – 15 z
Possible causes and
RF (female) (1)
Resistance Max. 1 z
RF (female) (2)
(Contact with 24 V circuit) Between CN-ST3 (female) (15) – CN-RF (female) (1) Voltage Max. 1 V
starting switch.
Between (15) and (23) 5 – 15 z
20-552 D31/37/39EX, PX-21

(1)
Circuit diagram related to RH pump F-EPC solenoid valve
D31/37/39EX, PX-21 20-553

(1)
Error code [DXA6KB] (RH pump F-EPC solenoid valve: Short circuit)
Action code Error code RH pump F-EPC solenoid valve: Short circuit
Trouble
Contents of
• When the signal is output to the RH pump F-EPC solenoid valve circuit, an abnormal current flows.
trouble
• Stops outputting to the RH pump F-EPC solenoid valve circuit.
Action of
• Stops outputting to the LH pump F-EPC solenoid valve circuit, too.
controller
turned OFF.
• The output state (command current, sensed current) to the RH pump F-EPC solenoid valve can be
Related checked in the monitoring mode. (Code: 52400-RF PUMP, Code: 52408-RF PUMP)
ward direction).

starting switch.
Defective RH pump
CN-RF (male) Resistance

Possible causes and

2
(Contact with ground cir- Between CN-ST3 (female) (15) – CN-RF (female) (1)
starting switch.
Between (15) and (13) 5 – 15 z
20-554 D31/37/39EX, PX-21

(1)
Circuit diagram related to RH pump F-EPC solenoid valve
D31/37/39EX, PX-21 20-555

(1)
Error code [DXA7KA] (RH pump R-EPC solenoid valve: Disconnection)
Action code Error code RH pump R-EPC solenoid valve: Disconnection

Trouble
Contents of
• When the signal is output to the RH pump R-EPC solenoid valve circuit, no current flows.
trouble
• Stops outputting to the RH pump R-EPC solenoid valve circuit.
Action of
• Stops outputting to the LH pump R-EPC solenoid valve circuit, too.
controller
turned OFF.
• The output state (command current, sensed current) to the RH pump R-EPC solenoid valve can be
Related checked in the monitoring mode. (Code: 52402-RR PUMP, Code: 52410-RR PUMP)
reverse direction).

Defective RH pump starting switch.
CN-RR (male) Resistance
Between (1) and (2) 5 – 15 z
Possible causes and
RR (female) (1)
Resistance Max. 1 z
RR (female) (2)
(Contact with 24 V circuit) Between CN-ST3 (female) (16) – CN-RR (female) (1) Voltage Max. 1 V
starting switch.
Between (16) and (23) 5 – 15 z
20-556 D31/37/39EX, PX-21

(1)
Circuit diagram related to RH pump R-EPC solenoid valve
D31/37/39EX, PX-21 20-557

(1)
Error code [DXA7KB] (RH pump R-EPC solenoid valve: Short circuit)
Action code Error code RH pump R-EPC solenoid valve: Short circuit
Trouble
Contents of
• When the signal is output to the RH pump R-EPC solenoid valve circuit, an abnormal current flows.
trouble
• Stops outputting to the RH pump R-EPC solenoid valve circuit.
Action of
• Stops outputting to the LH pump R-EPC solenoid valve circuit, too.
controller
turned OFF.
• The output state (command current, sensed current) to the RH pump R-EPC solenoid valve can be
Related checked in the monitoring mode. (Code: 52402-RR PUMP, Code: 52410-RR PUMP)
reverse direction).

starting switch.
Defective RH pump R-
CN-RR (male) Resistance
1 EPC solenoid valve

Possible causes and

2
(Contact with ground cir- Between CN-ST3 (female) (16) – CN-RR (female) (1)
starting switch.
Between (16) and (13) 5 – 15 z
20-558 D31/37/39EX, PX-21

(1)
Circuit diagram related to RH pump R-EPC solenoid valve
D31/37/39EX, PX-21 20-559

(1)
TROUBLESHOOTING OF
ELECTRICAL SYSTEM (E MODE)
Before carrying out troubleshooting for electrical system (E-mode) ........................................................... 20-602
E-1 Engine does not start............................................................................................................................ 20-605
E-2 Engine is not preheated ....................................................................................................................... 20-610
E-3 Engine does not stop............................................................................................................................ 20-612
E-4 When starting switch is turned ON, any item does not light up ............................................................ 20-614
E-5 When starting switch is turned ON, all items light up and none of them goes off................................. 20-616
E-6 Charge level caution flashes while engine is running........................................................................... 20-616
E-7 Emergency warning items flash while engine is running...................................................................... 20-618
E-8 Preheating pilot lamp does not light up during preheating operation ................................................... 20-624
E-9 Engine coolant thermometer is abnormal............................................................................................. 20-626
E-10 HST oil thermometer is abnormal....................................................................................................... 20-628
E-11 Fuel level gauge is abnormal.............................................................................................................. 20-630
E-12 Reverse travel speed indicator is abnormal ....................................................................................... 20-632
E-13 Gear speed, set travel speed, and shift mode indicator is abnormal.................................................. 20-632
E-14 Multi-information section is abnormal ................................................................................................. 20-632
E-15 Caution lamp does not flash or does not go off .................................................................................. 20-632
E-16 Caution buzzer does not sound or does not stop ............................................................................... 20-633
E-17 Reverse travel speed setting switch does not function ...................................................................... 20-634
E-18 Shift mode switch does not function ................................................................................................... 20-636
E-19 Buzzer cancel switch does not function ............................................................................................. 20-638
E-20 Information switch does not function .................................................................................................. 20-640
E-21 System is not set in service mode or is not set out of service mode.................................................. 20-642
E-22 Backup alarm does not sound............................................................................................................ 20-644
E-23 Headlamp or rear lamp does not light up ........................................................................................... 20-646
E-24 Canopy heater does not operate [Canopy specification].................................................................... 20-648
E-25 Air conditioner does not operate [Cab specification] .......................................................................... 20-650
E-26 Windshield wiper and windshield washer do not operate [Cab specification] .................................... 20-655
D31/37/39EX, PX-21 20-601

(1)
BEFORE CARRYING OUT TROUBLESHOOTING
TROUBLESHOOTING FOR ELECTRICAL SYSTEM (E-MODE)

FOR ELECTRICAL SYSTEM (E-MODE)
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 1 (FB1)
Fuse
Type of power supply Fuse No. Destination of power
capacity
1 Lamp relay
20A
(Between terminals 1 and 6) Headlamp and rear lamp
2 Monitor panel (Switch power supply)
10A
Switch power supply (Between terminals 2 and 7) Caution buzzer
(Fusible link CN-H2) 3
10A HST controller
(Between terminals 3 and 8)
4
10A Horn
Switch 5
15A Engine stop solenoid
(Starting switch ACC) (Between terminals 5 and 10)
Fuse box 2 (FB2)
Fuse
capacity
Monitor panel (Constant power supply)
Constant power supply 1 Service switch
10A
(Fusible link CN-H1) (Between terminals 1 and 6) Constant power supply for fuse box (FB3)
[Cab specification]
2
10A Spare fuse (No destination)
Switch power supply 3
15A Canopy heater [Canopy specification]
(Fusible link CN-H2) (Between terminals 3 and 8)
4
20A Spare power supply (Connector CN17)
Constant power supply 5
30A Starting switch (Terminal B)
(Fusible link CN-H1) (Between terminals 5 and 10)
20-602 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING FOR ELECTRICAL SYSTEM (E-MODE)
Fuse box 3 (FB3) [Cab specification]
Fuse
capacity
Radio (Constant power supply) [Specification for Japan]
Constant power supply 1
10A Radio with cassette player (Constant power supply)
(Fuse box FB1-6) (Between terminals 1 and F)
[Specification for North America and EU]
Radio (Switch power supply) [Specification for Japan]
Radio with cassette player (Switch power supply)
2
20A [Specification for North America and EU]
(Between terminals 2 and B)
Cigarette lighter
Room lamp
3
Switch power supply 10A Rear wiper and washer
(Fusible link CN-H3)
4
30A Air conditioner
5
10A Front wiper and washer
6 (–) (Unused)
Locations and Nos. of fuses
D31/37/39EX, PX-21 20-603

(1)

a The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before carrying out troubleshooting, understand that information fully.
Trouble Trouble which occurred in the machine

Related
information
<Contents of description)
1
<Troubles in wiring harness>
• Disconnection
Connector is connected imperfectly or wiring harness is broken.
• Grounding fault
Wiring harness which is not connected to chassis ground circuit is in contact with
chassis ground circuit.

• Short circuit with power source
Possible causes and
2 Wiring harness which is not connected to power source (24 V) circuit is in contact
Possible causes of with power source (24 V) circuit.
trouble • Short circuit
(Given numbers are Independent wiring harnesses are in contact with each other abnormally.
reference numbers,
which do not indicate <Precautions for troubleshooting>
priority) 1) Method of indicating connector No. and handling of T-adapter
3 Insert or connect T-adapter as explained below for troubleshooting, unless
otherwise specified.
• If connector No. has no marks of “male” and “female”, disconnect connector and
insert T-adapters in both male side and female side.
• If connector No. has marks of “male” and “female”, disconnect connector and
connect T-adapter to only male side or female side.
1) Entry order of pin Nos. and handling of circuit tester leads
Connect positive (+) lead and negative (–) lead of circuit tester as explained below
4
for troubleshooting, unless otherwise specified.
• Connect positive (+) lead to pin No. or harness entered on front side.
• Connect negative (–) lead to pin No. or harness entered on rear side.
Related circuit diagram
This is a circuit diagram of the part related to troubleshooting.

• Connector No.: Shows the “Type-Number of pin” and “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 ( ): Roughly shows the location on the machine.
20-604 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING E-1
E-1 Engine does not start
Trouble (1) 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
Related engine can start, [P] is lighted up on the monitor panel.)
information • Since the HST controller controls the neutral safety and parking brake relay with the travel lock switch
signal, check that a related error code is not displayed before carrying out troubleshooting. (If error
code [D130KA], [D130KB], [DD14KB], or [DDQ2KA] is displayed, carry out troubleshooting for it first.)

Low charge level of Battery voltage Electrolyte specific gravity
1
battery Min. 24 V Min. 1.26
a Prepare with starting switch OFF (Disconnect CN-KS (250)), then carry out
troubleshooting with starting switch in OFF and START positions.
Defective starting switch CN-KS Starting switch Resistance
2
OFF Min. 1 Mz
Between 250 and 280
START Max. 1 z
Defective neutral safety troubleshooting.
3 and parking brake relay
(Internal disconnection) Operate the travel lock switch between FREE and LOCK positions. If the neutral
safety and parking brake relay makes an operating sound, it is normal.
a Prepare with starting switch OFF (keeping wiring harness connected), then carry
out troubleshooting with starting switch in START position.
Safety relay Voltage
Between CN-T3 and

Possible causes and
Power supply input 20 – 30 V

chassis ground
Defective starting motor Between CN4 (1) and
Starting input 20 – 30 V
4 safety relay chassis ground
(Internal disconnection) Between CN4 (2) and
Charging input Max. 1 V
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.
out troubleshooting with starting switch in START position.
Starting motor Voltage
Between CN-T1 and
Defective starting motor Power supply input 20 – 30 V
5 chassis ground
(Internal defect)
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.
Defective alternator out troubleshooting with starting switch ON.
6
(Internal short circuit) Alternator Voltage
Between CN-T16 and chassis ground Max. 1 V
D31/37/39EX, PX-21 20-605

(1)
TROUBLESHOOTING E-1

starting switch.
Wiring harness between CN-KS (280) and CN11
(female) (3)
harness
7 (Disconnection in wiring Wiring harness between CN11 (female) (5) and CN4
Resistance Max. 1 z
harness or defective (female) (1)
contact 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
Max. 1 z
Wiring harness between CN-T1 and CN-T3 Resistance

Possible causes and
starting switch.
Between CN-KS (280) – CN11 (female) (3) or CN-S03
(female) (7) or another related circuit wiring harness Resistance Min. 1 Mz
and chassis ground
Short circuit with chassis Between CN11 (female) (5) – CN4 (female) (1) or
ground in wiring harness Resistance Min. 1 Mz
8 CN15 (female) (1) wiring harness and chassis ground
(Contact with ground
circuit) Between CN-T4 – CNT2 wiring harness and chassis
ground
Between CN-T8 – CNT1 wiring harness and chassis
ground
Between CN-T1 – CN-T3 wiring harness and chassis
ground
source in wiring harness
9 Between CN-4 (female) (2) – CN-T16 or CN-S04
(Contact with 24 V
circuit) (female) (9) or CN-ST1 (female) (15) or another related Voltage Max. 1 V
circuit wiring harness and chassis ground
20-606 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING E-1
Circuit diagram related to engine preheating, starting, charging, and stopping functions
D31/37/39EX, PX-21 20-607

(1)
TROUBLESHOOTING E-1
Trouble (2) Starting motor rotates but engine does not start.
Related • Since the engine stop solenoid is installed, fuel injection is not started until the solenoid pulls the
information governor lever of the fuel injection pump to the RUN position.

1 Defective fuse (FB1-5) If the fuse is broken, the circuit probably has a grounding fault, etc. (See Cause 5.)
out troubleshooting with starting switch ON.
Engine stop solenoid Voltage/Resistance
Between T17 and chassis
Defective engine stop Power supply 20 – 30 V
2 ground
solenoid (Internal defect)
Between T18 and chassis
Chassis ground Max. 1 z
ground
If the power supply and chassis ground are normal and the solenoid does not
operated, the engine stop solenoid is defective.

Possible causes and
Defective diode starting switch.
3
(Internal short circuit) CN-D3 (male) Resistance (Continuity)
harness Wiring harness between CN-KS (270) and FB1 (5) Resistance Max. 1 z
4 (Disconnection in wiring
harness or defective Wiring harness between FB1 (10) and CN-T17 Resistance Max. 1 z
contact in connector) Wiring harness between CN-T18 and chassis ground
Resistance Max. 1 z
(CN-T20)
starting switch.
Short circuit with chassis
Between CN-KS (270) – FB1 (5) or CN11 (female) (1)
ground in wiring harness
5 or CN-ST3 (14), (24) wiring harness and chassis Resistance Min. 1 Mz
ground
circuit)
Between FB1 (10) – CN-T17 or CN-D3 (female) (1)
and chassis ground
20-608 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING E-1
D31/37/39EX, PX-21 20-609

(1)
TROUBLESHOOTING E-2
E-2 Engine is not preheated
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
Related
lamp does not light up”.)
information
• When the starting switch is turned to the START position, if the engine does not crank, carry out
troubleshooting for “Engine does not start”.

a Prepare with starting switch OFF (Disconnect CN-KS (250)), then carry out
troubleshooting with starting switch in OFF and START positions.
Defective starting switch CN-KS Starting switch Resistance
1
OFF Min. 1 Mz
Between 250 and 255
HEAT Max. 1 z
out troubleshooting with starting switch in HEAT position.
Heater relay Voltage
Between CN-T12 and
Power supply input 20 – 30 V
chassis ground
Defective heater relay
2 Between CN-T5 and
(Internal defect) Preheating input 20 – 30 V
chassis ground
Between CN-T6 and

Preheating output 20 – 30 V
Possible causes and
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 intake air starting switch.
3 heater
Intake air heater Continuity
Between terminals There is continuity
starting switch.
harness
4 (Disconnection in wiring Wiring harness between CN-KS (255) and CN-T5 Resistance Max. 1 z
harness or defective Wiring harness between CN-T1 and CN-T12 Resistance Max. 1 z
Wiring harness between CN-T6 and CN-RH Resistance Max. 1 z
starting switch.
Short circuit with chassis Between CN-KS (255) – CN-T5 wiring harness and
ground in wiring harness chassis ground
5
(Contact with ground Between CN-T1 – CN-T12 wiring harness and chassis
ground
Between CN-T6 – CN-RH or CN-S03 (female) (9)
20-610 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING E-2
D31/37/39EX, PX-21 20-611

(1)
TROUBLESHOOTING E-3
E-3 Engine does not stop
Trouble • Engine does not stop.

Related • Since the engine stop solenoid is installed, fuel injection is not stopped until the solenoid pulls the
information governor lever of the fuel injection pump to the STOP position.

Defective engine stop When terminal CN-T17 of the solenoid is disconnected while the engine is running,
1
Possible causes and
solenoid (Internal defect) if the engine does not stop, the engine stop solenoid is defective.
starting switch.
Between CN-KS (270) – FB1 (5) or CN11 (female) (11)
source in wiring harness
2 or CN-ST3 (14), (24) wiring harness and chassis Voltage Max. 1 V
(Contact with 24 V
ground
circuit)
Between FB1 (10) – CN-T17 or CN-D3 (female) (1)
Voltage Max. 1 V
and chassis ground
20-612 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING E-3
D31/37/39EX, PX-21 20-613

(1)
TROUBLESHOOTING E-4
E-4 When starting switch is turned ON, any item does not light up
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 2 seconds.

Defective fuses
1 If the fuse is broken, the circuit probably has a grounding fault, etc. (See Cause 3.)
(FB1-2. FB2-1)
starting switch.
Disconnection in wiring Wiring harness between FB1-(7) and CN-S03 (female)
harness Resistance Max. 1 z
(1) or (2)
Wiring harness between FB2-(6) and CN-S03 (female)

contact in connector) (5) or (6)
Possible causes and
Wiring harness between CN-S03 (3) or (4) and chassis

Resistance Max. 1 z
ground (CN-T36)
starting switch.
Short circuit with chassis Between FB1-(7) – CN-S03 (female) (1) or (2) or
ground in wiring harness another related circuit wiring harness and chassis Resistance Min. 1 Mz
3
(Contact with ground ground
circuit) Between FB2-(6) – CN-S03 (female) (5) or (6) or
another related circuit wiring harness and chassis Resistance Min. 1 Mz
ground
troubleshooting.
4 Defective monitor panel CN-S03 Voltage
Between (1), (2) and (3), (4) 20 – 30 V
Between (5), (6) and (3), (4) 20 – 30 V
20-614 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING E-4
Circuit diagram related to monitor panel power supply
D31/37/39EX, PX-21 20-615

(1)
TROUBLESHOOTING E-5, E-6
E-5 When starting switch is turned ON, all items light up and none of them goes off
Trouble • When starting switch is turned ON, all items light up and none of them goes off
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 2 seconds.
Possible Cause Standard value in normal state/Remarks on troubleshooting

causes and
standard value Defective monitor Troubleshooting cannot be carried out since the defect is in the monitor
1
in normal state panel panel.
E-6 Charge level caution flashes while engine is running
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

a Prepare with starting switch OFF, then start engine and carry out troubleshooting.
Defective alternator Alternator Engine speed Voltage
1
(Defective generation) Between CN-T16 and Above medium (half)
20 – 30 V
chassis ground speed
Possible causes and

harness or defective Wiring harness between CN-ST1 (female) (15) and
Resistance Max. 1 z
contact in connector) CN-T16
3 Between CN-S04 (female) (9) – CN-T16 or CN4
circuit) (female) (2) or CN-ST1 (female) (15) or another related Resistance Min. 1 Mz
circuit wiring harness and chassis ground
a Prepare with starting switch OFF, then start engine and carry out troubleshooting.
CN-ST1 Engine speed Voltage
4 HST controller
Between (15) and chassis Above medium (half)
20 – 30 V
ground speed
20-616 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING E-6
D31/37/39EX, PX-21 20-617

(1)
TROUBLESHOOTING E-7
E-7 Emergency warning items flash while engine is running
Trouble (1) Engine oil pressure caution lamp flashes.

• If abnormality is detected while the engine is running, the engine oil pressure caution lamp flashes and
Related the caution buzzer sounds.
information • The input state (ON/OFF) from the engine oil pressure switch can be checked in the monitoring mode.
(Monitoring code: 40922-Mon SW, 6th from left)

Low engine oil pressure
1 Since low engine oil pressure is detected, check it.
a Prepare with starting switch OFF, then hold starting switch OFF and start engine
and carry out troubleshooting.
Defective engine oil

2 pressure switch T19 Engine Resistance
Possible causes and
(Internal short circuit) Between terminal and Stopped Max. 1 z

ground Operated Min. 1 Mz
3
(Contact with ground Between CN-S03 (female) (12) – CN-T19 wiring
harness and chassis ground
4 Defective monitor panel CN-S03 Engine Voltage
Between (12) and chassis Stopped Max. 1 V
ground Operated 20 – 30 V
Circuit diagram related to engine oil pressure switch
20-618 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING E-7
Trouble (2) Engine coolant temperature caution lamp flashes.

• If abnormality is detected while the engine is running, the engine coolant temperature caution lamp
flashes and the caution buzzer sounds.
Related • The engine coolant temperature caution lamp flashes and goes off according to indication of the engine
information coolant thermometer.
• The input state (coolant temperature) from the engine coolant temperature sensor can be checked in
the monitoring mode. (Monitoring code: 04102-ENG. TEMP.)

Overheating of engine Since overheating of engine coolant is detected, check it. (When coolant
1 coolant temperature is above 102 °C: Lamp flashes, above 108 °C: Lamp flashes and
Possible causes and
(When system is normal) buzzer sounds)

If indication of the engine coolant thermometer is abnormal, carry out
troubleshooting for “Engine coolant thermometer is abnormal”.
Defective engine coolant
2 temperature system Coolant thermometer See the figure below.
(monitor panel system) White range Red range
Coolant temperature lamp
OFF Flashing
If neither of causes 1 and 2 is the cause of the trouble, the monitor panel may be
3 Defective monitor panel defective (Troubleshooting cannot be carried out since the defect is in the monitor
panel).
Indication of engine coolant thermometer

(a Coolant temperature is rough standard for changing indication)
D31/37/39EX, PX-21 20-619

(1)
TROUBLESHOOTING E-7
Trouble (3) HST oil temperature caution lamp flashes.

• If abnormality is detected while the engine is running, the HST oil temperature caution lamp flashes
and the caution buzzer sounds.
Related • The HST oil temperature caution lamp flashes and goes off according to indication of the engine
information coolant thermometer.
• The input state (oil temperature) from the HST oil temperature sensor can be checked in the monitoring
mode. (Monitoring code: 85001-HST TEMP.)

Overheating of HST oil Since overheating of HST oil is detected, check it. (When oil temperature is above
1
(When system is normal) 100 °C: Lamp flashes, above 110 °C: Lamp flashes and buzzer sounds)
Possible causes and
If indication of the HST oil thermometer is abnormal, carry out troubleshooting for
“HST oil thermometer is abnormal”.
Defective HST oil
2 temperature system Oil thermometer See the figure below.
(monitor panel system) White range Red range
Oil temperature lamp
OFF Flashing
If neither of causes 1 and 2 is the cause of the trouble, the monitor panel may be
panel).
Indication of HST oil thermometer (a Oil temperature is rough standard for changing indication)
20-620 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING E-7
Trouble (4) 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 the
information communication system.
• The input state (ON/OFF) from the HST charge filter clogging switch can be checked in the monitoring
mode. (Monitoring code: 40910, 4th from left)

Clogging of HST charge
1 filter Since clogging of the HST charge filter is detected, check it.
Difference between inlet
Defective HST charge T34 and outlet pressures of Resistance
2 filter clogging switch HST filter
(Internal short circuit) Max. 0.2 MPa
Min. 1 Mz
Between terminal and {Max. 2 kg/cm2}

chassis ground Min. 0.2 MPa
Possible causes and
Max. 1 z
{Min. 2 kg/cm2}
3
(Contact with ground Between CN-ST1 (female) (5) - CN-T34 wiring harness
and chassis ground
a Prepare with starting switch OFF, then hold starting switch ON and start engine
Difference between inlet
CN-ST1 and outlet pressures of Voltage
4 Defective HST controller HST filter
Max. 0.2 MPa
5 – 11 V
Between (5) and chassis {Max. 2 kg/cm2}
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 may be
panel).
Circuit diagram related to HST charge filter clogging switch
D31/37/39EX, PX-21 20-621

(1)
TROUBLESHOOTING E-7
Trouble (5) 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 • The signals from the HST charge pressure switch are received from the HST controller through the
• The input state (ON/OFF) from the HST charge pressure switch can be checked in the monitoring
mode. (Monitoring code: 40910-S/T SW1, 3rd from left)

Low HST charge
1 pressure Since low HST charge pressure is detected, check it.
Defective HST charge CN-BS (male) Engine Resistance
2 pressure switch Stopped Min. 1 Mz
Between (1) and (2) Operated
(Parking brake lever: Max. 1 z

FREE)
Possible causes and
harness
CN-BS (female) (2)
harness or defective
contact in connector) Wiring harness between CN-ST1 (female) (4) and CN-
Resistance Max. 1 z
BS (female) (1)
a Prepare with starting switch OFF, then hold starting switch ON and start engine
and carry out troubleshooting. (When checking while engine is operated, set
parking brake lever in FREE position and release brake pedal.)
4 Defective HST controller CN-ST1 Engine Voltage
Stopped
5 – 11 V
Between (11) and (4) (Starting switch: ON)
Operated Max. 1 V
If none of causes 1 – 4 is the cause of the trouble, the monitor panel may be
panel).
Circuit diagram related to HST charge pressure switch
20-622 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING E-8
E-8 Preheating pilot lamp does not light up during preheating operation
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
preheating operation. (When the intake air heater is not heated, carry out troubleshooting for “Engine
Related
is not preheated”.)
information
• The input state (ON/OFF) from the heater relay can be checked in the monitoring mode. (Monitoring
code: 40921-Mon SW1, 6th from left)

harness or defective Wiring harness between CN-S03 (female) (9) and CN-
Resistance Max. 1 z
Possible causes and
contact in connector) T6
2
(Contact with ground Between CN-S03 (female) (9) – CN-T6 wiring harness
and chassis ground
a Prepare with starting switch OFF, then hold starting switch in OFF and START
position and carry out troubleshooting.
3 Defective monitor panel CN-S03 Starting switch Voltage
Between (9) and chassis OFF Max. 1 V
ground HEAT 20 – 30 V
20-624 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING E-8
D31/37/39EX, PX-21 20-625

(1)
TROUBLESHOOTING E-9
E-9 Engine coolant thermometer is abnormal
Trouble • Engine coolant thermometer is abnormal.

• If the engine coolant temperature sensor system becomes defective, error code [B@BCNS] may be
Related displayed and recorded.
information • The input state (voltage) from the engine coolant temperature sensor can be checked in the monitoring
mode. (Monitoring mode: 04106-ENG. TEMP.)

a Prepare with starting switch OFF, then hold starting switch OFF or start engine
Defective engine coolant Engine coolant
temperature sensor CN20 (male) Resistance
1 temperature
(Internal disconnection
or short circuit) Between (1) and (2) 3.5 k – 90 kz
Between (1), (2) and 10 – 100°C
Min. 1 Mz
chassis ground
harness
Wiring harness between CN-S04 (female) (11) and
Possible causes and
CN20 (female) (1)

contact in connector) Wiring harness between CN20 (female) (2) and
Resistance Max. 1 z
chassis ground (CN-T36)
3
(Contact with ground Between CN-S04 (female) (11) – CN20 (female) (1)
4
(Contact with 24 V Between CN-S04 (female) (11) – CN20 (female) (1)
a Prepare with starting switch OFF, then hold starting switch OFF or start engine
Engine coolant
5 Defective monitor panel CN-S04 (female) Resistance
temperature
Between (11) and chassis
10 – 100°C 3.5 k – 90 kz
ground
20-626 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING E-9
Circuit diagram related to engine coolant temperature sensor
D31/37/39EX, PX-21 20-627

(1)
TROUBLESHOOTING E-10
E-10 HST oil thermometer is abnormal
Trouble • HST oil thermometer is abnormal

• The signals from the HST oil temperature sensor are received from the HST controller through the
communication system.
Related • If the HST oil temperature sensor system becomes defective, error code [B@CRNS] may be displayed
information and recorded.
• The input state (voltage) from the HST oil temperature sensor can be checked in the monitoring mode.
(Monitoring mode: 04402-HST. TEMP.)

starting switch.
Defective HST oil
temperature sensor CN12 (male) HST oil temperature Resistance
1
(Internal disconnection Between (1) and (2) 3.5 k – 90 kz
or short circuit) 10 – 100°C
Between (1), (2) and
Min. 1 Mz
chassis ground
harness

CN12 (female) (1)
Possible causes and
contact in connector) Wiring harness between CN-ST1 (female) (21) and

Resistance Max. 1 z
CN12 (female) (2)
3
(Contact with ground Between CN-ST1 (female) (9) – CN12 (female) (1)
4
(Contact with 24 V Between CN-ST1 (female) (9) – CN12 (female) (1)
troubleshooting.
5 HST controller
CN-ST1 HST oil temperature Voltage
Between (9) and (21) 10 – 100°C 2.0 – 4.8 V
If none of causes 1 - 5 is the cause of the trouble, the monitor panel may be
panel).
20-628 D31/37/39EX, PX-21

(1)
Circuit diagram related to HST oil temperature sensor
D31/37/39EX, PX-21 20-629

(1)
E-11 Fuel level gauge is abnormal
Trouble • Fuel level gauge is abnormal

Related
information

Defective fuel level starting switch.
sensor CN13 (male) Fuel tank Resistance
1
or short circuit) Full Max. 12 z
Between (1) and (2)
Empty Min. 68 z
harness
Wiring harness between CN-S04 (female) (10) and

CN13 (female) (1)
Possible causes and
contact in connector) Wiring harness between CN13 (female) (2) and CN-
Resistance Max. 1 z
S03 (female) (3)
3
(Contact with ground Between CN-S04 (female) (10) – CN13 (female) (1)
4
(Contact with 24 V Between CN-S04 (female) (10) – CN13 (female) (1)
starting switch.
CN-S03 (female)
5 Defective monitor panel Fuel tank Resistance
CN-S04 (female)
Between CN-S04 (10) and Full Max. 12 z
CN-S03 (3) Empty Min. 68 z
20-630 D31/37/39EX, PX-21

(1)
Circuit diagram related to fuel level sensor
D31/37/39EX, PX-21 20-631

(1)
TROUBLESHOOTING E-12, E-13, E-14, E-15
E-12 Reverse travel speed indicator is abnormal
Trouble • Reverse travel speed indicator is abnormal.

Related • Display information of the reverse travel speed indicator is received from the HST controller through
information the communication system.

causes and
1
E-13 Gear speed, set travel speed, and shift mode indicator is abnormal
Trouble • Gear speed, set travel speed, and shift mode indicator is abnormal.
• Display information of the gear speed, set travel speed, and shift mode indicator is received from the
Related HST controller through the communication system.
information • Display of the gear speed, set travel speed, and shift mode indicator in the quick shift mode is different
from that in the variable shift mode.

causes and
1
E-14 Multi-information section is abnormal
Trouble (1) Service meter does not move forward while engine is running.
Related • The service meter counts the time by the signals from the engine speed sensor.
information • While the service meter is moving forward, the hourglass mark is displayed.

Possible
Defective engine If error code [DLE2KA] or [DLE2KB] is displayed, carry out troubleshooting
causes and 1
speed signal sensor for it first.
standard value
in normal state Defective monitor Troubleshooting cannot be carried out since the defect is in the monitor
2
panel panel.
Trouble (2) Multi-information section does not display any item.

Related • Display information of the multi-information section is received from the HST controller through the

causes and
1
E-15 Caution lamp does not flash or does not go off
Trouble • Caution lamp does not flash or does not go off.

Related
information

causes and
1
20-632 D31/37/39EX, PX-21

(1)
E-16 Caution buzzer does not sound or does not stop
Trouble • Caution buzzer does not sound or does not stop.

Related • If there is a short circuit in the caution buzzer system, an error code is displayed. No error codes are
information displayed when other troubles occur, however.

starting switch.
Defective caution buzzer
2 (Internal disconnection CN-CB (male) Resistance
or short circuit) Between (2) and (1) Min. 1 kz

Possible causes and
harness
Wiring harness between FB1 (7) and CN-CB (female)
(1)
contact in connector) Wiring harness between CN-CB (female) (2) and CN-
Resistance Max. 1 z
S03 (female) (18)
ground in wiring harness Between FB1 (7) – CN-CB (female) (1) or CN-S03
(Contact with ground (female) (1) or (2) wiring harness and chassis ground
circuit) Between CN-CB (female) (2) – CN-S03 (female) (18)
troubleshooting.
5 Defective monitor panel CN-S03 Caution buzzer Voltage
Between (18) and chassis Stopped 20 – 30 V
ground Operated (Sounded) Max. 3 V
Circuit diagram related to caution buzzer
D31/37/39EX, PX-21 20-633

(1)
E-17 Reverse travel speed setting switch does not function
Trouble • Reverse travel speed setting switch does not function.

Related • If there is a short circuit in the reverse travel speed setting system, an error code is displayed. No error
information codes are displayed when other troubles occur, however.

starting switch.
Defective reverse travel CN-REV (male) Resistance
setting switch
speed setting switch
1 Neutral Min. 1 Mz
Between (1) and (2)
or short circuit) Higher speed (Right) Max. 1 z
Neutral Min. 1 Mz
Between (1) and (3)
Lower speed (Left) Max. 1 z
starting switch.

CN-REV (female) (2)
Possible causes and
Resistance Max. 1 z
contact in connector) CN-REV (female) (3)
Resistance Max. 1 z
CN-REV (female) (1)
ground in wiring harness Between CN-ST2 (female) (25) – CN-REV (female) (2)
(Contact with ground wiring harness and chassis ground
circuit) Between CN-ST2 (female) (35) – CN-REV (female) (3)
troubleshooting.
setting switch
4 Defective HST controller Neutral 5 – 11 V
CN-ST1 (10) Higher speed (Right) Max. 1 V
Between CN-ST2 (35) and Neutral 5 – 11 V
CN-ST1 (10) Lower speed (Left) Max. 1 V
20-634 D31/37/39EX, PX-21

(1)
Circuit diagram related to reverse travel speed setting switch
D31/37/39EX, PX-21 20-635

(1)
E-18 Shift mode switch does not function
Trouble • Shift mode switch does not function.

Related
information

Defective shift mode starting switch.
switch CN-MTS (male) Shift mode switch Resistance
1
or short circuit) Variable shift mode (Left) Min. 1 Mz
Between (1) and (2)
Quick shift mode (Right) Max. 1 z
Possible causes and
harness
CN-MTS (female) (2)
contact in connector) Wiring harness between CN-ST1 (female) (10) and
Resistance Max. 1 z
CN-MTS (female) (3)
3
(Contact with ground Between CN-ST2 (female) (37) – CN-MTS (female) (2)
troubleshooting.
4 Defective HST controller CN-ST1, CN-ST2 Shift mode switch Voltage
Between CN-ST2 (37) and Variable shift mode (Left) 5 – 11 V
CN-ST1 (10) Quick shift mode (Right) Max. 1 V
Circuit diagram related to shift mode switch
20-636 D31/37/39EX, PX-21

(1)
E-19 Buzzer cancel switch does not function
Trouble • Buzzer cancel switch does not function.

Related
information

starting switch.
Defective buzzer cancel CN-BUZ (male) Buzzer cancel switch Resistance
switch Neutral Min. 1 Mz
1
(Internal disconnection Between (1) and (2)
or short circuit) t (Right) Max. 1 z
Neutral Min. 1 Mz
Between (1) and (3)
U (Left) Max. 1 z
starting switch.

CN-BUZ (female) (2)
Possible causes and
Resistance Max. 1 z
contact in connector) CN-BUZ (female) (3)
Resistance Max. 1 z
CN-BUZ (female) (1)
ground in wiring harness Between CN-ST2 (female) (36) – CN-BUZ (female) (2)
circuit) Between CN-ST2 (female) (26) – CN-BUZ (female) (3)
troubleshooting.
CN-ST1, CN-ST2 Buzzer cancel switch Voltage
4 Defective HST controller Between CN-ST2 (36) and Neutral 5 – 11 V
CN-ST1 (10) t (Right) Max. 1 V
CN-ST1 (10) U (Left) Max. 1 V
20-638 D31/37/39EX, PX-21

(1)
Circuit diagram related to buzzer cancel switch
D31/37/39EX, PX-21 20-639

(1)
E-20 Information switch does not function
Trouble • Information switch does not function.

Related
information

starting switch.
Defective information CN-CUR (male) Information switch Resistance
switch Neutral Min. 1 Mz
1
or short circuit) > (Right) Max. 1 z
Neutral Min. 1 Mz
Between (1) and (3)
< (Left) Max. 1 z
starting switch.

CN-CUR (female) (2)
Possible causes and
harness or defective Wiring harness between CN-ST2 (female) (6) and CN-
Resistance Max. 1 z
contact in connector) CUR (female) (3)
Resistance Max. 1 z
CN-CUR (female) (1)
ground in wiring harness Between CN-ST2 (female) (16) – CN-CUR (female) (2)
circuit) Between CN-ST2 (female) (6) – CN-CUR (female) (3)
troubleshooting.
CN-ST1, CN-ST2 Information switch Voltage
4 Defective HST controller Between CN-ST2 (16) and Neutral 5 – 11 V
CN-ST1 (10) > (Right) Max. 1 V
CN-ST1 (10) < (Left) Max. 1 V
20-640 D31/37/39EX, PX-21

(1)
Circuit diagram related to information switch
D31/37/39EX, PX-21 20-641

(1)
E-21 System is not set in service mode or is not set out of service mode
Trouble • System is not set in service mode or is not set out of service mode.
Related
information

Since the buzzer cancel switch system may be defective, check its operation. (If it
Defective buzzer cancel
1 does not operate normally, carry out troubleshooting for “Buzzer cancel switch does
switch system
not function”.)
Since the information switch system may be defective, check its operation. (If it
Defective information
2 does not operate normally, carry out troubleshooting for “Information switch does
switch system
not function”.)
starting switch.
Defective service switch
4 (Internal disconnection CN-S24 Service switch Resistance
or short circuit) Between (1) and (2) OFF (Upper position) Min. 1 Mz
Between (4) and (5) ON (Lower position) Max. 1 z
starting switch.
Disconnection in wiring Wiring harness between FB2 (6) and CN-S24 (1) Resistance Max. 1 z
harness Wiring harness between CN-S03 (female) (16) and

Resistance Max. 1 z
5 (Disconnection in wiring CN-S24 (2)
Possible causes and

contact in connector) Resistance Max. 1 z
CN-S24 (4)
Resistance Max. 1 z
S24 (5)
starting switch.
Between FB2 (6) – CN-S34 (1) or CN-S03 (female) (5)
Short circuit with chassis or (6) or another related circuit wiring harness and Resistance Min. 1 Mz
ground in wiring harness chassis ground
6
circuit) Between CN-S03 (female) (16) – CN-S24 (2) wiring
Between CN-ST1 (female) (6) – CN-S24 (5) wiring
troubleshooting.
7 Defective monitor panel CN-S03 Service switch Voltage
Between (16) and chassis OFF (Upper position) Max. 1 V
ground ON (Lower position) 20 – 30 V
troubleshooting.
8 Defective HST controller CN-ST1 Service switch Voltage
OFF (Upper position) 5 - 11 V
Between (6) and (10)
ON (Lower position) Max. 1 V
20-642 D31/37/39EX, PX-21

(1)
Circuit diagram related to service switch
D31/37/39EX, PX-21 20-643

(1)
E-23 Headlamp or rear lamp does not light up
Trouble • Headlamp or rear lamp does not light up.

Related • Note that the connector Nos. of the headlamps and rear lamps of the canopy specification are different
information from those of the cab specification.

Defective left headlamp
If only the left headlamp does not light up, it may have a bad contact or a broken
1 (Bad contact or
bulb. Check it directly.
breakage of bulb)
Defective right headlamp
If only the right headlamp does not light up, it may have a bad contact or a broken
2 (Bad contact or
bulb. Check it directly.
breakage of bulb)
Defective rear (Bad
If only the rear lamp does not light up, it may have a bad contact or a broken bulb.
3 contact or breakage of
Check it directly.
bulb)
starting switch.
Defective lamp switch CN-FWL (male) Lamp switch Resistance
5
Q (OFF) Min. 1 Mz
Between (2) and (3)
| (ON) Max. 1 z
troubleshooting.
Possible causes and
Defective lamp relay

6
(Internal defect) Turn the lamp switch on and OFF. If the lamp relay makes an operating sound, it is
normal.
starting switch.
Wiring harness between FB1 (6) and CN-FWL (2) or
Resistance Max. 1 z
CN-54 (female) (1) or (3)
Disconnection in wiring Wiring harness between CN-FWL (female) (3) and CN-
54 (female) (5)
harness or defective Wiring harness between CN-54 (female) (6) and
Resistance Max. 1 z
contact in connector) chassis ground (CN-T10)
Wiring harness between CN54 (female) (2) or (4),
Resistance Max. 1 z
CN33, and each lamp connector (female) (1)
Wiring harness between each lamp connector (female)
Resistance Max. 1 z
(2), CN33, and chassis ground (CN-T35)
starting switch.
Between FB1 (6) – CN-FWL (2) or CN54 (female) (1)
Short circuit with chassis Resistance Min. 1 Mz
or (3) wiring harness and chassis ground
8 Between CN-FWL (female) (3) – CN54 (female) (5) or
circuit) CN-S03 (female) (8) wiring harness and chassis Resistance Min. 1 Mz
ground
Between CN-54 (female) (2) or (4) – CN-33 - each
lamp connector (female) (1) and chassis ground
20-646 D31/37/39EX, PX-21

(1)
Circuit diagram related to lamp and panel night lighting system
D31/37/39EX, PX-21 20-647

(1)
E-24 Canopy heater does not operate [Canopy specification]
Trouble • Canopy 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.)

starting switch.
CN-HS (male) Heater switch Resistance
OFF Min. 1 Mz
Defective heater switch
2 (Internal disconnection Between (4) and (3) I Max. 1 z
or short circuit) II Max. 1 z
OFF Min. 1 Mz
Between (4) and (2) I Min. 1 Mz
II Max. 1 z
Possible causes and
starting switch.
Wiring harness between FB2 (8) and CN-HS (female)
(4)
harness
Wiring harness between CN-HS (female) (3) and CN92
(female) (3)
contact in connector) Wiring harness between CN-HS (female) (2) and CN92
Resistance Max. 1 z
(female) (1)
Wiring harness between CN92 (female) (4) and
Resistance Max. 1 z
chassis ground (CNT10)
starting switch.
Short circuit with chassis Between FB2 (8) – CN-HS (female) (4) wiring harness
ground in wiring harness and chassis ground
4
(Contact with ground Between CN-HS (female) (3) – CN92 (female) (3)
Between CN-HS (female) (2) – CN92 (female) (1)
Defective heater unit
5 If none of causes 1 – 5 is the cause of the trouble, the heater unit may be defective.
(Internal defect)
20-648 D31/37/39EX, PX-21

(1)
Circuit diagram related to canopy heater
D31/37/39EX, PX-21 20-649

(1)
E-25 Air conditioner does not operate [Cab specification]
Trouble (1) Air does not come out.

Related
information

1 Defective fuse (FB3-4) If the fuse is broken, the circuit probably has a grounding fault, etc.
Defective blower main starting switch.
2
relay (Coil side) CN-R1 (male) Resistance
Between (1) and (2) 240 ± 40 z
a Prepare with starting switch OFF, then turn starting switch and air conditioner
switch ON and carry out troubleshooting.
Blower main relay
3 CN-R1 Air flow selector switch Voltage
(Contact side)
Lo 20 – 30 V
ground
Defective blower Hi relay starting switch.
4
(Coil side) CN-R2 (male) Resistance
Between (1) and (2) 240 ± 40 z
Defective blower Hi relay troubleshooting.
5
(Contact side) When the air flow selector switch is set in the “Hi” position, if the blower motor
rotates, the blower “Hi” relay is normal.

Possible causes and
Defective blower Mid starting switch.
6
Between (1) and (2) 240 ± 40 z
Defective blower Mid troubleshooting.
7
relay (Contact side) When the air flow selector switch is set in the “t” position, if the blower motor
rotates, the blower “Mid” relay is normal.
starting switch.
8 Defective resistor CN-R (male) Resistance
Between (2) and (4) 2.0 z ± 7%
Between (3) and (4) 0.8 z ± 7%
troubleshooting.
9 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.
starting switch.
Disconnection in wiring Wiring harness between FB3 (4) and CN80 (female)
(13C)
harness or defective Wiring harness between FB3 (4) and CN-R1 (female)
Resistance Max. 1 z
contact in connector) (13B)
Wiring harness between FB3 (4) and CN-R2 (female)
Resistance Max. 1 z
(13E)
20-650 D31/37/39EX, PX-21

(1)

Resistance Max. 1 z
(13H)
Resistance Max. 1 z
(6C)
Wiring harness between CN80 (female) (D0) and
Resistance Max. 1 z
CN81 (male) (0A)
Wiring harness between CN-R1 (female) (11B) and
Resistance Max. 1 z
CN-B (female) (11A)
Wiring harness between CN-R1 (female) (14A) and
Resistance Max. 1 z
CN80 (female) (14B)
Wiring harness between CN-R2 (female) (18A) and

CN80 (female) (18B)
Possible causes and
harness
Wiring harness between CN-R2 (female) (0H) and
CN81 (male) (0A)
contact in connector) Wiring harness between CN-R3 (female) (17A) and
Resistance Max. 1 z
CN80 (female) (17B)
Resistance Max. 1 z
CN81 (male) (0A)
Wiring harness between CN-R (female) (0E) and CN81
Resistance Max. 1 z
(male) (0A)
Wiring harness between CN-R (female) (12A) and CN-
Resistance Max. 1 z
R3 (female) (12B)
Wiring harness between CN-B (female) (10A) and CN-
Resistance Max. 1 z
R (female) (10C)
Wiring harness between CN-B (female) (10A) and CN-
Resistance Max. 1 z
R2 (female) (10B)
If none of causes 1 – 10 is the cause of the trouble, the control panel may be
11 Defective control panel
defective.
Mistake in checking If the cause is not found out, a mistake may be made in check the trouble. In this
12
trouble case, carry out troubleshooting for “Air is not cooled”.
D31/37/39EX, PX-21 20-651

(1)
Trouble (2) Air is not cooled.

Related
information

1 Defective fuse (FB3-4) If the fuse is broken, the circuit probably has a grounding fault, etc.
CN-P Air flow selector switch Voltage
Any position 20 – 30 V
Defective pressure ground
2
switch a Prepare with starting switch OFF, then start engine and turn air conditioner switch
ON and carry out troubleshooting.
CN-P Air flow selector switch Voltage
ground
Defective compressor starting switch.
3
clutch relay (Coil side) CN-R4 (male) Resistance
Between (1) and (2) 240 ± 40 z
Defective compressor switch ON and carry out troubleshooting.
4 clutch relay CN-R4 Air flow selector switch Voltage
(Contact side) Between (4) and chassis

Possible causes and
ground
Defective condenser starting switch.
5
Between (1) and (2) 240 ± 40 z
Defective condenser
6 CN-R5 Air flow selector switch Voltage
relay (Contact side)
ground
starting switch.
7 Defective thermistor
CN-T (male) Resistance
Between (1) and (2) Max. 3,500 z
Defective condenser Hi starting switch.
8
Between (1) and (2) 240 ± 40 z
Defective condenser Hi switch ON and carry out troubleshooting.
9
relay (Contact side) When the medium pressure switch of the pressure switch operates, if the
condenser motor rotates, the condenser Hi relay is normal.
Defective condenser starting switch.
10
resistor Condenser resistor Resistance
Between (1) and (2) 2.8 z ± 5%
20-652 D31/37/39EX, PX-21

(1)

Defective condenser switch ON and carry out troubleshooting.
11
motor When the air conditioner switch is turned ON, if the condenser motor rotates, the
condenser motor is normal.
Defective compressor
12 The compressor magnetic clutch may be defective. Check it directly.
magnetic clutch
13 Defective compressor The compressor may be defective. Check it directly.
starting switch.
Resistance Max. 1 z
(6D)
Resistance Max. 1 z
(6B)
Resistance Max. 1 z
(13I)
Resistance Max. 1 z
(13D)
Wiring harness between CN80 (female) (15B) and CN-
Resistance Max. 1 z
T (female) (15A)
Wiring harness between CN80 (female) (16C) and CN-

Resistance Max. 1 z
Possible causes and
t (female) (16B)
Wiring harness between CN-P (female) (26B) and
Resistance Max. 1 z
CN80 (female) (26A)
Wiring harness between CN-P (female) (29A) and CN-
R6 (female) (29B)
Wiring harness between CN-R4 (female) (27C) and
CN-R5 (female) (27B)
defective contact in
connector) Wiring harness between CN-R4 (female) (27C), CN-R5
Resistance Max. 1 z
(female) (27)) and CN-P (female) (27A)
Resistance Max. 1 z
CN81 (male) (9A)
Resistance Max. 1 z
condenser motor (female) (C361)
Resistance Max. 1 z
CN-P (female) (28A)
Wiring harness between CN-R6 (female) (0K) and
Resistance Max. 1 z
Resistance Max. 1 z
condenser resistor (female) (C381)
Wiring harness between CN-R6 (female) (0I) and
Resistance Max. 1 z
Wiring harness between condenser resistor (female)
Resistance Max. 1 z
(C04) and chassis ground (CN-T35)
Wiring harness between condenser motor (female)
Resistance Max. 1 z
(C38) and condenser resistor (C381)
If none of causes 1 – 10 is the cause of the trouble, the control panel may be
15 Defective control panel
defective.
D31/37/39EX, PX-21 20-653

(1)
Circuit diagram related to air conditioner
20-654 D31/37/39EX, PX-21

(1)
E-26 Windshield wiper and windshield washer do not operate [Cab specification]
Trouble (1) Windshield wiper and windshield washer do not operate.

Related
• Before carry out troubleshooting, check that the wiper arm and blade are not deformed or sticked.
information

starting switch.
Defective front wiper CN65 (male) Front wiper switch Resistance
switch OFF Min. 1 Mz
2
or short circuit) ON Max. 1 z
OFF Max. 1 z
Between (4) and (5)
ON Min. 1 Mz
starting switch.
CN68 (female) Front wiper switch Voltage or resistance
20 – 30 V
ground
ON
Defective front wiper Max. 1 z
3 ground
motor (Internal defect)
OFF Max. 1 z
ground
ON 20 – 30 V
ground
Possible causes and
If the voltage and resistance are normal but the front wiper does not operate, the
front wiper motor is defective.
starting switch.
Wiring harness between FB3 (5) and CN65 (female)
Resistance Max. 1 z
(3)
(6) (Note: If only this wiring harness is disconnected,
the wiper operates but does not return to regular
harness position when it stops.)
harness or defective Wiring harness between CN65 (female) (4) and CN68
Resistance Max. 1 z
contact in connector) (female) (2)
Resistance Max. 1 z
Wiring harness between CN65 (female) (5) and CN68
(female) (5) (Note: If only this wiring harness is
Resistance Max. 1 z
disconnected, the wiper operates but does not return to
regular position when it stops.)
starting switch.
Between FB3 (5) – CN65 (female) (2) or (3) wiring
Short circuit with chassis harness and chassis ground
ground in wiring harness Between FB3 (5) – CN68 (female) (6) wiring harness
(Contact with ground and chassis ground
circuit) Between CN65 (female) (4) – CN68 (female) wiring
Between CN65 (female) (5) – CN68 (female) (5) wiring
D31/37/39EX, PX-21 20-655

(1)
Trouble (2) Rear wiper does not operate.

Related
• Before carry out troubleshooting, check that the wiper arm and blade are not deformed or sticked.
information

Defective wiper motor If the circuit breaker is turned OFF (If it operates), the circuit probably has a
2
circuit breaker grounding fault, etc. (See cause 4.)
starting switch.
Defective rear wiper CN64 Rear wiper switch Resistance
switch OFF Min. 1 Mz
3
or short circuit) ON Max. 1 z
OFF Max. 1 z
Between (4) and (5)
ON Min. 1 Mz
a Prepare with starting switch OFF, then keep starting switch OFF or turn it ON and
20 – 30 V
ground
OFF
Defective rear wiper Max. 1 z
Possible causes and
4 ground
motor (Internal defect)
ON 20 – 30 V
ground
OFF Max. 1 z
ground
If the voltage and resistance are normal but the rear wiper does not operate, the
rear wiper motor is defective.
starting switch.
Resistance Max. 1 z
(3)
(3) (Note: If only this wiring harness is disconnected,
Resistance Max. 1 z
the wiper operates but does not return to regular
Disconnection in wiring position when it stops.)
harness
(female) (1)
contact in connector) Wiring harness between CN66 (female) (2) and CN69
Resistance Max. 1 z
(female) (1)
Resistance Max. 1 z
(female) (4) (Note: If only this wiring harness is
Resistance Max. 1 z
disconnected, the wiper operates but does not return to
regular position when it stops.)
20-656 D31/37/39EX, PX-21

(1)

starting switch.
Between FB3 (3) - CN64 (female) (2) or (3) wiring
Possible causes and
Short circuit with chassis Between FB (3) - CN69 (female) (3) wiring harness
ground in wiring harness and chassis ground
6
(Contact with ground Between CN64 (female) (4) – CN66 (female) (1) wiring
D31/37/39EX, PX-21 20-657

(1)
Trouble (3) Front windshield washer does not operate.

Related
• Before carry out troubleshooting, check that there is sufficient washing liquid in the tank.
information

Defective front wiper starting switch.
switch CN65 (male) Front wiper switch Resistance
2
or short circuit) OFF Min. 1 Mz
Between (2) and (1)
W/I or W/II Max. 1 z

Defective front washer 20 – 30 V
3 ground
Possible causes and
motor (Internal defect) W/I or W/II

Max. 1 z
ground
If the voltage and resistance are normal but the front washer does not operate, the
front washer motor is defective.
starting switch.
(2)
Resistance Max. 1 z
Resistance Max. 1 z
ground in wiring harness Between FB3 (5) – CN65 (female) (2) or (3) wiring
(Contact with ground harness and chassis ground
circuit) Between CN65 (female) (1) – CN63 (female) (1) wiring
20-658 D31/37/39EX, PX-21

(1)
Trouble (4) Rear windshield washer does not operate.

Related
• Before carry out troubleshooting, check that there is sufficient washing liquid in the tank.
information

Defective rear wiper starting switch.
switch CN64 (male) Rear wiper switch Resistance
2
or short circuit) OFF Min. 1 Mz
Between (2) and (1)
W/I or W/II Max. 1 z
CN62 (female) Rear wiper switch Voltage or resistance

Defective rear washer 20 – 30 V
3 ground
Possible causes and
motor (Internal defect) W/I or W/II

Max. 1 z
ground
If the voltage and resistance are normal but the rear washer does not operate, the
rear washer motor is defective.
starting switch.
(2)
Resistance Max. 1 z
Resistance Max. 1 z
ground in wiring harness Between FB3 (3) - CN64 (female) (2) or (3) wiring
(Contact with ground harness and chassis ground
circuit) Between CN64 (female) (1) – CN62 (female) (1) wiring
D31/37/39EX, PX-21 20-659

(1)
Circuit diagram related to wiper and windshield washer
20-660 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING OF HYDRAULIC
AND MECHANICAL SYSTEM (H MODE)
H-1 Right and left travel systems do not operate forward and in reverse (No travel systems operate) ...... 20-703
H-2 Right or left travel system does not operate forward and in reverse
(Only right or left travel system does not operate) ............................................................................... 20-704
H-3 Right or left travel system does not operate forward or in reverse (Only 1 system does not operate). 20-704
H-4 Speed or power of travel is low ............................................................................................................ 20-705
H-5 Gear is not shifted ................................................................................................................................ 20-706
H-6 Large shock is made when machine stops traveling............................................................................ 20-707
H-7 Machine deviates largely during travel ................................................................................................. 20-707
H-8 Hydraulic drift of travel is larger............................................................................................................ 20-708
H-9 Engine stalls or engine speed lowers extremely during travel ............................................................. 20-708
H-10 Abnormal sound comes out from around HST pump and motor........................................................ 20-709
H-11 Work equipment dose not operate at all............................................................................................. 20-710
H-12 Speed or power of whole work equipment is low ............................................................................... 20- 711
H-13 Speed or power of lifting blade is low ................................................................................................. 20-712
H-14 Speed or power of tilting blade is low ................................................................................................. 20-712
H-15 Speed or power of angling blade is low.............................................................................................. 20-713
H-16 Time lag in lifting blade is large .......................................................................................................... 20-714
H-17 Hydraulic drift of lifting blade is large.................................................................................................. 20-714
H-18 Hydraulic drift of tilting blade is large.................................................................................................. 20-714
H-19 Abnormal sound comes out from around work equipment pump and control valve........................... 20-715
H-20 HST oil temperature (Hydraulic oil temperature) rises too high ......................................................... 20-716
D31/37/39EX, PX-21 20-701

(1)

a The following information is summarized in the troubleshooting table. Before carrying out troubleshooting,
understand that information fully.
Trouble Trouble which occurred in the machine

Related
information

1
Possible causes and
Possible causes of
2 trouble
<Contents of description>
(Given numbers are
reference numbers,
3 which do not indicate
priority)
20-702 D31/37/39EX, PX-21

(3)
TROUBLESHOOTING H-1
H-1 Right and left travel systems do not operate forward and in reverse
(No travel systems operate)
Trouble • Right and left travel systems do not operate forward and in reverse (No travel systems operate).
Related
• Check that the oil level in the hydraulic tank is normal before carrying out troubleshooting.
information

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 charge filter
3 Clogging of charge filter
can be checked in the monitoring mode (40910-S/T SW1, 4th from left).
a Prepare with engine stopped, then run engine at high idling and carry out
troubleshooting.
Monitor panel HST charge
PCCS lever
(Adjustment mode) circuit pressure
Defective adjustment or
3.04 ± 0.29 MPa
malfunction of HST Neutral
4 3016-STALL CHECK {31 ± 3 kg/cm2}
pump
(charge safety valve) (Stall pressure test mode) 2.84 ± 0.49 MPa
Forward or reverse
{29 ± 5 kg/cm2}
If the oil pressure does not become normal after the adjustment, the charge safety
valve of the HST pump may have malfunction or defect in it. Check the charge
safety valve directly.
Possible causes and
troubleshooting.
PCCS lever
3.04 ± 0.29 MPa
motor
(charge relief valve) (Stall pressure test mode) 2.84 ± 0.49 MPa
Forward or reverse
{29 ± 5 kg/cm2}
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.
troubleshooting.
Malfunction of parking Parking brake lever and Parking brake solenoid Slow brake solenoid valve
brake solenoid valve or brake pedal valve output pressure output pressure
6
slow brake solenoid Lever: Free position 30.4 ± 0.49 MPa 30.4 ± 0.49 MPa
valve Pedal: Released {31 ± 5 kg/cm2} {31 ± 5 kg/cm2}
Lever: Lock position 0 MPa 0 MPa
Pedal: Pressed fully {0 kg/cm2} {0 kg/cm2}
Wrong operation of park-
The parking brake bypass valve (tow valve) may be operated (changed over)
7 ing brake bypass valve
wrongly. Check it directly.
(tow valve)
Defect in HST pump
8 The pump unit of the HST pump may have a defect in it. Check it directly.
(pump unit)
D31/37/39EX, PX-21 20-703

(1)
TROUBLESHOOTING H-2, H-3
H-2 Right or left travel system does not operate forward and in reverse
(Only right or left travel system does not operate)
• 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 The servo valve of the HST pump (on 1 side) may be malfunctioning.
1
pump (servo valve) Check it directly.
Possible causes and
Wrong operation of HST The towed valve of the HST pump (on 1 side) may be operated (opened) wrongly.
2
pump (towed valve) 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.
Defect in HST pump The parking brake of the HST motor (on 1 side) may have a defect in it.
4
(parking brake) 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.
H-3 Right or left travel system does not operate forward or in reverse
(Only 1 system does not operate)
Trouble • Right or left travel system does not operate forward or in reverse (Only 1 system does not operate).
• 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.
Related
(During idle travel: 3001-PUMP ADJST F, 3002-PUMP ADJST R)
information
(During actual travel: 3003-PU F-UP MPA, 3004-PU R-UP MAP, 3005-PU FHF MAP, 3006-PU R-HF
MAP)

a Prepare with starting switch ON, then run engine at high idling and carry out
troubleshooting.
Monitor panel
Malfunction of HST PCCS lever HST main circuit pressure
(Adjustment mode)
1 pump
(safety-suction valve) 39.2 – 45.1 MPa

Forward
3016-STALL CHECK {400 – 460 kg/cm2}
Possible causes and
(Stall pressure test mode) 39.2 – 45.1 MPa

Reverse
{400 – 460 kg/cm2}
troubleshooting.
Malfunction of HST PCCS lever EPC valve output pressure

2
pump (EPC valve) F1 (Travel) Min. 1.0 MPa {Min. 10 kg/cm 2}
N (Neutral) 0 MPa {0 kg/cm2}
R1 (Travel) Min. 1.0 MPa {Min. 10 kg/cm2}
3
4
20-704 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING H-4
H-4 Speed or power of travel is low
Trouble • Speed or power of travel is low.

• 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.
Related
(During idle travel: 3001-PUMP ADJST F, 3002-PUMP ADJST R)
information
(During actual travel: 3003-PU F-UP MPA, 3004-PU R-UP MAP, 3005-PU FHF MAP, 3006-PU R-HF
MAP)

The charge filter may be clogged. Check it directly. Clogging of the charge filter
2 Clogging of charge filter
can be checked in the monitoring mode (40910-S/T SW1, 4th from left).
troubleshooting.
PCCS lever
3.04 ± 0.29 MPa
pump
Forward or reverse
{29 ± 5 kg/cm2}
Possible causes and

troubleshooting.
PCCS lever
3.04 ± 0.29 MPa
motor
Forward or reverse
{29 ± 5 kg/cm2}
troubleshooting.
Monitor panel
PCCS lever HST relief pressure
Malfunction of (Adjustment mode)
5
safety-suction valve 39.2 – 45.1 MPa
Forward
3016-STALL CHECK {400 – 460 kg/cm2}
(Stall pressure test mode) 39.2 – 45.1 MPa
Reverse
{400 – 460 kg/cm2}
D31/37/39EX, PX-21 20-705

(1)
TROUBLESHOOTING H-5
H-5 Gear is not shifted
(1) Gear is not shifted to 2nd in quick shift mode.

Trouble
Gear is not shifted to medium speed range in variable shift mode.
Related
information

troubleshooting.
Possible causes and
Solenoid valve output

Malfunction of 2nd travel Shift mode PCCS lever
pressure
1 speed selection
solenoid valve 0 MPa
N1 (Neutral + 1st)
{0 kg/cm2}
Quick shift
30.9 ± 0.49 MPa
F2, R2 (Travel + 2nd)
{31 ± 5 kg/cm2}
Malfunction of HST If the machine deviates during travel, the HST motor may be malfunctioning.
2
motor Check the HST motor directly.
(2) Gear is not shifted to 3rd in quick shift mode.

Trouble
Gear is not shifted to high speed range in variable shift mode.
Related
information

troubleshooting.
Possible causes and
Solenoid valve output

Malfunction of 3rd travel Shift mode PCCS lever
pressure
1 speed selection
solenoid valve 0 MPa
N1 (Neutral + 1st)
{0 kg/cm2}
Quick shift
30.9 ± 0.49 MPa
F3, R3 (Travel + 3rd)
{31 ± 5 kg/cm2}
Malfunction of HST If the machine deviates during travel, the HST motor may be malfunctioning.
2
motor Check the HST motor directly.
20-706 D31/37/39EX, PX-21

(1)
H-6 Large shock is made when machine stops traveling
Trouble • Large shock is made when machine stops traveling.

Related
information

Defective air bleeding

Possible causes and
1 Air may be left in the servo valve of the HST pump. Bleed air again.
from HST pump
Warm up the engine (to the green range of the HST oil thermometer).
2 Low HST oil temperature
HST oil thermometer Green range
Defective initial
3 The initial adjustment of the pump may be defective. Adjust the pump again.
adjustment of pump
H-7 Machine deviates largely during travel
Trouble • Machine deviates largely during travel.

Related
information

1
Wrong operation of HST The towed valve of the HST pump (on 1 side) may be operated (opened) wrongly.
2
pump (towed valve) Check it directly.
3
Possible causes and

Defect in HST pump The parking brake of the HST motor (on 1 side) may have a defect in it.
4
(parking brake) Check it directly.
Malfunction of HST
The charge relief valve of the HST motor (on 1 side) may be malfunctioning.
5 motor
Check it directly.
(charge relief valve)
Defect in HST motor The motor unit of the HST motor (on 1 side) may have a defect in it.
6
(motor unit) Check it directly.
Defective HST motor If error code [DLM1KB], [DLM1MA], [DLM2KB], or [DLM2MA] is displayed, carry out
7
(speed sensor) troubleshooting for it.
from HST pump
D31/37/39EX, PX-21 20-707

(1)
H-8 Hydraulic drift of travel is larger
Trouble • Hydraulic drift of travel is large.

Related
information

troubleshooting.
Malfunction of HST Monitor panel PCCS lever HST relief pressure
1 pump 39.2 – 45.1 MPa

Forward
Possible causes and
(safety-suction valve) Stall pressure test mode {400 – 460 kg/cm2}

[3016] 39.2 – 45.1 MPa
Reverse
{400 – 460 kg/cm2}
Wrong operation of HST The towed valves of the HST pumps (on both sides) may be operated (opened)
2
pump (towed valve) wrongly. Check it directly.
Defect in HST pump Oil may be leaking in the pump unit of the HST pump (on both sides).
3
(pump unit) Check the pump unit directly.
Malfunction of HST The neutral positions of the servo valves of the HST motors (on both sides) may be
4
pump (servo valve) adjusted wrongly. Check them directly.
Leakage in HST motor Oil may be leaking in the motor units of the HST motors (on both sides).
5
(motor unit) Check the motor units directly.
H-9 Engine stalls or engine speed lowers extremely during travel
Trouble • Engine stalls or engine speed lowers extremely during travel.

Related
information

troubleshooting.
Possible causes and
Malfunction of HST PCCS lever EPC valve output pressure

1
pump (EPC valve) F1 (Travel) 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
3
20-708 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING H-10
H-10 Abnormal sound comes out from around HST pump and motor
Trouble • Abnormal sound comes out from around HST pump and motor.
Related
information

Low oil level in hydraulic
The oil level in the hydraulic tank may be low or improper oil may be used.
1 tank or use of improper
Check the oil directly.
oil
Clogging of charge
2 The charge pump suction strainer may be clogged. Check it directly.
pump suction strainer
Loosening of charge
3 The charge pump suction piping may be loosened. Check it directly.
pump suction piping
5 Clogging of charge filter The charge filter may be clogged. Check it directly.
troubleshooting.
PCCS lever
3.04 ± 0.29 MPa
pump
Forward or reverse
Possible causes and
{29 ± 5 kg/cm2}
troubleshooting.
PCCS lever
3.04 ± 0.29 MPa
motor
Forward or reverse
{29 ± 5 kg/cm2}
Defect in HST pump
(pump unit)
Loosening of piping
The piping between the HST pump and HST motor may be loosened.
9 between HST pump and
Check it directly.
HST motor
Defect in HST motor The motor unit of the HST motor may have a defect in it. Check it directly.
10
(motor unit) Troubleshooting cannot be carried out since the defect is in the motor unit.
from HST pump
D31/37/39EX, PX-21 20-709

(1)
H-11 Work equipment dose not operate at all
Trouble • Work equipment dose not operate at all.

Related
information

1 Defect in rear damper The rear damper may have a defect in it. Check it directly.
troubleshooting.
Defective adjustment or PCCS lever and blade control lever HST charge circuit pressure
malfunction of HST
4 All levers in neutral 2.84 ± 0.49 MPa {29 ± 5 kg/cm2}
pump
(charge relief valve) If the oil pressure does not become normal after adjustment, the HST charge relief
valve may have a malfunction or a defect in it. Check the HST charge relief valve
Possible causes and
directly.
Malfunction of work
5 equipment PPC lock The work equipment PPC lock valve may be malfunctioning. Check it directly.
valve
6 Defect in front PTO The front PTO may have a defect in it. Check it directly.
Defect in work
7 The work equipment pump may have a defect in it. Check it directly.
equipment pump
Malfunction of control
8 The unload valve of the control valve may be malfunctioning. Check it directly.
valve (unload valve)
troubleshooting.
Defective adjustment or Blade control lever Work equipment pump relief pressure
9 malfunction of control Relieve blade circuit
valve (main relief valve) 17.6 MPa {180 kg/cm2}
(by lifting, tilting, or angling).
If the oil pressure does not become normal after adjustment, the main relief valve
may have a malfunction or a defect in it. Check the main relief valve directly.
20-710 D31/37/39EX, PX-21

(1)
H-12 Speed or power of whole work equipment is low
Trouble • Speed or power of whole work equipment is low.

Related
information

troubleshooting.
Defective adjustment or PCCS lever and blade control lever HST charge circuit pressure
malfunction of HST
3 All levers in neutral 2.84 ± 0.49 MPa {29 ± 5 kg/cm2}

pump
Possible causes and
(charge relief valve) If the oil pressure does not become normal after adjustment, the HST charge relief
valve may have a malfunction or a defect in it. Check the HST charge relief valve
directly.
Defect in work
4 The work equipment pump may have a defect in it. Check it directly.
equipment pump
Malfunction of control
5 The unload valve of the control valve may be malfunctioning. Check it directly.
valve (unload valve)
troubleshooting.
6 malfunction of control Relief of blade circuit
(by lifting, tilting, or angling)
D31/37/39EX, PX-21 20-711

(1)
H-13 Speed or power of lifting blade is low
Trouble • Speed or power of lifting blade is low.

Related
• Check that the blade has not been modified before carrying out troubleshooting.
information

troubleshooting.
Blade control lever PPC valve output pressure
Malfunction of boom
1
PPC valve (lift) Raising stroke end Min. 1.65 MPa {Min. 16.8 kg/cm2}
Lowering position Min. 1.37 MPa {Min. 14.0 kg/cm2}

Possible causes and
Floating stroke end Min. 2.01 MPa {Min. 21.0 kg/cm2}

Malfunction of blade lift
2 The spool of the blade lift control valve may be malfunctioning. Check it directly.
control valve (spool)
The pressure compensation valve of the blade lift control valve may be malfunction-
3 control valve (pressure
ing. Check it directly.
compensation valve)
The suction valve of the blade lift control valve may be malfunctioning.
4 control valve
Check it directly.
(suction valve)
Defect in blade lift troubleshooting.
5
cylinder Blade lift cylinder Leakage from cylinder
Relief by raising 6.5 cc/min
H-14 Speed or power of tilting blade is low
Trouble • Speed or power of tilting blade is low.

Related
information

troubleshooting.
Malfunction of boom
1 Blade control lever PPC valve output pressure

PPC valve (tilt)
Left tilting stroke end Min. 1.72 MPa {Min. 17.5 kg/cm2}
Possible causes and
Right tilting stroke end Min. 1.72 MPa {Min. 17.5 kg/cm2}
2 The spool of the blade lift control valve may be malfunctioning. Check it directly.
control valve (spool)
Malfunction of blade tilt
The pressure compensation valve of the blade tilt control valve may be
3 control valve (pressure
malfunctioning. Check it directly.
compensation valve)
Defect in blade tilt troubleshooting.
4
cylinder Blade tilt cylinder Leakage from cylinder
Relief by tilting left 6.5 cc/min
20-712 D31/37/39EX, PX-21

(1)
H-15 Speed or power of angling blade is low
Trouble • Speed or power of angling blade is low.

Related
information

troubleshooting.
Malfunction of boom Blade control lever PPC valve output pressure
1
PPC 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
2 angle control valve The spool of the blade angle control valve may be malfunctioning. Check it directly.
Possible causes and
(spool)
angle control valve The pressure compensation valve of the blade angle control valve may be
3
(pressure compensation malfunctioning. Check it directly.
valve)
The safety valve of the blade angle control valve may be malfunctioning.
4 angle control valve
Check it directly.
(safety valve)
The suction valve of the blade angle control valve may be malfunctioning.
5 angle control valve
Check it directly.
(suction valve)
Defect in blade angle troubleshooting.
6
cylinder Blade angle cylinder Leakage from cylinder
Relief by right or left angling 6.0 cc/min
D31/37/39EX, PX-21 20-713

(1)
TROUBLESHOOTING H-16, H-17, H-18
H-16 Time lag in lifting blade is large
Trouble • Time lag in lifting blade is large.

Related
information

causes and Malfunction of blade lift
standard value The suction valve of the blade lift control valve may be malfunctioning.
1 control valve
in normal state Check it directly.
(suction valve)
H-17 Hydraulic drift of lifting blade is large
Trouble • Hydraulic drift of lifting blade is large

Related
information

Defective seal of blade
Possible 1 The seal of the blade lift control valve may be defective. Check it directly.
lift control valve (spool)
causes and
a Prepare with engine stopped, then run engine at high idling and carry
standard value
Defective seal of blade out troubleshooting.
in normal state 2
lift cylinder Blade lift cylinder Leakage from cylinder
Relief by raising 6.5 cc/min
H-18 Hydraulic drift of tilting blade is large
Trouble • Hydraulic drift of tilting blade is large

Related
information

Defective seal of blade
Possible 1 The seal of the blade tilt control valve may be defective. Check it directly.
tilt control valve (spool)
causes and
a Prepare with engine stopped, then run engine at high idling and carry
standard value
Defective seal of blade out troubleshooting.
in normal state 2
tilt cylinder Blade tilt cylinder Leakage from cylinder
Relief by tilting left 6.5 cc/min
20-714 D31/37/39EX, PX-21

(1)
H-19 Abnormal sound comes out from around work equipment pump and
control valve
Trouble • Abnormal sound comes out from around work equipment pump and control valve.
Related
information

oil
Clogging of work
2 equipment pump The work equipment pump suction strainer may be clogged. Check it directly.
suction strainer
Looseness of work
Possible causes and
3 The work equipment suction piping may be loosened. Check it directly.

equipment suction piping
troubleshooting.
Defect in work equip- The pump unit of the work equipment pump may have a defect in it.
5
ment pump (pump unit) Check it directly.
Loosening of piping
The piping between the HST pump and HST motor may be loosened.
6 between HST pump and
Check it directly.
HST motor
D31/37/39EX, PX-21 20-715

(1)
H-20 HST oil temperature (Hydraulic oil temperature) rises too high
Trouble • HST oil temperature (Hydraulic oil temperature) rises too high
Related
information

oil
Clogging of hydraulic oil
2 The fins and cores of the hydraulic oil cooler may be clogged. Check them directly.
cooler
Malfunction of HST
3 motor The charge relief valve of the HST motor may be malfunctioning. Check it directly.
(charge relief valve)
troubleshooting.
Possible causes and
Malfunction of HST Monitor panel PCCS lever HST relief pressure

4 pump 39.2 – 45.1 MPa
(safety-suction valve) Forward
Stall pressure test mode {400 – 460 kg/cm2}
[3016] 39.2 – 45.1 MPa
Reverse
{400 – 460 kg/cm2}
Defect in HST pump
(pump unit)
troubleshooting.
valve (main relief valve) 17.6 MPa {180kg/cm2}
Defect in work equip- The pump unit of the work equipment pump may have a defect in it.
7
ment pump (pump unit) Check it directly.
20-716 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING OF ENGINE
(S MODE)
Method of using troubleshooting charts ...................................................................................................... 20-802
S-1 Starting performance is poor (Starting always takes time) ................................................................... 20-806
S-2 Engine does not start............................................................................................................................ 20-807
S-3 Engine does not pick up smoothly (Follow-up is poor) ......................................................................... 20-810
S-4 Engine stops during operations .............................................................................................................20-811
S-5 Engine does not rotate smoothly (Hunting) .......................................................................................... 20-812
S-6 Engine lacks output (or lacks power) ................................................................................................... 20-813
S-7 Exhaust smoke is black (Incomplete combustion) ............................................................................... 20-814
S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................................... 20-815
S-9 Oil becomes contaminated quickly ....................................................................................................... 20-816
S-10 Fuel consumption is excessive........................................................................................................... 20-817
S-11 Oil is in cooling water, or water spurts back, or water level goes down.............................................. 20-818
S-12 Oil pressure caution lamp lights up (Drop in oil pressure).................................................................. 20-819
S-13 Oil level rises (Water, fuel in oil) ......................................................................................................... 20-820
S-14 Water temperature becomes too high (Overheating) ......................................................................... 20-821
S-15 Abnormal noise is made..................................................................................................................... 20-822
S-16 Vibration is excessive ......................................................................................................................... 20-823
D31/37/39EX, PX-21 20-801

(1)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

This troubleshooting chart is divided into three sec-
tions: questions, check items, and troubleshoot-
ing.
The questions and check items are used to pinpoint
high probability causes that can be located from the
failure symptoms or simple inspection without using
troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation.
[Questions]
Sections (A) + (B) in the chart on the right corre-
sponds to the items where answers can be obtained
from the user. The items in (B) are items that can be
obtained from the user, depending on the user's Causes
level.
[Check items]
The serviceman carries out simple inspection to nar-
row down the causes. The items under (C) in the
chart on the right correspond to this.
The serviceman narrows down the causes from
(b) (2) (3)
information (A) that he has obtained from the user
and the results of (C) that he has obtained from his
own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of proba-
bility, starting with the causes that have been
marked as having the highest probability form infor-
(a)
mation gained from [Questions] and [Check
Questions
(A) (b)
items].
(c)
(d)
(B) (e)
Check items
(C)
i
shooting
Trouble-
ii
iii
20-802 D31/37/39EX, PX-21

(1)
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with Q, and of these, causes that have a high proba-
bility are marked with w.
Check each of the [Questions] are [Check items]
in turn, and marked the Q or w in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is the
most probable cause, so start troubleshooting for
that item to make final confirmation of the cause.
1. For [Confirm Section, ask repair history] in
the [Questions] Section, ask the user, and
mark the Cause column with E to use as Causes
reference for locating the cause of the fail-
ure. However, do not use this when marking
calculations to narrow down the causes.
tion)
2. Use the E in the Cause column as refer-
njec
ence for [Degree of use (Operated for long
i
period)] in the [Questions] section as refer-
sive
nce
ence.
zzle
xces
r
fere
r line
As a rule, do not use it when calculating be
n no
nt
p (e
leme
inter
included if necessary to determine the order
inde
g
o
pum
timin
t i
injec
for troubleshooting.
er e
ger,
, cyl
tion
ction
lean
char
ized
ring
injec
air c
r inje
, se
urbo
ton
ctive
n pis
ged
ged
rope
ed t
Defe
Clog
Clog
Seiz
Wor
Imp
1 Confirm recent repair history
2 Degree of use Operated for long period
D31/37/39EX, PX-21 20-803

(1)
• Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms
have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became
weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with five causes.
Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
S-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black
• Insufficient intake of air
Causes
• Improper condition of fuel injection
• Excessive injection of fuel
d)
ead
tion)
eize
nd h
injec
er s
er a
eat
lung
sive
harg
lve s
nce
ck, p
timin ozzle
xces
rboc
fere
e, va
nt
p (ra
p (e
nn
leme
n tu
inter
ance
er
f valv
g
uffle
r inje injectio
pum
pum
ylind
twee
er e
ger,
lear
dm
act o
c
tion
tion
ction
lean
ir be
char
lve c
gge
ring
ed
injec
injec
cont
Legend
, seiz
air c
of a
, clo
urbo
r va
ton
: Possible causes (judging from Questions and check items)
ctive
ctive
ctive
n pis
kage
hed
: Most probable causes (judging from Questions and Check items)
ged
rope
ged
rope
ed t
: Possible causes due to length of use (used for a long period)
Defe
Defe
Defe
Crus
Clog
Clog
Seiz
Wor
Lea
Imp
Imp
: Items to confirm the cause.
Confirm recent repair history
Degree of use Operated for long period
Suddenly became black
Color of exhaust gas Gradually became black
Questions
Blue under light load

Engine oil must be added more frequently
Suddenly
Power was lost
Gradually
Non-specified fuel has been used
Noise of interference is heard from around turbocharger
Dust indicator is red
Blow-by gas is excessive
Engine pickup is poor and combustion is irregular
When exhaust manifold is touched immediately after
starting engine, temperature of some cylinders is low
Check items
Match marks on fuel injection pump are out of alignment

Seal on injection pump has come off
Clanging sound is heard from around cylinder head
Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp
When turbocharger is rotated by hand, it is found to be heavy

When air cleaner is inspected directly, it is found to be clogged
When compression pressure is measured, it is found to be low
Speed of some cylinders does not change when operating
Troubleshooting
on reduced cylinders
When check is made using delivery method, injection timing
is found to be incorrect
Injection pump test shows that injection amount is incorrect
When valve clearance is checked directly it is found to be
outside standard value
When muffler is removed, exhaust gas color returns to normal
When control rack is pushed, it is found to be heavy or does
not return
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Adjust
Adjust
Adjust
Clean
Remedy
20-804 D31/37/39EX, PX-21

(1)
Five causes
Step 1
Clarify the relationship between the three

symptoms in the [Questions] and [Check items]
section and the five Causes items in the vertical
column.
Three symptoms
Step 2
Add up the total of and marks where the

horizontal lines for the three symptoms and the
vertical columns for the causes intersect.
(1) Clogged air cleaner element:
(2) Air leakage between turbocharger
and head:
(3) Clogged, seized injection nozzle:
(4) Defective contact of valve, valve seat:
(5) Worn piston ring, cylinder:
Step 3
The calculation in Step 2 shows that the closest

relationship is with [Clogged air cleaner
element]. Follow this column down to the
troubleshooting area and carry out the
troubleshooting item marked . The Remedy is
given as [Clean], so carry out cleaning, and the
exhaust gas color should return to normal.
D31/37/39EX, PX-21 20-805

(1)
TROUBLESHOOTING S-1
S-1 Starting performance is poor (Starting always takes time)
General causes why exhaust smoke comes out but engine takes time to start
• Defective electrical system
• Insufficient supply of fuel
• Improper selection of fuel
(At ambient temperature of –10°C or below, ASTM
D975 No. 2 diesel fuel is used)
a Battery charging rate
Causes
Charging rate
Ambient 100% 90% 80% 75% 70%
k)
temperature
stuc
20°C 1.28 1.26 1.24 1.23 1.22
nger
0°C 1.29 1.27 1.25 1.24 1.23
, plu
eat
tank
el
–10°C 1.30 1.28 1.26 1.25 1.24
ing
canc
lve s
(rack
el pip
ry
fuel
batte
• The specific gravity should exceed the value
le
e, va
ator
g
t
nozz
le in
ump
r
men
in fu
aine
timin
er
r
for the charging rate of 70% in the above table.
e
der
pens
rated
f valv
heat
in
er ho
p
er ele
p str
tion
, stra
cylin
g, air
• In cold areas the specific gravity must exceed
tion
tion
p
t com
terio
r
pum
e air
act o
injec
tor
nato
reath
pum
injec
injec
filter
lean
the value for the charging rate of 75% in the
ggin
ing,
egula
or de
boos
intak
alter
feed
cont
fuel
air b
ton r
feed
air c
above table.
lo
fuel
fuel
fuel
c
r
ctive
ctive
ctive
ctive
ctive
ctive
ctive
ctive
age,
n pis
ged
tive
tive
ged
ged
ged
Leak
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Clog
Clog
Clog
Clog
Wor

Degree of use of machine Operated for long period
Gradually became worse
Ease of starting
Starts when warm
Questions
Preheating monitor does not light up

Replacement of filters has not been carried out according to operation
Manual
Non-specified fuel has being used
Air cleaner clogging monitor lights up
Battery charge monitor is ON
Starting motor cranks engine slowly
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low
Engine does not pick up smoothly, and combustion is irregular
Check items

Timing lock on fuel injection pump does not match
Mud is stuck to fuel tank cap
When engine is cranked with starting motor,
1) Little fuel comes out even when fuel injection pump piping sleeve nut is
loosened
2) Little fuel comes out even when fuel filter air bleed plug is loosened
Leakage from fuel piping
There is hunting from engine (rotation is irregular)

When air cleaner element is inspected directly, it is found to be clogged
When fuel filter, strainer are inspected directly, they are found to be clogged
When feed pump strainer is inspected directly, it is found to be clogged
Troubleshooting
Heater mount does not become warm

Is voltage 20 26 V between alternator terminal B and terminal E Yes
with engine at low idling? No
Either specific gravity of electrolyte or voltage of battery is low
Speed does not change when operation of certain cylinders is stopped
When control rack is pushed, it is found to be heavy or does not return
(check after removing fuel injection pump)
When fuel tank cap is inspected directly, it is found to be clogged
Adjust (*1)
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
Clean
Clean
Clean
Clean
*1. Use a test stand when adjusting.
20-806 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING S-2
S-2 Engine does not start
(1) Engine does not turn
General causes why engine does not turn Causes

• Seizure inside engine
a For seizure inside the engine,
carry out the troubleshooting for
S-4 Engine stops during opera-
tion.
n
• Hydraulic pump system error
ectio
• Defective electrical system
it
ttery
circu
conn
d ba
ting
inal
ch
otor
e
star
lay
t
term
swit
iora
lay
ng m
r y re
ty re
g of
eter
ting
ery
ear
atte
tarti
wirin
safe
or d
star
batt
ing g
b
s
ctive
ctive
ctive
ctive
ctive
ctive
ctive
en r
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Brok
Questions

Condition of horn when Horn does not sound
starting switch is turned ON Horn volume is low
Speed of rotation is low
When starting switch is Makes grating noise
turned to START, pinion Soon disengages pinion again
moves out, but
Makes rattling noise and does not turn
Check items
When starting switch is turned to START, pinion does not move out
Troubleshooting of defective wiring in starting circuit
When starting switch is turned to ON, there is no clicking sound

Battery terminal is loose
When battery is checked, battery electrolyte is found to be low
Specific gravity of electrolyte, voltage of battery is low

For the following conditions 1) - 4), turn the starting switch OFF,
connect the cord, and carry out troubleshooting
1) When terminal B and terminal C of starting switch are
Troubleshooting
connected, engine starts

2) When terminal B and terminal C of starting motor are
connected, engine starts
3) When terminal B and terminal C of safety relay are connected,
engine starts
4) There is no 24V between battery relay terminal BR and
terminal E
When ring gear is inspected directly, tooth surface is found to be
chipped
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
D31/37/39EX, PX-21 20-807

(1)
TROUBLESHOOTING S-2
(2) Engine turns but no exhaust smoke comes out (Fuel is not being injected)
General causes why engine turns but not exhaust smoke Causes
comes out
• Supply of fuel impossible
• Supply of fuel extremely small
d)
eize
• Improper selection of fuel (particularly in winter)
er s
Selection of fuel according to
nk
lung
t, ke
ambient temperature
el ta
Type of fuel
n
ck, p
shaf
pisto
–22 –4 –14 32 50 68 86 104°F
n fu
–30 –20 –10 0 10 20 30 140°C
p (ra
er
g
drive
ole i
pipin
r
ump
train
n e
ASTM D975 No.2
pum
er h
a
tank
ump
s
, str
fuel
Diesel oil
eed
d
h
m
tion
on p
ASTM D975A
l use
filter
reat
el in
king
u
No.1
en f
p
injec
air b
jecti
feed
nt fu
r fue
, lea
fuel
brok
ctive
en in
fficie
ged
ged
ged
ged
rope
ed,
Defe
Clog
Clog
Clog
Clog
Brok
Seiz
Insu
Imp
Questions

Exhaust smoke suddenly stops coming out (when starting again)
Replacement of filters has not been carried out according to
Operation Manual
Fuel tank is found to be empty
There is leakage from fuel piping
When fuel filter is drained, fuel does not come out
Check items

1) No fuel comes out even when fuel filter air bleed plug is
loosened
2) No fuel spurts out even when fuel injection pump piping sleeve
nut is loosened
Rust and water are found when fuel tank is drained
Inspect injection pump directly

When control rack is pushed, it is found to be heavy, or does not
Troubleshooting
return
Inspect feed pump directly
When fuel filter, strainer are inspected directly, they are found to be
clogged
When feed pump strainer is inspected directly, it is found to be
clogged
When fuel cap is inspected directly, it is found to be clogged
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Remedy
Add
20-808 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING S-2
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected)
General causes why exhaust smoke comes out but Causes

engine does not start
c.)
• Lack of rotating force due to defective electrical
r, et
system
leve
uck)
cker
y
spra
t
cap
e, ro
• Improper selection of fuel and oil
er s
tive
lung
tank
em
(valv
efec
syst
ck, p
ery
fuel
le, d
stem
er
batt
fuel
n
nt
p (ra
iner
le in
i
nozz
l
r
leme
er
e sy
e
der
ted
ir in
t
rain
stra
r ho
hea
pum
valv
iora
tion
er e
g, a
i
r, st
, cyl
e
mp
e air
d
h
tion
eter
injec
l use
lean
ken
reat
ggin
e
u
ring
t
p
ntak
l
injec
or d
f
, bro
feed
air b
air c
, clo
r fue
fuel
fuel
ton
i
ctive
ctive
ctive
ctive
n pis
kage
ged
ged
ged
ged
ged
rope
Defe
Defe
Defe
Clog
Defe
Clog
Clog
Clog
Clog
Wor
Lea
Imp
Suddenly failed to start
Questions
When engine is cranked, abnormal noise is heard from around cylinder

head
Non-specified fuel is being used
Replacement of filters has not been carried out according to Operation
Manual
Preheating monitor does not light up
Starting motor cranks engine slowly
When fuel lever is placed at FULL position, it does not contact stopper
Check items
1) Little fuel comes out even when injection pump piping sleeve nut is
loosened
2) No fuel comes out even when fuel filter air bleed plug is loosened
When fuel filter is drained, no fuel comes out
Remove head cover and check directly

When control rack is pushed, it is found to be heavy, or does not return
clogged
Troubleshooting
When feed pump strainer is inspected directly, it is found to be clogged

When air cleaner element is inspected directly, it is found to be clogged
Heater mount does not become warm
Either specific gravity of electrolyte or voltage of battery is low
When feed pump is operated, there is no response, or operation is
too heavy
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
D31/37/39EX, PX-21 20-809

(1)
TROUBLESHOOTING S-3
S-3 Engine does not pick up smoothly (Follow-up is poor)
General causes why engine does not pick up smoothly Causes

y
spra
• Improper fuel used
ap
seat
tive
nk c
alve
efec
ger
el ta
nce
nd v
plun
le, d
in fu
r
fere
r line
nt
g
iner
ve a
nozz
pipin
mp
leme
iner
inter
nce
hole
inde
st ra
n pu
f val
st ra
a
tion
er e
fuel
ger,
lear
her
, cyl
ump
act o
jectio
ilter,
injec
lean
char
reat
king
lve c
ring
ed p
cont
uel f
uel in
air c
air b
, lea
urbo
fuel
r va
ton
e
f
f
ctive
n pis
ged
ged
rope
ged
ged
ged
ed f
ed t
ged
Clog
Defe
Clog
Clog
Clog
Clog
Seiz
Seiz
Clog
Wor
Imp
Questions
Operation Manual
Engine pick-up suddenly became poor
Color of exhaust gas
Black
Check items

High idling speed under no load is normal, but speed suddenly
drops when load is applied
When air cleaner element is inspected directly, it is found to be

clogged
clogged
clogged
Troubleshooting
Speed does not change when operation of certain cylinders is

stopped
When valve clearance is checked directly, it is found to be outside
standard value
When feed pump is operated, operation is too light or too heavy
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
20-810 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING S-4
S-4 Engine stops during operations
General causes why engine stops during operations Causes

• Seized parts inside engine
c. )
r, et
)
• Overheating
tuck
leve
a If the engine is overheating and
er s
cker
the engine stops, carry out trou-
lung
e, ro
bleshooting for overheating.
od
nk
ck, p
valv
ing r
el ta
(See S-14 Water temperature
key
t
stem
ton
arin
p (ra
m (
ipme
becomes too high)
nect
in fu
p pis
,
t be
f t
p sy
r
g
yst e
m
a
aine
• Failure in hydraulic pump
equ
pipin
r
e sh
, con
n pu
aine
hole
shaf
pum
in
pum
s
a If the machine stops because of
r t ra
p str
tank
ary
v
e
o
iston
, st r
fuel
rank
her
valv
i
eed
d
t
the failure in hydraulic pump, carry
gea
uxili
injec
aulic
pum
mp
filter
el in
reat
king
ed c
ed p
ed f
c
out troubleshooting for H-mode.
a
i
ized
u
ynam
hydr
fuel
air b
feed
uel p
ump
nt fu
, lea
fuel
seiz
seiz
seiz
ctive
s
re in
en p
fficie
en d
en f
ged
ged
ged
ged
en,
en,
en,
en,
Failu
Defe
Brok
Brok
Clog
Clog
Clog
Clog
Brok
Brok
Brok
Brok
Brok
Insu
Abnormal noise was heard and
engine stopped suddenly
Condition when engine
Questions
Engine overheated and stopped

stopped
Engine stopped slowly
There was hunting and engine stopped
Operation Manual
Fuel level lamp lights up
Engine rotates, but stops when work equipment and travel
Check items
levers are operated

Does not turn at all
When it is attempted Turns in opposite direction
to turn by hand using
barring tool Moves amount of backlash
Carry out troubleshooting for H-mode
Shaft does not turn

Metal particles are found when oil is drained
Remove oil pan and inspect directly

Remove head cover and inspect directly
When gear train is inspected, it does not turn
Troubleshooting
Rotates when pump auxiliary equipment is removed

When fuel filter, strainer are inspected directly, they are found
to be clogged
When feed pump strainer is inspected directly, it is found
to be clogged
Inspect feed pump directly
When control rack is pushed, it is found to be heavy, or does
not return
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
Add
D31/37/39EX, PX-21 20-811

(1)
TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly (Hunting)
General causes why engine does not rotate smoothly Causes

• Air in fuel system
p
pum
• Defective governor mechanism
zzle
• Defective electronical governor mechanism
d no
feed
a If hunting stops when governor spring is dis-
p an
and
connected, carry out troubleshooting for the
pum
tank
troubleshooting for E-mode.
nk
feed
el ta
fuel
ck
or
a
rnor
vern
rol r
in fu
een
een
r
gove
aine
f go
w
cont
betw
betw
iner
hole
oo lo
p st r
nt o
st ra
tank
n of
n of
rcuit
cuit
her
t
stme
pum
lter,
ratio
ratio
r
el in
reat
in ci
in ci
eed
i
adju
uel f
ope
ope
feed
air b
nt fu
g sp
, air
, air
f
ctive
ctive
ctive
fficie
idlin
ged
ged
ged
ged
ged
Clog
Defe
Clog
Clog
Clog
Clog
Defe
Defe
Insu
Low
Occurs at a certain speed range
Questions
Occurs at low idling

Condition of hunting
Occurs even when speed is raised
Occurs on slopes
Operation Manual
Rust, water are found when fuel tank is drained
When feed pump is operated,
Check items
1) No response, light, return is quick

2) No response, light, return is normal
Engine speed sometimes rises too far
Engine is sometimes difficult to stop
When governor lever is moved it is found to be stiff

When injection pump is tested, governor is found to be improperly
adjusted
Troubleshooting

return
clogged
clogged
Correct
Correct
Adjust
Adjust
Adjust
Adjust
Clean
Clean
Clean
Remedy
Add
20-812 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING S-6
S-6 Engine lacks output (or lacks power)
General causes why engine lacks output Causes

y
spra
t
men
eat
ragm
(if non-specified fuel is used, output drops)
tive
t
lve s
djus
nk
• Lack of output due to overheating
efec
iaph
el ta
er
ce
ve a
d va
a If there is overheating and lack of output,
g
e, d
or d
eren
in fu
p plu
fecti
e an
carry out troubleshooting for S-14 over-
nt
iping
r
ozzl
nsat
aine
f
iner
leme
inter
hole
ance
r
pum
heating.
e
inde
valv
g, d
on n
uel p
mpe
p st r
st ra
er e
ger,
her
lear
, cyl
tion
prin
t of
jecti
st co
pum
ing f
ter,
reat
lean
char
ntac
lve c
njec
ring
or s
el in
il
boo
f
air b
feed
air c
, lea
urbo
fuel
o
vern
uel i
r va
ton
c
f u
ctive
ctive
n pis
ged
ged
ged
ged
rope
ged
ged
ed f
ed t
t go
Defe
Defe
Clog
Clog
Clog
Clog
Clog
Clog
Seiz
Seiz
Ben
Wor
Imp
Suddenly
Power was lost
Questions
Gradually
Operation Manual
Black
Check items
High idling speed under no load is normal, but speed suddenly

drops when load is applied
When exhaust manifold is touched immediately after starting
engine, temperature of some cylinders is low
High idling speed of engine is low

clogged
clogged
Troubleshooting

clogged
stopped
return
When valve clearance is checked directly, it is found to be outside
standard value
When fuel dial is placed at FULL position, lever does not contact
stopper
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
D31/37/39EX, PX-21 20-813

(1)
TROUBLESHOOTING S-7
S-7 Exhaust smoke is black (Incomplete combustion)
General causes why exhaust smoke is black Causes

ld
anifo
on)
d)
jecti
em
eize
ve in
intak
at
er s
e se
essi
lung
ger
timin ozzle
valv
(exc
char
nce
ck, p
on n
d
liner
fere
urbo
e an
ump
g
nt
p (ra
jecti
leme
inter
ance
der
ffler
t
valv
on p
pum
el in
twee
ction
cylin
u
er e
ger,
lear
dm
jecti
t of
u
tion
lean
ir be
l inje
f
char
ntac
lve c
gge
ring
n
zed
injec
fuel
air c
of a
r fue
, clo
o
urbo
, sei
r va
ton
c
ctive
ctive
ctive
n pis
kage
hed
ged
rope
ged
rope
ed t
Defe
Defe
Defe
Crus
Clog
Clog
Seiz
Wor
Lea
Imp
Imp
Suddenly became black
Color of exhaust gas Gradually became black
Questions

Suddenly
Power was lost
Gradually
When exhaust manifold is touched immediately after starting engine
Check items
Timing lock on fuel injection pump does not match

Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp

clogged
Troubleshooting

stopped
When check is made using delivery method, injection timing is
found to be incorrect
When valve clearance is checked directly it is found to be outside
standard value
When muffler is removed, exhaust color returns to normal
return
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Adjust
Clean
Remedy
20-814 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING S-8
S-8 Oil consumption is excessive (or exhaust smoke is blue)
a Do not run the engine at idling for more than 20 Causes

minutes continuously. (Both low and high idling)
rger
General causes why oil consumption is excessive
ocha
• Abnormal combustion of oil
Turb
• External leakage of oil
seal
d
• Wear of lubrication system
hea
c e
stem
hose
a
er
ken
r f
der
cool
al su
r
, bro
r line
e sy
r
cylin
e
plug
r oil
h
l, se
t
intak
ide)
brea
nde
d
nd
r
n
er o
iping
an o
a
rain
ine e
er e
, gu
e
, cyli
ar s
om
r or
il filt
oil d
oil p
oil p
blow
ring
stem
turb
in fr
oler
e
ring
n re
o
t h
from
rom
from
m
iston
brea
il co
al at
lve (
al at
ked
roke
ton
r o
f
f
en o
n pis
t suc
en p
kage
kage
kage
n se
kage
n va
n se
ged
n, b
Brok
Clog
Brok
Wor
Wor
Wor
Wor
Wor
Dus
Lea
Lea
Lea
Lea
Questions
Oil consumption suddenly increased

Engine oil becomes contaminated quickly
Exhaust smoke is blue under light load
Excessive
Amount of blow-by gas
None
Area around engine is dirty with oil
There is oil in engine cooling water
Check items
When exhaust pipe is removed, inside is found to be dirty

with oil
When turbocharger air supply pipe is removed, inside is
found to be dirty with oil
Oil level in damper chamber rises
Clamps for intake system are loose

When breather element is inspected, it is found to be clogged
with dirty oil
Troubleshooting
There is external leakage of oil from engine

Pressure-tightness test of oil cooler shows there is leakage
Excessive play of turbocharger shaft
Inspect rear seal directly
When intake manifold is removed, dust is found inside
When intake manifold is removed, inside is found to be dirty
with oil
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
D31/37/39EX, PX-21 20-815

(1)
TROUBLESHOOTING S-9
S-9 Oil becomes contaminated quickly
General causes why oil becomes contaminated quickly Causes

• Entry of exhaust gas due to internal wear
• Clogging of lubrication passage
• Improper oil used
end
• Operation under excessive load
bine
be
r tur
n tu
se
r ho
r
r line
e
drai
harg
athe
r oil
inde
ide
k
rboc
blac
, bre
arge
e gu
, cyl
at tu
r
ke is
ther
oole
boch
valv
ring
lter
seal
brea
smo
oil c
oil fi
ton
r
lve,
t u
ctive
n pis
ged
ged
ged
n va
ged
aust
Defe
Clog
Clog
Clog
Clog
Wor
Wor
Exh
Questions

Non-specified oil is being used
Black
Carry out troubleshooting for S-7 Exhaust smoke is black .

Excessive
Amount of blow-by gas
Check items
None
When oil filter is inspected, metal particles are found
When exhaust pipe is removed, inside is found to be dirty with oil
Engine oil temperature rises quickly

When breather element is inspected directly, hose is broken or is
Troubleshooting
found to be clogged with dirty oil

When oil filter is inspected directly, it is found to be clogged
When oil cooler is inspected directly, it is found to be clogged
Turbocharger oil drain tube is clogged
Excessive play of turbocharger shaft
When safety valve is directly inspected, spring is found to be
catching or broken
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
20-816 D31/37/39EX, PX-21

(1)
TROUBLESHOOTING S-10
S-10 Fuel consumption is excessive
General causes why fuel consumption is excessive Causes

• Leakage of fuel
tion)
injec
on)
y
r
l filte
spra
sive
g
(pist
prin
, fue
r
lder
nge
xces
ump
or s
r
cove
le ho
iping
u
p (e
vern
p
ed p
g
ump
uel p
nozz
imin
pum
ead
f go
e fe
p
ide h
on t
nt o
tion
n
tion
nsid
from
ectio
jecti
stme
injec
l ins
injec
eal i
age
n j
el in
f fue
i
adju
oil s
fuel
fuel
fuel
leak
f u
o
ctive
ctive
ctive
ctive
ctive
ctive
kage
rnal
Defe
Defe
Defe
Defe
Defe
Defe
Exte
Lea
Questions

More than for other machines of same
Condition of fuel model
consumption Gradually increased
Suddenly increased
Black
Exhaust smoke color
White
There is irregular combustion
Check items

Timing lock on fuel injection pump is misaligned
There is external leakage of fuel from engine
Engine oil level rises and smells of diesel fuel
Engine low idling and high idling speeds are high
Injection pump measurement shows that injection amount is excessive

Troubleshooting

When check is made using delivery method, fuel injection timing is
found to be incorrect
Remove feed pump and inspect directly
When engine speed is measured, low idling and high idling speeds
are found to be high
Replace
Replace
Correct
Correct
Correct
Adjust
Adjust
Adjust
Remedy
D31/37/39EX, PX-21 20-817

(1)
S-11 Oil is in cooling water, or water spurts back, or water level goes down
General causes why oil in cooling water Causes

• Internal leakage in lubrication system
• Internal leakage in cooling system
sket
k
d ga
bloc
ring
oler
hea
, O-
der
itting
il co
cylin
core
ad,
lic o
r he
by p
ks in
oler
linde
drau
used
il co
crac
y
y
en o
en h
en c
s ca
rnal
Brok
Brok
Hole
Brok
Inte
Questions

Suddenly increased
Oil level
Gradually increased
Hard water is being used as cooling water
Engine oil level has risen, oil is cloudy white
Check items
Excessive air bubbles inside radiator, spurts back

Hydraulic oil, transmission oil is cloudy white
When hydraulic oil, transmission oil is drained, water is found

shooting
Trouble-
Pressure-tightness test of cylinder head shows there is leakage

Replace
Replace
Replace
Replace
Replace
Remedy
20-818 D31/37/39EX, PX-21

(1)
S-12 Oil pressure caution lamp lights up (Drop in oil pressure)
General causes why oil pressure lamp lights up

• Leakage, clogging, wear of lubricating system
• Defective oil pressure control Causes
• Improper oil used (improper viscosity)
• Deterioration of oil due to overheating
a Standards for engine oil selection

Selection of oil according to
Type of
ambient temperature
fuel
g
pipin
–30 –20 –10 0 10 20 30 140°C
pan
or
il pa
g
SAE30CD
sens
aulic
azin
e oil
r
e
uctio nside o
enso
valv
Engine SAE10WCD
e br
hydr
ure
insid
l
urna
e
an
v
oil
vel s
lator
ump
SAE10W-30CD
ress
n pip
f val
shed
oil p
ipe i
g, jo
iner
n oil
lter
oil le
regu
relie
oil p
oil p
SAE15W-40CD
oil p
oil fi
stra
il in
, cru
arin
uel i
ctive
ctive
ctive
ctive
ctive
of o
en s
n be
ged
ged
ged
king
er, f
Defe
Defe
Defe
Defe
Defe
Lack
Brok
Clog
Clog
Clog
Wor
Wat
Lea
Questions
Replacement of filters has not been carried out according

to Operation Manual
Oil pressure monitor lights up
Lights up at low idling
Condition when oil Lights up at low, high idling
pressure lamp lights up
Lights up on slopes
Sometimes lights up
Check items
There is crushing, leakage from hydraulic piping (external)

Oil level monitor lights up
When oil level in oil pan is inspected, it is found to be low
Metal particles are stuck to oil filter element
Oil is cloudy white or smells of diesel oil
When oil filter is inspected, it is found to be clogged

for S-13 Oil level rises .
Carry out troubleshooting

Troubleshooting
Oil pump rotation is heavy, there is play

There is catching of relief valve or regulator valve, spring
or valve guide is broken
Oil pressure monitor goes OFF when oil level sensor
is replaced
When oil pressure is measured, it is found to be within
standard value
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
Add
D31/37/39EX, PX-21 20-819

(1)
S-13 Oil level rises (Water, fuel in oil)
a If there is oil in the cooling water, carry out trou- Causes

bleshooting for “S-11 Oil is in cooling water, or
water level goes down”.
over
General causes why oil level rises
ad c
seal
• Water in oil (milky white)
m p
e he
u
• Fuel in oil (diluted, and smells of diesel fuel)
ent
p
et
tion
e
gask
insid
uipm
• Entry of oil from other component
rfac
eve
njec
ring
k
y eq
d
iping
s
r sle
bloc
hea
uel i
, O-
seal
r
e
a
mp
ad,
der
core
itting
f
ld
li
rear
stat
e
auxi
le ho
insid
l f ro
r he
cylin
by p
rmo
oler
ged
p
f fue
nozz
linde
pum
part
side
e
il co
ama
e
h
d
o
t
y
s ma
ctive
ctive
ctive
ks in
ctive
en o
en c
kage
n, d
Defe
Defe
Defe
Hole
Brok
Defe
Crac
Brok
Wor
Lea
Questions

There is oil in radiator cooling water
Fuel must be added more frequently
Exhaust smoke is white
When engine is first started, drops of water come from muffler
Leave radiator cap open. When engine is run at idling, an abnormal
number of bubbles appear, or water spurts back
Check items
Oil level goes down in damper chamber

Oil level goes down in hydraulic tank
Engine oil smells of diesel fuel
Water temperature is low

Pressure-tightness test of cylinder head shows there is leakage
Troubleshooting
Inspect rear seal directly

When pump auxiliary equipment is removed, seal is found to be
damaged
Remove fuel injection pump and inspect directly
Defective contact with thermostat seal valve
Remove oil pan and check directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
20-820 D31/37/39EX, PX-21

(1)
S-14 Water temperature becomes too high (Overheating)
General causes why water temperature becomes too high Causes

• Lack of cooling air (deformation, damage of fan)
• Drop in heat dissipation efficiency
• Defective cooling circulation system
• Oil temperature of hydraulic pump system goes exce-
sively high
h
o hig
en)
a Carry out troubleshooting for H-mode.
ge
sket
t op
re to
y
gau
pulle
d ga
s no
ins
ratu
ture
tor f
hea
fan
ler
(doe
mpe
lve
pera
o
radia
worn
il co
,
e va
core
g
ead
r
oil te
stat
wate
pittin
r tem
p
pum
o
shed
er h
ssur
o
ing,
ator
ken
m
mp
ling
e by
wate
ther
ylind
ater
slipp
e
, bro
radi
, cru
ic pu
r
o
d
of co
en w
s ma
ctive
ctive
ctive
en c
ged
ged
ged
belt
raul
Lack
Defe
Brok
Brok
Defe
Clog
Defe
Hole
Clog
Clog
Hyd
Fan
Suddenly overheated
Questions
Condition of overheating
Always tends to overheat
Water temperature Rises quickly
gauge Does not go down from red range
Radiator water level sensor lights up
Fan belt whines under sudden load
Cloudy white oil is floating on cooling water
Cooling water flows out from overflow hose
Excessive air bubbles inside radiator, water spurts back
Engine oil level has risen, oil is cloudy white
Check items
There is play when fan pulley is rotated

Radiator shroud, inside of underguard are clogged with dirt
or mud
When light bulb is held behind radiator, no light passes through
Water is leaking because of cracks in hose or loose clamps
When belt tension is inspected, it is found to be loose
Power train oil temperature enters red range faster than engine
water temperature
Temperature difference between top and bottom radiator tanks

Carry out troubleshooting for H-mode
is excessive
Temperature difference between top and bottom radiator tanks
is slight
When water filler port is inspected, core is found to be clogged
Troubleshooting
When function test is carried out on thermostat, it does not

open even at cracking temperature
When water temperature is measured, it is found to be normal
When oil cooler is inspected directly, it is found to be clogged
When measurement is made with radiator cap tester, set
pressure is found to be low
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Add
D31/37/39EX, PX-21 20-821

(1)
S-15 Abnormal noise is made
a Judge if the noise is an internal noise or an external noise. Causes
ifold
e)
c.)
General causes why abnormal noise is made
ngin
r, et
man
n)
d)
• Abnormality due to defective parts
tion)
ss e
sitio
eize
leve
take
• Abnormal combustion
f po
c
erle
er s
ker
• Air sucked in from intake system
nd in
ve in
ut o
r (lin
ung
, roc
ance
er a
rd o
essi
k, pl
inde
alve
zzle
lear
e
g
boa
c
renc
nce
(rac
r
, cyl
m (v
a
n no
p (e
lve c
boch
fere
ding
erfe
ring
ash
ump
yste
ectio
pum
of va
r
inter
u
(divi
lt int
ackl
iston
on p
t
lve s
g
j
een
tion
n
n
i
ushi
ain b
n be
ent
ger,
fler
fuel
jecti
of p
betw
ic va
injec
justm
muf
ed b
char
n, fa
ar tr
ized
el in
ear
ynam
of air
fuel
side
seiz
urbo
d
d fa
r ge
ve w
e
u
a
s
f
ctive
ctive
ctive
en d
ct in
,
rme
age
rope
ged
ed t
ing,
essi
Defe
Leak
Defe
Defe
Defo
Defe
Brok
Clog
Miss
Seiz
Imp
Exc
Questions
Condition of abnormal Gradually occurred

noise Suddenly occurred
Black
Metal particles are found in oil filter
Engine pickup is poor and combustion is abnormal
Check items
When exhaust manifold is touched immediately after starting

engine, temperature of some cylinders is low
Seal on fuel injection pump has come off
Abnormal noise is loud when accelerating engine
Leakage of air between turbocharger and cylinder head, loose
clamp
Vibrating noise is heard from around muffler

Remove gear cover and inspect directly
Troubleshooting
stopped
When control rack is pushed, it is found to be heavy, or does
not return
Fan is deformed, belt is loose
When valve clearance is checked, it is found to be outside
standard value
Remove cylinder head cover and inspect directly
When muffler is removed, abnormal noise disappears
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
20-822 D31/37/39EX, PX-21

(1)
S-16 Vibration is excessive
a If there is abnormal noise together with the Causes

vibration, carry out troubleshooting also for
k)
“S-15 Abnormal noise is made”.
stuc
etc.
tion)
General causes why vibration is excessive
ver,
injec
• Defective parts (abnormal wear, breakage)
er le
ligne
ion
• Improper alignment
fuel
rock
cush
misa
• Abnormal combustion
sive
lve,
ken
mp
xces
ng
va
ic pu
, bro
(
eari
p (e
e m
raul
ain b
bolts
ash
syst
pum
r
mpe
d
ackl
y
d, m
e
ting
valv
tion
e da
ain b
and
oun
g ro
injec
g
mic
ushin
nsid
e
ar tr
em
ectin
dyna
i
fuel
g
art i
f en
ngin
r ge
mb
conn
ctive
ctive
en p
ter o
n ca
rope
se e
n
Defe
Defe
Brok
Wor
Wor
Cen
Loo
Imp
Questions
Suddenly increased
Condition of vibration
Gradually increased
Metal particles are found in oil filter
Oil pressure is low at low idling
Check items
Vibration occurs at mid-range speed

Vibration follows engine speed
Exhaust smoke is black
Seal on fuel injection pump has come off

Remove side cover and inspect directly
Troubleshooting
Inspect directly for loose engine mounting bolts, broken cushion

Inspect inside of damper directly
When face runout and radial runout are inspected, they are found to
be incorrect
Remove front cover and inspect directly
Remove fuel head cover and inspect directly
Fuel injection pump test shows that fuel injection amount is incorrect
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
D31/37/39EX, PX-21 20-823

(1)
30 DISASSEMBLY AND ASSEMBLY
How to read this manual ................................. 30- 2 Disassembly and assembly of recoil spring
Coating materials list....................................... 30- 4 assembly ....................................................30-49
Special tool list ................................................ 30- 6 Disassembly and assembly of idler
Sketches of special tools ................................ 30- 8 assembly ....................................................30-52
Removal and installation of fuel injection Disassembly and assembly of track roller
pump assembly ......................................... 30- 9 assembly ....................................................30-55
Removal and installation of cylinder head Disassembly and assembly of carrier roller
assembly ................................................... 30-13 assembly ....................................................30-59
Removal and installation of Removal and installation of HST pump
engine front seal ........................................ 30-20 assembly ....................................................30-61
Removal and installation of Removal and installation of idler and recoil spring
engine rear seal ......................................... 30-23 assembly ....................................................30-63
Removal and installation of radiator guard Disassembly and assembly of main control
assembly ................................................... 30-25 valve assembly...........................................30-66
Disassembly and assembly of radiator, Removal and installation of blade assembly....30-74
oil cooler, and charge air cooler Disassembly and assembly of hydraulic
assemblies................................................. 30-28 cylinder assemblies ....................................30-76
Removal and installation of engine and Removal and installation of operator’s seat
HST pump assembly ................................. 30-32 frame assembly ..........................................30-79
Removal and installation of damper................ 30-35 Removal and installation of fuel tank
Spreading and installation of track shoe assembly ....................................................30-83
assembly ................................................... 30-36 Removal and installation of hydraulic tank
Removal and installation of HST motor and assembly ....................................................30-84
final drive assembly ................................... 30-38 Removal and installation of HST controller
Disassembly and assembly of final drive assembly ....................................................30-86
assembly ................................................... 30-40
Removal and installation of idler and
recoil spring assembly ............................... 30-48
D31/37/39EX, PX-21 30-1

(5)
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
HOW TO READ THIS MANUAL

1. Removal and installation of assemblies
Special tools Removal

• Special tools which are deemed necessary • The “Removal” section contains procedures and
for removal or installation of parts are de- precautions for implementing the work, know-
scribed as A1,•••X1 etc. and their part how and the amount of oil or coolant to be
names, part numbers and quantities are de- drained.
scribed in the special tool list. • General tools that are necessary for removal are
• Also the following information is described in described as [1], [2]•••etc. and their part names,
the special tool list. part numbers and quantities are not described.
1) Necessity • Various symbols used in the “Removal” section
t : Special tools that cannot be substituted are explained and listed below.
and should always be used (installed). k : This mark indicates safety-related precau-
q : Special tools that will be useful if avail- tions that must be followed when imple-
able and are substitutable with com- menting the work.
mercially available tools. a : Know-how or precautions for work
2) Distinction of new and existing special tools [*1] : This mark shows that there are instructions or
N : Tools newly developed for this precautions for installing parts.
6: This mark shows the amount of oil or coolant
model. They respectively have a
new part number.
to be drained.
4: Weight of part or component
R : Tools with upgraded part numbers.
They are remodeled from already
available tools for other models.
Blank: Tools already available for other
models. They can be used without Installation
any modification. • Except where otherwise instructed, installation
3) Circle mark Q in sketch column: of parts is done in the reverse order of removal.
• The sketch of the special tool is present- • Instructions and precautions for installing parts
ed in the section of “Sketches of special are shown with [*1] mark in the “Installation”
tools”. section, identifying which step the instructions
• This mark means part No. of special are intended for.
* *** ****
tools starting with 79 T- -
and that they can not be supplied from
• General tools that are necessary for installation
are described as [1], [2]•••etc. and their part
Komatsu in Japan (i.e. locally made names, part numbers and quantities are not
parts). described.
• Marks shown in the “Installation” section stand
for the following.
k : Precautions related to safety in execution of
work.
a : This mark gives guidance or precautions when
doing the procedure.
2: Type of coating material
3: Tightening torque
5: Quantity of oil or coolant to be added
Sketches of special tools

• Various special tools are illustrated for the con-
venience of local manufacture.
30-2 D31/37/39EX, PX-21

(5)
2. Disassembly and assembly of assemblies Disassembly

• In “Disassembly” section, the work procedures,
Special tools precautions and know-how for carrying out
• Special tools which are deemed necessary those procedures, and quantity of the oil and
for disassembly or assembly of parts are de- coolant drained are described.
scribed as A1,•••X1 etc. and their part • General tools that are necessary for disassem-
names, part numbers and quantities are de- bly are described as [1], [2]•••etc. and their part
scribed in the special tool list. names, part numbers and quantities are not
• Also the following information is described in described.
the special tool list. • The meanings of the symbols used in “Disas-
1) Necessity sembly” section are as follows.
t : Special tools that cannot be substituted k : This mark indicates safety-related precau-
and should always be used (installed). tions that must be followed when imple-
q : Special tools that will be useful if avail- menting the work.
able and are substitutable with com- a : Know-how or precautions for work
6: Quantity of oil or coolant drained
mercially available tools.
2) Distinction of new and existing special tools
N : Tools newly developed for this
model. They respectively have a
new part number.
Assembly
R : Tools with upgraded part numbers.
They are remodeled from already • In “Assembly” section, the work procedures,
available tools for other models. precautions and know-how for carrying out
Blank: Tools already available for other those procedures, and quantity of the oil and
models. They can be used without coolant added are described.
any modification. • General tools that are necessary for assembly
3) Circle mark Q in sketch column: are described as [1], [2]•••etc. and their part
• The sketch of the special tool is present- names, part numbers and quantities are not
ed in the section of “Sketches of special described.
tools”. • The meanings of the symbols used in “Assem-
bly” section are as follows.
k : Precautions related to safety in execution
• This mark means part No. of special
* *** ****
tools starting with 79 T- -
and that they can not be supplied from of work
Komatsu in Japan (i.e. locally made a : This mark gives guidance or precautions when
doing the procedure.
2: Type of coating material
parts).
3: Tightening torque
5: Quantity of oil or coolant to be added
Sketches of special tools

• Various special tools are illustrated for the con-
venience of local manufacture.
D31/37/39EX, PX-21 30-3

(5)
COATING MATERIALS LIST (Rev. 2007.06)

a The recommended coating materials such as adhesives, gasket sealants, and greases used for disassembly
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, polypropy-
20 g Polyethylene lene, tetrafluoroethylene and vinyl chloride), rub-
LT-1B 790-129-9050
(2 pcs.) container ber, metal, and non-metal parts which require
immediate and strong adhesion.
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
LT-3 (Set of adhesive Can • Used to stick and seal metal, glass, and plastics.
Hardener: 500 g
and hardener)
Polyethylene
Adhesive
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 met-
als.
• 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 stick or seal gaskets and packings of
LG-1 790-129-9010 200 g Tube
power train case, etc.
• 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 nipples
of hydraulic piping.
Gasket sealant
• Features: Silicon-based heat and cold-resistant

sealant.
LG-6 790-129-9020 200 g Tube • Used to seal flange surfaces and threaded por-
tions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9070 1 kg Tube • Used to seal flywheel housing, intake manifold,
oil pan, thermostat housing, etc.
LG-8 • Features: Silicon-based, heat and cold-resistant,
ThreeBond 419-15-18131 100 g Tube vibration-resistant, impact-resistant sealant.
1207B • Used to seal transfer case, etc.
30-4 D31/37/39EX, PX-21

(5)
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Used for rough surfaces such as the circle gear top
LG-9
seal which does not need to be clamped, water
ThreeBond 790-129-9310 200 g Tube
resistance of the clearance at the welded area, etc.
1206D
• Can be coated with paint.
Gasket sealant
LG-10 • Used as lubricant/sealant when the radiator hoses

ThreeBond 790-129-9320 200 g Tube are inserted.
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 steer-
1121 ing case etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
Molybdenum
• Used to prevent scuffing and seizure of press-fitted

lubricant
disulfide
portions, shrink-fitted portions, and threaded por-

LM-P 09940-00040 200 g Tube
tions.
• Used to lubricate linkages, bearings, etc.
• Feature: Seizure and scuffing prevention compound

compound
prevention
with metallic super-fine-grain, etc.

Seizure
LC-G
— — Can • Used for the mounting bolt in the high temperature
NEVER-SEEZ
area of the exhaust manifold and the turbocharger,
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 swing
disulfide grease SYG2-400M-A 400 g x 20 container 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.
Hyper White SYG2-400T-A
Grease
400 g Bellows-type • Seizure resistance, heat resistance and water resis-

Grease G2-T, SYG2-16CNT
container tance higher than molybdenum disulfide grease.
G0-T (*) SYG0-400T-A (*)
16 kg Can • Not conspicuous on machine since color is white.
*: For cold district SYG0-16CNT (*)
Biogrease SYG2-400B
G2-B, G2-BT (*) SYGA-16CNB 400 g Bellows-type • Since this grease is decomposed by natural bacte-
*: For use at high SYG2-400BT (*) container ria in short period, it has less effects on microorgan-
temperature and SYGA-16CNBT 16 kg Can isms, animals, and plants.
under high load (*)
• Feature: Silicone grease with wide using tempera-
G2-S ture range, high resistance to thermal-oxidative deg-
ThreeBond — 200 g Tube radation and performance to prevent deterioration of
1855 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.
D31/37/39EX, PX-21 30-5

(5)
DISASSEMBLY AND ASSEMBLY 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 manufac-
container
580 SUPER ture)
SUNSTAR 417-926-3910
• Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manufac-
PRIMER 580 container
ture)
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 manufac-
435-95
ture)
• Used as primer for black ceramic-coated sur-
SUNSTAR
face on glass side and for hard polycarbonate-
GLASS
22M-54-27240 150 ml Can coated surface.
PRIMER
(Using limit: 4 months after date of manufac-
435-41
ture)
SUNSTAR • Used as primer for sash (Almite).
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months after date of manufac-
container
GP-402 ture)
SUNSTAR • “S” is used for high-temperature season and
PENGUINE “W” for low-temperature season as adhesive
Polyethylene
SEAL 580 417-926-3910 320 ml for glass.
container
SUPER “S” or (Using limit: 4 months after date of manufac-
“W” ture)
Adhesive
• Used as adhesive for glass.

Sika Japan, Polyethylene
20Y-54-39850 310 ml (Using limit: 6 months after date of manufac-
Sikaflex 256HV container
Adhesive for cab glass
ture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manufac-
SUPER 560 container) ture)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months after date of manufac-
container
SEAL No. 2505 ture)
Caulking material
SEKISUI • Used to seal front window.

Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months after date of manufac-
container
SEALANT ture)
• 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 manufac-
TOSSEAL 381
ture)
30-5-1 D31/37/39EX, PX-21

(5)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

a Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they are items to be locally manufactured).
a Necessity: t ...........Cannot be substituted, must always be installed (used)

q............Extremely useful if available or can be substituted with commercially available part
a New/Remodel: N............Tools with new part numbers, newly developed for this model
R: ...........Tools with upgraded part numbers, remodeled from items already available for oth-
er models
Blank: ....Tools already available for other models, can be used without any modification
a Tools marked Q in the Sketch column are tools introduced in the sketches of the special tools (See SKETCH-
ES OF SPECIAL TOOLS).
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Component Part No. Part Name Nature of work, remarks
1 795-799-1131 Gear t 1 Cranking of engine

Removal, installation of fuel
injection pump assembly Removal of injection
2 795-799-1390 Remover t 1
pump gear
Removal, installation of nozzle A Removal of nozzle
3 795-799-1170 Puller q 1
holder assembly holder
Removal, installation of cylinder Installation of cylinder
4 790-331-1110 Wrench t 1
head assembly head bolt
Installation of engine
Removal, installation of engine 1 795-799-2610 Installer t 1
B rear seal
front seal
2 795-799-2620 Installer t 1 Installation of dust seal
Removal, installation of engine Removal of engine rear
C 795-931-1100 Seal puller q 1
rear seal seal
791-830-1320 Rod t 1
01580-01613 Nut t 1
01643-31645 Washer t 1
Pulling out of planetary
1 790-101-2540 Washer t 1
pinion shaft
790-101-2102 Puller assembly t 1
Disassembly, assembly of final
J 790-201-2830 Spacer t 1
drive assembly
790-101-1102 Hydraulic pump t 1
Loosening, tightening of
2 791-427-1410 Wrench t 1 N
round nut
Installation of floating
3 791-545-1510 Installer t 1
seal
Press fitting of idler
1 791T-430-3210 Push tool t 1 Q
Disassembly, assembly of idler bushing
L
assembly Installation of idler
2 791-675-1510 Installer t 1
floating seal
Press fitting of track
3 791T-430-3220 Push tool t 1 Q
roller bushing
Disassembly, assembly of track Installation of track roller
4 791-651-1510 Installer t 1
roller assembly floating seal
L
Charging with oil, air
5 790-601-1000 Oil pump t 1
leakage check
Disassembly, assembly of Installation of carrier
6 791-430-3230 Installer t 1
carrier roller assembly roller floating seal
30-6 D31/37/39EX, PX-21

(1)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Component Part No. Part Name Nature of work, remarks
791-685-8006 Compressor (B) t 1

790-201-2860 Spacer t 1
Disassembly, assembly of 791-635-3160 Extension t 1 Removal, installation of
M
recoil spring assembly Cylinder recoil spring
790-101-1600 t 1
(686 kN {70 tons})
790-101-1102 Pump t 1
791-630-3200 Remover t 1
Cylinder Removal, installation of
Disassembly, assembly of track R 790-101-1300 t 1
(980 kN {100 tons}) ring pin
790-502-1003 Repair stand t 1 Disassembly, assembly
1
790-101-1102 Pump t 1 of hydraulic cylinder
Removal, installation of
2 790-330-1100 Wrench t 1
cylinder head
Loosening, tightening of
3 790-302-1270 Socket t 1
piston nut
4 790-720-1000 Expander t 1
796-720-1650 Rubber band q 1 Installation of piston ring
5
Disassembly, assembly of 07281-01029 Clamp q 1
U
hydraulic cylinder assembly
790-201-1720 Push tool kit 1
790-201-1751 • Push tool t 1
6 Press fitting of bushing
790-101-5021 • Grip t 1
01010-50816 • Bolt t 1
790-201-1500 Push tool kit 1
790-201-1560 • Plate t 1
7 Press fitting of dust seal
790-101-5021 • Grip t 1
01010-50816 • Bolt t 1
D31/37/39EX, PX-21 30-7

(1)
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS

NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
L1 Push tool
L3 Push tool
30-8 D31/37/39EX, PX-21

(1)
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
REMOVAL AND 6. Remove engine stop solenoid (5). [*3]
INSTALLATION OF FUEL 7. Disconnect air tube (6).

INJECTION PUMP ASSEMBLY
SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
1 795-799-1131 Gear t 1
A
2 795-799-1390 Remover t 1
REMOVAL
1. Open up both engine hoods (1).
8. Disconnect fuel inlet hoses (7) and (8) and
return hose (9).
2. Remove left engine side cover (2).
9. Remove fuel tubes (10) and (11).

3. Close the fuel stop valve.
10. Remove lubrication tube (12).
4. Disconnect fuel control linkage (3). [*1]
11. Disconnect 4 fuel injection tubes (13).
5. Disconnect decelerator pedal linkage (4). [*2]
a Disconnect the tube end on the fuel injection
pump side.
D31/37/39EX, PX-21 30-9

(1)
12. Using tool A1, rotate the crankshaft forward to 17. Remove 4 mounting bolts (18) and fuel injection
match the timing gear to the fuel injection timing. pump assembly (19).
a See TESTING AND ADJUSTING, Testing
and adjusting fuel injection timing.
13. Remove cap (14). [*4]

a Remove with a filter wrench, etc.
14. Remove injection pump nut (15). [*5]

a Take care not to drop the nut in the case.
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1] [*2]
a Adjust the fuel control linkage and decelera-
tor pedal linkage. For details, see TESTING
15. Using tool A2, disconnect the shaft and drive AND ADJUSTING, Adjusting fuel control le-
gear of the fuel injection pump. ver linkage and decelerator pedal linkage.
[*3]
a Adjust the engine stop solenoid linkage. For
details, see TESTING AND ADJUSTING,
Adjusting engine stop solenoid linkage.
[*4]
a Tighten the cap by turning it by 180 degrees.
[*5]
a Install the fuel injection pump assembly ac-
1) Using tool A1, crank the engine forward
slowly and push No. 1 cylinder compression
16. Remove brackets (16) and (17). top dead center positioning pin (20) into the
gear.
30-10 D31/37/39EX, PX-21

(1)
a Referring to the following, push positioning 4) Install fuel injection pump assembly (19)
3 Nut: 43 ± 6 Nm {4.38 ± 0.61 kgm}

pin (20) into the gear securely. and tighten nut (18).
• Dimension "a" of pin in free state: 24 mm
• Dimension "b" of pin when it is in contact
with gear: 20 mm
• Dimension "c" of pin when it is pushed
into gear: 16 mm
a Stop barring immediately after the position-
ing pin is pushed in (to prevent the position-
ing pin from being broken).
5) Tighten fuel injection pump nut (15).

a When installing the nut, take care ex-
3 Nut:
tremely not to drop it in the case.
12.5 ± 2.5 Nm {1.27 ± 0.25 kgm}

a This value is not the final torque.
a Do not heighten the tightening torque of
2) Remove plug (21) and timing pin (22). the nut more than above value so that
the No. 1 cylinder compression top dead
center positioning pin will not be dam-
aged.
3) Reverse the fitting position of timing pin (22)

and match the groove of the timing pin to
pointer (23) in the pump and tighten plug
(21) temporarily. 6) Disengage No. 1 cylinder compression top
a If the tooth of pointer (23) is not matched dead center positioning pin (20).
to the hole of the timing pin, match it by
turning the fuel injection pump shaft.
D31/37/39EX, PX-21 30-11

(1)
7) Remove plug (21) and install timing pin (22)

in the reversed fitting position, then install
3 Plug: 14.7 Nm {1.5 kgm}

the plug to the fuel injection pump.
8) Tighten fuel injection pump nut (15)
3 Nut: 95 ± 10 Nm {9.7 ± 1.02 kgm}

securely.
• After the above work, carry out installation in the

reverse order to removal.
a Adjust the fuel injection timing. For details, see

TESTING AND ADJUSTING, Adjusting fuel in-
jection timing.
• Bleeding air
Bleed air from the fuel circuit. For details, see
TESTING AND ADJUSTING, Bleeding air from
fuel circuit.
30-12 D31/37/39EX, PX-21

(1)
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
REMOVAL AND 3. Close the fuel stop valve.
INSTALLATION OF 4. Remove clip of heater hose (2) and disconnect

CYLINDER HEAD ASSEMBLY dust indicator hose (3).
a Disconnect the dust indicator hose end on
SPECIAL TOOLS the air cleaner side.
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
3 795-799-1170 Puller q 1
A
4 790-331-1110 Wrench t 1
REMOVAL
k Disconnect the cable from the negative (–) ter-
minal of the battery.
k If the water temperature in the radiator is high,
you may get scalded. Accordingly, wait until the
5. Using eyebolts, lift off engine hood (4).
water temperature lowers, then drain.
4 Engine hood: 45 kg
1. Remove the mounting bolts and cover (1).
2. Loosen the radiator cap and drain the cooling

water.
6 Radiator: Approx. 20 l
6. Remove both engine covers (5).
D31/37/39EX, PX-21 30-13

(1)
7. Disconnect charge air cooler hose (6). [*1] 12. Disconnect 3 wiring connectors (13) and remove
the heater relay. [*5]
• Secured with bolt (CNT5)
• Secured with nut (CNT6), (CNT12)
13. Disconnect compressor wiring connector

(CN23) (14).
14. Disconnect engine stop solenoid wiring har-

nesses (CNT17) and (CNT18) (15).
15. Disconnect wiring harness clamp (16).
8. Disconnect air cleaner hose (7). [*2]
9. Remove air cleaner band (8). [*3]
16. Disconnect engine water temperature sensor

connector (CN20) (17).
10. Disconnect the 3 wiring connectors, then dis-

connect the wiring harness clamp.
• (9): (CN1)
• (10): (CN2)
• (11): (CN3)
11. Remove the mounting bolt and air cleaner

assembly (12). [*4]
17. Disconnect 2 alternator wiring harnesses. [*6]

• (18): (CNT15)
• (19): (CNT16)
30-14 D31/37/39EX, PX-21

(1)
18. Disconnect charge air cooler hose (20). [*7] 29. Remove 2 mounting bolts (32) and alternator
assembly (33).
19. Disconnect oil filler tube (21) and oil filler hose
(22).
30. Remove the brackets and clamps from 2 places

and disconnect 4 fuel tubes (34). [*12]
20. Disconnect harness clamp (23). a Disconnect the fuel tubes in order from the
No. 1 tube (on the fan side).
21. Remove muffler clamp (24). [*8]
31. Disconnect the linkage of engine stop solenoid
22. Remove the mounting bolts and lift off muffler (35) and remove the engine stop solenoid. [*13]
assembly (25).
a Remove the 4 upper and 2 lower muffler 32. Remove the clamp and 2 delivery tubes (36).
mounting bolts. [*14]
4 Muffler assembly: 33. Remove the mounting bolt and bracket (37).
40 kg (Including bracket) [*15]
a Remover the bracket and the fuel filter to-
gether.
34. Remove air tube (38).
35. Remove bracket (39) and spill tube (40).
36. Disconnect boost hose (41) and remove clamp

(42).
a Disconnect boost hose end on the intake
side.
23. Remove reservoir tank (26). [*9]
24. Disconnect radiator hose (27). [*10]
25. Disconnect heater hose (28).
26. Remove compressor bracket (29).
27. Remove fan guard (30).

a Remove only the right fan guard.
28. Remove fan belt (31). [*11]

a Using a wrench, etc., remove the fan belt
from the tension pulley.
D31/37/39EX, PX-21 30-15

(1)
37. Remove water drain tube (43). 43. Remove the intake air heater ground wire, con-
a Remove the 2 mounting bolts, and the tube nector (52), intake air heater (53), and cover
is removed and divided into 2 pieces. (54). [*20]
38. Disconnect charge air cooler hose (44). [*16]
39. Disconnect turbocharger lubrication inlet tube

(45) and outlet tube (46). [*17]
a Disconnect end of tube (45) on the oil filter
side.
40. Remove bracket (47) and cover (48).
44. Remove 4 nozzle holder assemblies (55).
41. Remove turbocharger assembly (49) and

exhaust manifold (50). [*18]
a If the nozzle holder is difficult to remove, use

tool A3.
a Take care that dirt and foreign matter will not
enter the mounting part of the nozzle holder.
42. Remove 4 head covers (51). [*19]
30-16 D31/37/39EX, PX-21

(1)
45. Remove rocker arm assembly (56). [*21] INSTALLATION

a Loosen the locknut, then loosen the adjust- • Carry out installation in the reverse order to
ment screw by 2 – 3 turns. removal.
[*1]
a When connecting the hose, apply spray
3 Charge air cooler hose clamp:

grease to the mating part (tube).
5.9 ± 0.5 Nm {0.6 ± 0.05 kgm}
3 Air cleaner hose clamp:

[*2]
5.9 ± 0.5 Nm {0.6 ± 0.05 kgm}
3 Band: 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}

[*3]
46. Remove push rod (57). [*4]

a Install the air cleaner cover with the top mark
up.
3 Bolt: 1.86 – 2.45 Nm {0.19 – 0.25 kgm}

[*5]
3 Nut: 2.45 – 2.94 Nm {0.25 – 0.3 kgm}
3 Nut: 23.5 – 29.4 Nm {2.4 – 3 kgm}

[*6]
[*7]

47. Lift off cylinder head assembly (58). 5.9 ± 0.5 Nm {0.6 ± 0.05 kgm}
4 Cylinder head assembly: 40 kg [*8]
3 Clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

a Use a new clamp.
48. Remove cylinder head gasket (59).
[*9]
a Pass the reservoir tank drain hose through
the guide pipe of the shroud.
3 Radiator hose clamp:

[*10]
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
3 Tension pulley bolt:

[*11]
43 ± 6 Nm {4.38 ± 0.61 kgm}
3 Bracket mounting bolt:

[*12]
24 ± 4 Nm {2.45 ± 0.41 kgm}
[*13]
a Adjust the engine stop solenoid linkage. For
details, see TESTING AND ADJUSTING,
Adjusting engine stop solenoid linkage.
D31/37/39EX, PX-21 30-17

(1)

[*14]
24 ± 4 Nm {2.45 ± 0.41 kgm}

[*15]
24 ± 4 Nm {2.45 ± 0.41 kgm}
[*16]

5.9 ± 0.5 Nm {0.6 ± 0.05 kgm}
3 Nipple: 34 ± 5 Nm {3.5 ± 0.5 kgm}

[*17] 2nd time: Tighten to 120 ± 5 Nm
3 Bolt: 10 ± 2 Nm {1.0 ± 2.0 kgm}

{12.24 ± 0.51 kgm} in
the order of [3], [6], [11],
and [14].
3 Nut: 29.4 – 44.2 Nm {3 – 4.5 kgm}

[*18] 3rd time:
i) When using tool A4
• Tighten bolts by 90 ± 5° in the
3 Bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm}

[*19] order of [1] – [18] with an angle
tightening wrench (Tool A4).
[*20]
a Secure clearance of at least 10 mm between
the ground wire and fuel tube.
[*21]
• Install the rocker arm assembly and cylinder
head assembly according to the following
procedure.
a Check that there is not dirt or foreign
matter on the mating face of the cylinder
head and in the cylinders.
1) Set cylinder head gasket (59) to the cylinder
block.
a Check that the gasket is matched to the ii) When not using tool A4
holes of the block. • Make marks on the bolts and
2) Sling cylinder head assembly (58) and set it head with a marker pen, then
to the cylinder block. tighten each bolt by 90 ± 5°.
3) Install push rod (57).
4) Install rocker arm assembly (56) and tighten
the bolt with your fingers.
a Check that the adjustment screw ball is
fitted to the socket of the push rod.
5) Tighten the cylinder head mounting bolts in
2 Apply engine oil (SAE15W-40) to

the order shown in the following figure.
the threads and seats of the
3 Cylinder head mounting bolt:

mounting bolts.
1st time: Tighten to 90 ± 5 Nm

{9.18 ± 0.51 kgm} in the
order of [1] – [18].
30-18 D31/37/39EX, PX-21

(1)
3 Rocker arm mounting bolt:

6) Tighten rocker arm assembly (56).
24 ± 4 Nm {2.45 ± 0.41 kgm}
a Adjust the valve clearance. For details, see

TESTING AND ADJUSTING, Adjusting
valve clearance.
• Refilling with water

a Add water through the water filler to the
specified level. Run the engine until the wa-
ter is heated, then check the water level
again.
• Bleeding air
a Bleed air from the fuel circuit. For details,
see TESTING AND ADJUSTING, Bleeding
air from fuel circuit.
D31/37/39EX, PX-21 30-19

(1)
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
REMOVAL AND 5. Remove 4 mounting bolts (4) and crankshaft

pulley/vibration damper (5). [*1]
INSTALLATION OF ENGINE
FRONT SEAL 6. Remove 27 mounting bolts (6) and cover (7).
[*2]
SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
1 795-799-2610 Installer t 1
B
2 795-799-2620 Installer t 1
REMOVAL
7. Remove dust seal (8).
1. Remove the radiator guard assembly. For
details, see REMOVAL OF RADIATOR GUARD
ASSEMBLY.
2. Remove 4 mounting bolts and fan (1).
8. Remove seal (9). [*3]
3. Using lever [1], remove fan belt (2).

k Take care not catch your fingers between
the tensioner and fan pulley.
4. Remove fan pulley (3).
30-20 D31/37/39EX, PX-21

(1)
INSTALLATION 4) Tighten the 20 mounting bolts in the fol-
3 Mounting bolt:
• Carry out installation in the reverse order to lowing order.
removal.
24 ± 4 Nm {2.45 ± 0.41 kgm}
3 Mounting bolt of crankshaft pulley/

[*1]
vibration damper:
125 ± 5 Nm {12.75 ± 0.51 kgm}
a Install the crankshaft pulley/vibration damper
lightly, then install the fan belt and tighten the
mounting bolts to the specified torque.
[*2]
a Install the front cover according to the follow-
ing procedure.
1) Apply ThreeBond 1207D or equivalent
in the form of a string 1 – 2 mm thick to
the gasket fitting face of the front cover.
a Limit the projection of the gasket
from the oil pan fitting face to 0.25
mm.
2) Install the gasket to the front cover, and
then install them to the engine.
3) Tighten the 7 mounting bolts in the fol-
3 Mounting bolt:
lowing order.
24 ± 4 Nm {2.45 ± 0.41 kgm}
D31/37/39EX, PX-21 30-21

(1)
[*3] [*4]
a Install the dust seal to the crankshaft accord- a Install the engine front seal to the front cover
ing to the following procedure. according to the following procedure.
a Even if a dust seal has not been installed, in- 1) Set engine front seal (7) to tool B1.
stall the dust seal contained in the front seal a Since plastic part [2] on the inside of the
kit. engine front seal is used to guide the
1) Install dust seal (8) to the end of the front cover to the crankshaft, do not re-
crankshaft. move it from the engine front seal.
2) Using tool B2, press fit dust seal (8). 2) Press fit engine front seal (7) to front cover
a Press fit the dust seal until the inside (6).
end of tool B2 touches the end of the a Press fit the engine front seal until the
crankshaft. shoulder of tool B1 touches the inside
end of the front cover.
30-22 D31/37/39EX, PX-21

(1)
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
REMOVAL AND 2) Screw the tip of seal puller C into the drilled
hole and slide the hammer to remove
INSTALLATION OF ENGINE engine rear seal (2).
REAR SEAL
SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
C 795-931-1100 Seal puller q 1
REMOVAL
1. Remove the coupling. For details, see REMOVAL
AND INSTALLATION OF DAMPER.
a Method of removing with screwdriver
2. Remove the mounting bolts, set guide bolts [1], • Break the seal carrier of engine rear seal
and lift off flywheel assembly (1). [*1] (2) with a screwdriver to remove the en-
gine rear seal.
4 Flywheel assembly: 35 kg a Take care not to damage the seal fitting
part of the flywheel housing and the seal
contact surface of the crankshaft.
3. Remove engine rear seal (2). [*2]

a Method of removing with seal puller
1) Make a hole about 3 mm in diameter on the
seal carrier with a drill.
D31/37/39EX, PX-21 30-23

(1)
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
INSTALLATION 2) Insert seal (3) and pilot [2] together in the

• Carry out installation in the reverse order to crankshaft and push the seal carrier into the
removal. flywheel housing.
a Before inserting the seal, clean, de-
[*1] grease, and dry the seal contact surface
a Tighten the mounting bolts in the order show of the crankshaft.
3 Flywheel mounting bolt:

below.
3) Pull out pilot [2] and push in seal (3) further.
137 ± 7 Nm {13.97 ± 0.71 kgm}
4) Using aligning tool [3], insert the seal to the

[*2] proper depth.
a Install the engine rear seal according to the a Lightly hit the top, bottom, right, and left
following procedure. of the aligning tool with a hammer to
1) Insert pilot [2] in new seal (3). push in the seal, taking care that the seal
a Before inserting the pilot, clean, de- carrier will not be bent.
grease, and dry the lip surface of the
seal.
30-24 D31/37/39EX, PX-21

(1)
DISASSEMBLY AND ASSEMBLY RADIATOR GUARD
REMOVAL AND 4. Using eyebolts, lift off engine hood (4).
INSTALLATION OF 4 Engine hood: 80 kg

RADIATOR GUARD
ASSEMBLY
REMOVAL
k Lower the work equipment to the ground and
stop the engine. Then, loosen the hydraulic oil
filler cap slowly to release the internal pressure
of the hydraulic tank.
k If the water temperature in the radiator is high,
you may get scalded. Accordingly, wait until the
water temperature lowers, then drain.
1. Remove the mounting bolts and cover (1). 5. Remove both engine covers (5).

water.
6. Remove reservoir tank bracket (6) and discon-

nect reservoir tank hose (7). [*1]
7. Disconnect charge air cooler outlet hose (8).
3. Remove clip of heater hose (2) and disconnect 8. Disconnect radiator inlet hose (9).
dust indicator hose (3).
a Disconnect the dust indicator hose end on 9. Disconnect horn wiring connector (CN22) (10).
the air cleaner side.
10. Remove both fan guards (11).
D31/37/39EX, PX-21 30-25

(1)
11. Disconnect oil cooler outlet hose (12). 15. Sling radiator guard assembly (17) temporarily
a Prepare a blind plug before disconnecting and remove 8 mounting bolts (16) from both
the hose. sides and 2 from the underside. [*2]
12. Disconnect radiator outlet hose (13). 16. Lift off radiator guard assembly (17).
13. Disconnect charge air cooler inlet hose (14). 4 Radiator guard assembly: 370 kg
14. Disconnect oil cooler inlet hose (15).

a Prepare a blind plug before disconnecting
the hose.
30-26 D31/37/39EX, PX-21

(1)
INSTALLATION
removal.
[*1]
a Pass the reservoir tank drain hose through
the guide pipe of the shroud.
3 Radiator hose clamp:


8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
5.9 ± 0.5 Nm {0.6 ± 0.05 kgm}
[*2]
a When installing the radiator guard assembly,
peep through hole "a" to check that there is
not clearance between the stopper and
frame on each side.
k Never insert your finger in hole "a".
3 Mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
a Install the radiator guard assembly so that
distance "b" between back side of the shroud
and the compressor bracket of the air condi-
tioner will be 142 mm.
• Refilling with water

a Add water through the water filler to the
specified level. Run the engine to heighten
the water temperature. Then, check the wa-
ter level again.
• Refilling with oil (Hydraulic tank)

a Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.
• Bleeding air (HST circuit)

a Bleed air from the HST pump circuit. For de-
tails, see REMOVAL OF HST PUMP AS-
SEMBLY.
D31/37/39EX, PX-21 30-27

(1)
DISASSEMBLY AND ASSEMBLY RADIATOR, OIL COOLER, AND CHARGE AIR COOLER
DISASSEMBLY AND 2. Oil cooler assembly

1) Remove 4 upper mounting bolts (9) and 2
ASSEMBLY OF RADIATOR, lower mounting bolts (10).
OIL COOLER, AND CHARGE
AIR COOLER ASSEMBLIES
DISASSEMBLY
1. Charge air cooler assembly
1) Remove horn wiring (1).
2) Remove tube (2).
3) Remove cover (3) and shroud (4).
4) Remove upper covers (5) and (6).

5) Remove lower cover (7).
2) Remove left cleaning and inspection cover

(11).
a If the mounting bolt of the cleaning and
inspection cover is loosened with an im-
pact wrench, it is loosened too much and
the bolt pin is broken. Accordingly, loos-
en it with a wrench by hand.
a If the oil cooler assembly is removed
without removing the cleaning and in-
spection cover, the pin may touch and
break the core. Accordingly, remove the
6) Remove charge air cooler assembly (8). cleaning and inspection cover first.
30-28 D31/37/39EX, PX-21

(1)
3) Lift off oil cooler assembly (12). 2) Remove right cleaning and inspection cover
4
(15).
Oil cooler: 35 kg a If the mounting bolt of the cleaning and
inspection cover is loosened with an im-
pact wrench, it is loosened too much and
the bolt pin is broken. Accordingly, loos-
a If the oil cooler assembly is removed
without removing the cleaning and in-
spection cover, the pin may touch and
break the core. Accordingly, remove the
cleaning and inspection cover first.
3. Radiator assembly
1) Remove 4 upper mounting bolts (13) and 2
lower mounting bolts (14).
3) Lift off radiator (16).
4 Radiator: 80 kg
D31/37/39EX, PX-21 30-29

(1)
ASSEMBLY 3) Install 2 lower mounting bolts (14) and 4

1. Radiator assembly upper mounting bolts (13).
1) Sling and install radiator assembly (16).
a When inserting the radiator assembly in
the radiator guard, apply grease to the
seat.
4 Radiator: 80 kg
2) Install right cleaning and inspection cover

(15).
inspection cover is tightened with an im-
pact wrench, it is tightened too much and
the bolt pin is broken. Accordingly, tight-
2. Oil cooler assembly
1) Sling and install oil cooler assembly (12).
a When inserting the oil cooler assembly
in the radiator guard, apply grease to the
seat.
4 Oil cooler: 35 kg
30-30 D31/37/39EX, PX-21

(1)
2) Install left cleaning and inspection cover 3. Charge air cooler assembly
(11). 1) Install charge air cooler assembly (8).
inspection cover is tightened with an im-
pact wrench, it is tightened too much and
the bolt pin is broken. Accordingly, tight-
2) Install lower cover (7).

3) Install upper covers (6) and (5).
3) Install 2 lower mounting bolts (10) and 4

upper mounting bolts (9).
4) Install shroud (4) and cover (3).

5) Install tube (2).
6) Install horn wiring (1).
D31/37/39EX, PX-21 30-31

(1)
DISASSEMBLY AND ASSEMBLY ENGINE AND HST PUMP
REMOVAL AND 6. Disconnect 8 HST pump hoses.

• (10): Drain port T3
[*1]
INSTALLATION OF ENGINE • (11): Charge pump suction port S3

AND HST PUMP ASSEMBLY • (12): PPC inlet
• (13): From charge filter
REMOVAL • (14): To charge filter
1. Remove the radiator guard assembly. For • (15): To right HST motor reverse
details, see REMOVAL OF RADIATOR GUARD (Hose color band: Blue)
ASSEMBLY. • (16): To left HST motor forward
(Hose color band: Yellow)
2. Remove the operator's seat frame assembly. • (17): To right HST motor forward
For details, see REMOVAL AND INSTALLA- (Hose color band: Green)
TION OF OPERATOR'S SEAT FRAME ASSEM- • (18): To left HST motor reverse
BLY. (Hose color band: Orange)
3. Disconnect wiring connectors (1) – (6) above the

HST pump.
• (1): RH pump pressure sensor connector RP
• (2): LH pump pressure sensor connector LP
• (3): RH pump R-EPC solenoid valve con-
nector RR (Color band: Blue)
• (4): RH pump F-EPC solenoid valve con-
nector RF (Color band: Green)
• (5): LH pump R-EPC solenoid valve connec-
tor LR (Color band: Red)
• (6): LH pump F-EPC solenoid valve connec-
tor LF (Color band: Yellow)
4. Disconnect work equipment valve hoses (7) and 7. Remove 2 fuse boxes (19) and disconnect 3 wir-
(8). ing harness clamps (20).
• (7): To oil cooler (Hose color band: Blue) a There is 1 wiring harness clamp inside.
• (8): To work equipment pump
(Hose color band: Red)
5. Disconnect hydraulic tank hose (9).

• From oil cooler to hydraulic tank filter
30-32 D31/37/39EX, PX-21

(1)
8. Disconnect 4 wiring harness clamps (21). 14. Disconnect the 4 wiring connectors.
a There are 1 wiring harness clamp inside and • (32): CN1
1 installed together with other parts. • (33): CN2
• (34): CN3
9. Disconnect starting motor wiring harness (22).
a Disconnect only the positive (+) side.
10. Disconnect safety relay connector CN4 (23) and

intermediate connectors CN2 (24), CN1 (25),
and CN3 (26).
• (35): CN-EN
11. Remove the 8 mounting bolts and lift off front

bracket (27). [*2]
4 Front bracket: 65 kg
15. Disconnect starting motor wiring harness (36).

• CN-T1: Starting motor terminal B
• CN-T2: Starting motor terminal C
16. Disconnect engine ground wire (37). [*4]
12. Disconnect the 2 hoses of work equipment

pump (28). [*3]
• Upper hose: Discharge
• Lower hose: Suction
13. Disconnect the 3 fuel hoses.

• (29): Fuel outlet
• (30): Fuel inlet
• (31): Fuel outlet
D31/37/39EX, PX-21 30-33

(1)
17. Disconnect heater hoses (38) and (39). INSTALLATION

18. Sling the engine and HST pump assembly tem- removal.
porarily and remove 4 mounting bolts (40) at the
3 Flange mounting bolt:

front and rear. [*5] [*1]
98 – 123 Nm {10 – 12.5 kgm}
2 Mounting bolt: Adhesive (LT-2)

[*2]
3 Hose clamp:
[*3]
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*4]
a Install the engine ground terminal straight
down.

19. Lift off engine and HST pump assembly (41). [*5]
4 Engine and HST pump assembly: 3 Mounting bolt:

650 kg 245 – 308.7 Nm {25 – 31.5 kgm}
30-34 D31/37/39EX, PX-21

(1)
DISASSEMBLY AND ASSEMBLY DAMPER
REMOVAL AND INSTALLATION

INSTALLATION OF DAMPER removal.
a Clean the pump mating face thoroughly.
REMOVAL a Take care not to apply too much gasket seal-
1. Remove the operator’s cab frame assembly. ant.
For details, see REMOVAL OF OPERATOR’S
CAB FRAME ASSEMBLY. [*1]
a Apply gasket sealant to the mating faces of
2. Remove the HST pump assembly. For details, the HST pump assembly and cover and to
see REMOVAL OF HST PUMP ASSEMBLY.
2 Mating face:
those of flywheel housing and cover.
3. Remove 12 cover mounting bolts (1). [*1]

3 Mounting bolt:
Gasket sealant (LG-6)
58.8 – 73.5 Nm {6 – 7.5 kgm}
[*2]
a Install the coupling with the inside projection

directed toward the output (pump) side.
3 Mounting bolt:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
4. Using guide bolt [1] and forcing screw [2],

remove cover (2).
5. Remove 8 coupling mounting bolts (3) and cou-

pling (4). [*2]
D31/37/39EX, PX-21 30-35

(1)
DISASSEMBLY AND ASSEMBLY TRACK SHOE
SPREADING AND 3. Loosen lubricator (2) to lower the tension of the

track shoe. [*1]
INSTALLATION OF TRACK k Since the pressure in the recoil spring cylin-
SHOE ASSEMBLY der is very high, do not loosen the lubricator
more than one turn. If the track tension is
SPECIAL TOOLS not lowered, move the machine forward and
in reverse.
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
791-630-3200 Remover t 1
Cylinder
R 790-101-1300 t 1
(980 kN {100 tons})
SPREADING
1. Position the master link properly.
a Start the engine and position each master
link in front of the idler.
4. Remove the track shoe of master link (3). [*2]
a Set a block, jack, etc. under the track shoe in
a Pull both sides of the master link with wires
front of each idler.
and chain blocks and remove the master link
bolts to disconnect the master link.
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).
30-36 D31/37/39EX, PX-21

(1)
DISASSEMBLY AND ASSEMBLY TRACK SHOE
INSTALLATION
removal.
[*1]
a Adjust the tension of the track shoe. For de-
tails, see TESTING AND ADJUSTING, Test-
ing adjusting tension of track shoe.
a Tension of track shoe: 20 – 30 mm
[*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] –
2 Master link bolt:

[4] in 2 steps.
Seizure prevention compound

(MARUZEN MOLYMAX No. 2 or
3 Master link bolt:

equivalent)
Initial torque:
147.1 ± 19.6 Nm {15 ± 2 kgm}
Retightening angle: 180 ± 10°
D31/37/39EX, PX-21 30-37

(1)
DISASSEMBLY AND ASSEMBLY HST MOTOR AND FINAL DRIVE
REMOVAL AND 4. Disconnect speed sensor connector LRS (3a)

and remove all the wiring harness clamps on the
INSTALLATION OF HST sensor side.
MOTOR AND FINAL DRIVE a The HST motor speed sensor connector on
ASSEMBLY the right side is RRS.
REMOVAL
1. Spread the track shoe. For details, see

SPREADING TRACK SHOE.
2. Using hydraulic jacks, lift up the machine body

and set stand [1] under the steering case.
5. Disconnect main hoses (4) and (5). [*1]
• (4): Left HST motor, reverse
(Hose color band: Orange)
• (5): Left HST motor, forward
(Hose color band: Yellow)
• (4): Right HST motor, reverse
(Hose color band: Blue)
• (5): Right HST motor, forward
(Hose color band: Green)
6. Disconnect pilot hoses (6) and (7).

• (6): Left HST motor, change to 3rd gear
speed (Hose color band: Green)
• (7): Left HST motor, change to 2nd gear
speed (Hose color band: Yellow)
3. Remove covers (1), (2), and (3).
• (6): Right HST motor, change to 2nd gear
speed (Hose color band: Yellow)
• (7): Right HST motor, change to 3rd gear
speed (Hose color band: Green)
7. Disconnect parking brake hose (8).

• Hose color band: Orange
8. Disconnect drain hose (9).
30-38 D31/37/39EX, PX-21

(1)
DISASSEMBLY AND ASSEMBLY HST MOTOR AND FINAL DRIVE
9. Remove the mounting bolts and guard (10). [*2] INSTALLATION

removal.
3 Mounting bolt:
[*1]
98 – 123 Nm {10 – 12.5 kgm}
2 Guard mounting bolt: Adhesive (LT-2)

[*2]
a Take extreme care that each hose will not be

twisted when connected.

10. Sling HST motor and final drive assembly (11) level. Run the engine to circulate the oil
temporarily. through the system. Then, check the oil level
again.
11. Remove the 24 mounting bolts and HST motor
and final drive assembly (11). • Bleeding air (HST circuit)
a If shims are inserted, check their quantity a Bleed air from the HST pump circuit. For de-
and positions. tails, see INSTALLATION OF HST PUMP
4
ASSEMBLY.
HST motor and final drive assembly
(Each side): 300 kg
D31/37/39EX, PX-21 30-39

(1)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
DISASSEMBLY AND 2) Using 2 forcing screws [1], remove cover

(2).
ASSEMBLY OF FINAL DRIVE
ASSEMBLY
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
J 790-101-2102 Puller assembly t 1 3. Ring gear
790-201-2830 Spacer t 1 1) Remove 18 mounting bolts (3).
2 791-427-1410 Wrench t 1 N
3 791-545-1510 Installer t 1
DISASSEMBLY
1. Draining oil
Remove the drain plug to drain the oil from the
final drive case.
6 Final drive case: 3.91 l
2. Cover 2) Using 2 forcing screws [2], remove ring gear

1) Remove 12 mounting bolts (1). (4).
30-40 D31/37/39EX, PX-21

(1)
4. No. 1 planetary carrier assembly 6. No. 2 sun gear

1) Remove thrust washer (5). 1) Remove thrust washer (13).
2) Remove No. 1 planetary carrier assembly 2) Remove No. 2 sun gear (14).
(6).
7. No. 2 planetary carrier assembly (HST motor

3) Disassemble No. 1 planetary carrier assem- case)
bly according to the following procedure. 1) Remove mounting bolts (15).
i) Drive pin (7) into shaft (8). a 3 sets
a 3 sets
ii) Remove shaft (8) from No. 1 planetary
carrier assembly.
a After removing the shaft, remove pin
(7) from shaft (8).
a 3 sets
iii) Remove 2 thrust washers (9), gear (10),
and bearing (11).
a 3 sets.
2) Using tools J1, pull shaft (16) out of No. 2

planetary carrier assembly.
a 3 sets
5. No. 1 sun gear

Remove No. 1 sun gear (12) first.
D31/37/39EX, PX-21 30-41

(1)
3) Remove ball (17). 8. Hub assembly

a 3 sets 1) Remove lock plate (22).
4) Remove gear (18) from No. 2 planetary car-
rier 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
3) Using 2 eyebolts [3], remove hub assembly

(24) from No. 2 planetary carrier assembly
(HST motor case).
7) Remove thrust washer (21).
30-42 D31/37/39EX, PX-21

(1)
4) Disassemble the hub assembly according to ASSEMBLY

the following procedure. a Clean the all parts and check them for dirt or
i) Remove floating seal (25). damage. Coat their sliding surfaces with engine
ii) Remove 2 inner race bearings (26). oil before installing.
a Adjust the pre-load at the normal temperature
while the temperature difference between the
travel motor case, bearing, hub, and nut is 3° or
less.
1. HST motor case (No. 2 planetary carrier

assembly)
Using tool J3, install floating seal (28).
a Remove all oil and grease from the O-ring
and O-ring contact surface, and dry them be-
fore installing the floating seal.
a Insert the tool by pushing the O-ring.
a After installing the floating seal, check that its
slant is within 1 mm.
iii) Remove 2 outer race bearings (27). a After installing the floating seal, thinly apply
power line oil (TO30) to the sliding parts.
9. HST motor case (No. 2 planetary carrier

assembly) 2. Assembly of hub assembly
Remove floating seal (28) from HST motor case 1) Using the push tool, press fit 2 outer race
(29). bearings (27).
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 can-
not go through the clearance between
the outer race end and hub.
D31/37/39EX, PX-21 30-43

(5)
2) Using the push tool, press fit 2 inner race 5) Using push tool [4], press the inner race on
bearing (26). the bearing on the nut side with a press.
3) Using tool J3, install floating seal (25) to the a Pressing force on inner race:
hub assembly. 8.8 – 12.7 kN {0.9 – 1.3 tons}
a For the installation procedure, see step 1 a After installing hub assembly (24), re-
above. volve the hub by 2 – 3 turns against the
HST motor case.
4) Using eyebolts [3], set hub assembly (24) to

No. 2 planetary carrier assembly (HST 6) Tighten the nut and adjust the pre-load on
motor case). the bearing according to the following proce-
a When inserting the hub assembly in the dure.
No. 2 planetary carrier assembly (HST a If nut (23) is not tightened sufficiently
motor case), check that the bearing and (bearings (26) slant and do not go all the
HST motor case insertion surface are way), the contact surfaces of floating
free from flaws, burrs and dirt and take seals (25) and (28) may be damaged.
care that the bearing will not slant. Accordingly, tighten nut (23) securely
according to the shown procedure.
1] Using tool J2, tighten nut (23) to 490

Nm {50 kgm} temporarily. Rotate hub
assembly (24) to the right by 3 turns and
then to the left by 3 turns, and then
tighten nut (23) again to 490 Nm {50
kgm}.
a Tighten the nut to 490 Nm {50 kgm}
to prevent the bearing from slanting.
2 Nut: Molybdenum disulfide
lubricant (LM-P)
2] Loosen nut (23) to below 196 Nm {20
kgm}.
a Do not loosen to 0 Nm {0 kgm}. If
you have loosened to 0 Nm {0 kgm},
tighten again to 490 Nm {50 kgm}.
30-44 D31/37/39EX, PX-21

(5)
3] Tighten nut (23) to 245 Nm {25 kgm}. (2) When tightening the nut, check that
Rotate hub assembly (24) to the right by the rotation angle of the nut is 0.5 –
3 turns and then to the left by 3 turns, 1 adjustment notch of the nut by the
and then tighten nut (23) again to 245 deviation of the nut from the match
Nm {25 kgm}. mark made in step 4].
4] Make match mark (a) between nut (23) 7) Install lock plate (22).
and HST motor case (29).
a If the lock plate is turned over, it deviates

5] Tighten nut (23) to the range of 245 – by 1/2 notch. Accordingly, install it so
490 Nm {25 – 50 kgm}. Using push-pull that its claw will be fitted to a notch of the
2 Threads of mounting bolt:

scale [5], adjust the pre-load on the nut.
bearing (the rotating force of the hub at
3 Mounting bolt:
a bolt hole on its periphery). Both of the Adhesive (LT-2)
following must be satisfied.
(1) Rotating force at bolt hole on 58.8 – 73.5 Nm {6 – 7.5 kgm}
periphery of hub: 127 – 206 N {13 –
21 kg}
D31/37/39EX, PX-21 30-45

(5)
3 Mounting bolt:
3. No. 2 planetary carrier assembly 6) Tighten mounting bolt (15).
1) Install thrust washer (21).
98 – 122.5 Nm {10 – 12.5 kgm}
a After assembling No. 2 planetary carrier
assembly, check that gear (18) rotates
smoothly.
a 3 sets
2) Install 2 outer race bearings (20) to the gear.

a 3 sets
4. No. 2 sun gear

Install sun gear (14) and thrust washer (13) to
No. 2 planetary carrier assembly.
3) Install 2 inner race bearings (19) to gear

(18).
a 3 sets
4) Install gear (18) to No. 2 planetary carrier
assembly.
a 3 sets
5) Install shaft (16) and ball (17) to No. 2 plane- 5. No. 1 sun gear
tary carrier assembly. Install No. 1 sun gear (12).
a Install the shaft by expansion fit.
a Match the hole of the shaft to that of the
carrier and install the shaft by hitting it
lightly with a plastic hammer, etc.
a 3 sets
30-46 D31/37/39EX, PX-21

(5)
6. No. 1 planetary carrier assembly 2) Install No. 1 planetary carrier assembly (6).
1) Assemble No. 1 planetary carrier assembly 3) Install thrust washer (5).
a Replace the thrust washers and pin with
new ones.
i) Install bearing (11) to gear (10) and fit
upper and lower thrust washers (9),
then set gear (10) to No. 1 planetary
carrier assembly.
ii) 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.
iii) Insert pin (7).
7. Ring gear
1) Fit the O-ring to the hub side. Using eye-
bolts [2] and matching the bolt holes of ring
gear (4) to those of the hub, install ring gear
(4).
a Degrease the mating faces of the ring
gear and hub.
a After inserting the pin, bend pin "a" of the

carrier.
2) Tighten ring gear (4) with 18 mounting bolts
3 Mounting bolt:
(3).
245 – 308.7 Nm {25 – 31.5 kgm}
a After assembling No. 1 planetary carrier

assembly, check that gear (10) rotates
smoothly.
D31/37/39EX, PX-21 30-47

(5)
8. Cover
1) Using 2 through bolts [1], install cover (2).
2) Install cover (2) to the ring gear with 12
2 Cover mating face:

mounting bolts (1).
3 Mounting bolt:
Gasket sealant (1207B)
98 – 122.5 Nm {10 – 12.5 kgm}
9. Refilling with oil

Tighten the plug and add power line oil through
3 Plug: 58.8 – 78.4 Nm {6.0 – 8.0 kgm}

the oil filler.
5 Final drive case:

Approx. 3.91 l (TO30)
a Check the oil level after installing the travel
motor and final drive assembly to the ma-
chine body.
30-47-1 D31/37/39EX, PX-21

(5)
DISASSEMBLY AND ASSEMBLY IDLER AND RECOIL SPRING

INSTALLATION OF IDLER removal.
AND RECOIL SPRING
ASSEMBLY
REMOVAL
1. Spread the track shoe. For details, see
SPREADING 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:

170 kg
3. Remove bolt (2) and separate idler (3) and recoil

spring assembly (4) from each other.
4 Idler: 100 kg
4 Recoil spring assembly: 70 kg
30-48 D31/37/39EX, PX-21

(1)
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY
SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
791-685-8006 Compressor (B) t 1

790-201-2860 Spacer t 1
791-635-3160 Extension t 1
M
Cylinder
790-101-1600 t 1
(686 kN {70 tons})
790-101-1102 Pump t 1
2) Apply hydraulic pressure slowly to com-

DISASSEMBLY press the spring and tighten nut (6).
3) Remove 2 lock plates (7) and nut (6).
1. Remove the mounting bolts and lock plate (1).
a Compress the spring until the nut be-
comes loose.
2. Remove valve (3)
a Release the hydraulic pressure slowly to
lower the tension of the spring to zero.
3. Remove rod assembly (5) from recoil spring
4) Remove pilot (9) and cylinder (10) from
assembly (4).
spring (8).
5) Remove snap ring (11), spacer (12), dust seal
4. Disassembly of recoil spring assembly
(13), and bushing (14) from cylinder (10).
1) Set recoil spring assembly (4) to tool M.
kSince the installed load of the spring is
5. Disassembly of rod assembly
large and dangerous, set it securely.
1) Remove wear ring (16) from rod assembly
a Installed load of spring:
(5).
71.54 kN {7,300 kg}
2) Remove snap ring (17) and U-packing (18).
D31/37/39EX, PX-21 30-49

(1)
ASSEMBLY
1. Assembly of rod assembly 3) Using push tool [3], install spacer (12) and
1) Install U-packing (18) to rod assembly (5) 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 [1], press fit bushing (14) to
cylinder (10).
a Secure the cylinder with block [2].
2) Install seal (13) to cylinder (10).
30-50 D31/37/39EX, PX-21

(1)
4) Install cylinder (10) and pilot (9) to spring

(8), then set them to tool M.
5) Apply hydraulic pressure slowly to com-
press the spring.
6) Set the installed length of the spring to "a".
7) Position the spring with nut (6) and lock it
3 Nut: 294 Nm {30.0 kgm}

with lock plate (7).
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
2 Inside of cylinder: Grease (G2-LI)

"A".
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).
3 Valve: 58.8 – 88.2 Nm {6 – 9 kgm}

a Install the valve with the fitting out.
D31/37/39EX, PX-21 30-51

(1)
DISASSEMBLY AND ASSEMBLY IDLER
DISASSEMBLY AND
ASSEMBLY OF IDLER
ASSEMBLY
SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
1 791T-430-3210 Push tool t 1 Q

L
2 791-675-1510 Installer t 1
5. Pull idler (7) out of the shaft and support assem-
bly.
DISASSEMBLY
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).
30-52 D31/37/39EX, PX-21

(1)
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.
a After installing the floating seal, check that its
slant is within 1mm and its projection [a] is
6.5 – 10.5 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
2 Bolt: Liquid adhesive (LT-2)

(11).
3 Nut: 89 – 123 Nm {9 – 12.5 kgm}
D31/37/39EX, PX-21 30-53

(1)
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 (7). tighten the plug.
5
3 Plug: 98 – 137 Nm {10 – 14 kgm}
l (SAE30-CD)
Oil: Approx. 160 ml
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 {9 – 12.5 kgm}

13. Install shims (2) and guide (1).
30-54 D31/37/39EX, PX-21

(1)
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
DISASSEMBLY AND 4. Remove floating seal (5) from collar (3).
ASSEMBLY OF TRACK 5. Pull out roller (6) from shaft.

ROLLER ASSEMBLY
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 6. Remove floating seals (7) and (8) from roller (6).
1. Remove plug (1) and drain oil.
6
7. Remove bushing (9) and (10) from roller (6).
l
Track roller: Approx. 150 ml
8. Remove ring (11), then remove collar (12) from

2. Set roller assembly (2) to block [1]. shaft (13).
3. Push collar (3) and pull out ring (4), then remove
collar (3).
D31/37/39EX, PX-21 30-55

(1)
9. Remove floating seal (14) from collar (12). a Precautions when assembling floating seal.
1) When assembling the floating seal,
10. Remove O-rings (15) from shaft (13). degrease and dry the parts indicated
with thick line A (O-ring and mating face
of the O-ring).
2) After assembling the floating seal,
check that the angle of the seal is less
than 1 mm.
3) After assembling, check that protrusion
[a] of the floating seal is within a range
of 7 – 11 mm.
ASSEMBLY
1. Fit O-rings (15) to shaft (13) and assemble collar
(12), then install ring (11).
a After assembling, tighten plug (1) temporari-
ly.
2. Using tool L4, install floating seal (14) to collar

(12). 3. Using push tool [1], press fit bushings (9) and
2 Bushing press-fitting portion:

(10) to roller (6).
Engine oil (EO30-CD)

a Bushing press-fitting force:
29.4 ± 3.92 kN {3.0 ± 0.4 ton}
30-56 D31/37/39EX, PX-21

(1)
4. Install floating seal (8) to roller (6). 7. Install floating seal (8).
a For details of the precautions when installing a For details of the precautions when installing
the floating seals, see Step 2, a Precautions the floating seals, see Step 2, a Precautions
when assembling floating seal. when assembling floating seal.
5. Set shaft (13) and collar (12) assembly on block 8. Install floating seal (5) to collar (3).
[2], then assemble roller (6). a For details of the precautions when installing
a Coat the sliding surface of the floating seal the floating seals, see Step 2, a Precaution
with engine oil, and make sure that no dirt or when assembling floating seal.
dust sticks to the surface. a Coat the sliding surface of the floating seal
a When assembling the roller, coat the shaft or with engine oil, and make sure that no dirt or
bushing with engine oil. dust sticks to the surface.
6. Refilling with oil 9. Fit roller (2) to collar (3), then install ring (4).
Pour oil through clearance between shaft (13)
and roller (6).
5 Roller: Approx. 150 ml l (EO30-CD)

a When using tool B to add the oil, add the oil
after completing the total assembly.
D31/37/39EX, PX-21 30-57

(1)
10. Using tool L5, apply basic pressure to roller oil 12. Checking oil level
filler port, and check for leakage of air from seal. Stand the track roller as shown in the diagram
a Basic pressure: 0.1 MPa {1 kg/cm2} below and leave it for a short time, then insert a
a Method of checking wire from the oil filler port and check height L to
The basic pressure shall be maintained for the oil surface.
10 seconds and the indicator of the gauge a Distance L from end face of shaft to oil sur-
shall not go down. face: 106 mm
3 Plug: 117.7 ± 19.6 Nm {12 ± 2 kgm}

13. Tighten plug (1).
11. If oil was not added in Step 6, use tool L5, to fill
track roller assembly with oil.
5 Track roller oil:

l (EO30-CD)
Approx. 150 ml
30-58 D31/37/39EX, PX-21

(1)
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
DISASSEMBLY AND 5. Disassembly of shaft, support assembly

1) Remove floating seal (8) from shaft and
ASSEMBLY OF CARRIER support assembly (7).
ROLLER ASSEMBLY 2) Set shaft and support assembly (7) on block
[3], and using push tool [4], remove shaft
SPECIAL TOOLS (10) from support (9) with press.
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
L 6 791-430-3230 Installer t 1
DISASSEMBLY
1. Remove cap (1) from carrier roller assembly.
2. Remove bolt (2), then remove plate (3).
3. Remove roller assembly (4).
4. Disassembly of roller assembly

1) Remove floating seal (5) from roller assem-
bly (4).
2) Set roller assembly on block [1], and using
push tool [2], remove bushing (6).
D31/37/39EX, PX-21 30-59

(1)
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
ASSEMBLY 2. Assembly of roller assembly.

1. Assembly of shaft, support assembly. Using push tool [7], press fit bushing (6).
1) Set support (9) on block [5], and using push
tool [6], press fit shaft (10). 3. Set shaft and support assembly (7) in position,
a Press-fitting force: and assemble roller assembly (4).
2 Shaft: Anti-friction compound (LM-P)

19.6 – 106.8 kN (2 – 10.9 ton)
3 Mounting bolt:
4. Assemble plate (3), and tighten with bolt (2).
2) Install floating seals (8) and (5).
a When installing the floating seal, de- 176.5 ± 19.6 Nm {18 ± 2 kgm}
grease and dry the parts indicated 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 pro-
jection [a] is 4 – 8 mm.
5. Fill roller with oil.
5 l
Carrier roller: Approx. 200 – 220 ml
(Engine oil EO30-CD)
6. Fit O-ring to cap (1) and install to carrier roller

assembly.
30-60 D31/37/39EX, PX-21

(1)
DISASSEMBLY AND ASSEMBLY HST PUMP
REMOVAL AND 3. Disconnect work equipment valve hoses (7) and

(8).
INSTALLATION OF HST PUMP • (7): To oil cooler (Hose color band: Blue)
ASSEMBLY • (8): To work equipment pump
(Hose color band: Red)
REMOVAL
k Lower the work equipment to the ground and 4. Disconnect hydraulic tank hose (9).
stop the engine. Then, loosen the hydraulic oil • From oil cooler to hydraulic tank filter
filler cap slowly to release the residual pressure
in the hydraulic tank. 5. Disconnect 8 HST pump hoses. [*1]
• (10): Drain port T3
1. Remove the operator's seat frame assembly. • (11): Charge pump suction port S3
For details, see REMOVAL AND INSTALLA- • (12): PPC inlet
TION OF OPERATOR'S SEAT FRAME ASSEM- • (13): From charge filter
BLY. • (14): To charge filter
• (15): To right HST motor reverse
2. Disconnect wiring connectors (1) – (6) above the (Hose color band: Blue)
HST pump. • (16): To left HST motor forward
• (1): RH pump pressure sensor connector RP (Hose color band: Yellow)
• (2): LH pump pressure sensor connector LP • (17): To right HST motor forward
• (3): RH pump R-EPC solenoid valve con- (Hose color band: Green)
nector RR (Color band: Blue) • (18): To left HST motor reverse
• (4): RH pump F-EPC solenoid valve con- (Hose color band: Orange)
nector RF (Color band: Green)
• (5): LH pump R-EPC solenoid valve connec-
tor LR (Color band: Red)
• (6): LH pump F-EPC solenoid valve connec-
tor LF (Color band: Yellow)
D31/37/39EX, PX-21 30-61

(1)
DISASSEMBLY AND ASSEMBLY HST PUMP
6. Sling HST pump assembly (19) temporarily and INSTALLATION

remove the 6 mounting bolts. [*2] • Carry out installation in the reverse order to
• M12 bolt: 4 pieces removal.
• M16 bolt: 2 pieces
a When assembling the parts, take extreme care
7. Lift off HST pump assembly (19). not to twist the hoses.
4
3 Mounting bolts of flanges of hoses (15)
HST pump assembly: 140 kg [*1]
– (18): 98 – 123 Nm {10 – 12.5 kgm}
2 Threads of mounting bolt:

[*2]
Gasket sealant (LG-5)
• Bleeding air
a Bleed air from the HST circuit. For details,
air from HST circuit.

again.
a If the HST pump assembly was replaced, adjust

the new HST pump assembly according to
TESTING AND ADJUSTING, Special functions
of monitor panel (EMMS), 8-SERVICE ADJUST
MODE.
30-62 D31/37/39EX, PX-21

(1)
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
REMOVAL AND 3. Disconnect the following 8 main control valve

PPC hoses.
INSTALLATION OF MAIN • (3): Return to hydraulic tank
CONTROL VALVE ASSEMBLY • (4): To suction pipe
• (5): Angle right (Hose color band: Green)
REMOVAL • (6): Tilt left (Hose color band: White)
k Lower the work equipment to the ground and • (7): Lift up (Hose color band: Red)
stop the engine. Then, loosen the hydraulic oil • (8): Angle left (Hose color band: Blue)
filler cap slowly to release the internal pressure • (9): Tilt right (Hose color band: Brown)
of the hydraulic tank. • (10): Lift down (Hose color band: Orange)
a Plug the disconnected pipes and hoses to pre-
vent foreign matter from entering them.
a Put tags to the disconnected hoses to prevent a
mistake in re-connecting them.
1. Remove the 4 mounting bolts and rear cover (1).
4. Disconnect 2 heater hoses (11).
5. Remove the 2 mounting bolts and seat belt (12).
6. Remove mounting bolts (13).
2. Remove the 4 mounting bolts and charge pump

oil filter bracket (2).
a Move the bracket aside so that it will not be
an obstacle to the work to disconnect the
equipment hoses.
7. Lean the operator’s seat assembly (14) forward.
D31/37/39EX, PX-21 30-63

(1)
8. Disconnect the following 10 main control valve INSTALLATION

main hoses. • Carry out installation in the reverse order to
• (15): Angle left removal.
• (16): Angle right a Take extreme care that each hose will not be
• (17): Tilt right twisted when connected.
• (18): Tilt left
• (19), (20): Lift down • Refilling with oil (Hydraulic tank)
• (21), (22): Lift up a Add oil through the oil filler to the specified
• (23): To oil cooler (Hose color band: Blue) level. Run the engine to circulate the oil
• (24): To hydraulic pump through the system. Then, check the oil level
(Hose color band: Red) again.
9. Remove clamp (25). • Bleeding air (HST circuit)

10. Remove the 4 mounting bolts and main control tails, see INSTALLATION OF HST PUMP
valve assembly (26). ASSEMBLY.
30-64 D31/37/39EX, PX-21

(1)
DISASSEMBLY AND
ASSEMBLY OF MAIN
CONTROL VALVE ASSEMBLY
DISASSEMBLY
Disassembly of main control valve assem-
bly 1/2
a Since the safety valve assembly cannot be set to
proper pressure while it is mounted on the ma-
chine, do not disassemble it.
a Do not remove the upper and lower covers and
each block.
1. Plug (Pressure releasing)

1) Remove plug (1) to release the pressure
from the circuit.
2) Remove the O-ring and backup rings (2)
and (3).
2. Unload valve
1) Remove unload valve assembly (4).
2) Remove the O-ring and ring (6) from sleeve
(5).
3) Remove plug (7) and spring (8) from sleeve
(5).
4) Remove plug (9) and spring (10).
a Do not remove the spool, seal, and LS
selector valve.

Remove 6 plugs (11), 3 springs (12), and 3
springs (13).
a Do not remove the valve and piston.
4. Suction valve assemblies

Remove 3 suction valve assemblies (14).
a Do not disassemble the suction valve as-
sembly.
5. Main relief valve assembly

Remove main relief valve assembly (15), O-ring,
and ring (16).
a Do not disassemble the main relief valve.
6. Check valves (Angle)

Remove 2 plugs (17), 2 valves (18), and 2
springs (19).
7. Cooler bypass valve

Remove plug (20), valve (21), and spring (22).
8. Plugs
Remove 2 plugs (23), plug (24), plug (25), and 2
plugs (26).
30-66 D31/37/39EX, PX-21

(1)
D31/37/39EX, PX-21 30-67

(1)
Disassembly of main control valve assem-

bly 2/2
1. Angle control valve
1) Remove the mounting bolts, case (27), bolt
(28), spring (29), and retainer (30).
a When loosening bolt (28), take care ex-
tremely not to damage the spool.
2) Remove the mounting bolts and case (31).
a Do not remove the retainer, spool, and
plug.
a Since the spring has a part No. different
from the others, check its free length.
2. Tilt control valve

1) Remove the mounting bolts, case (32), bolt
(33), spring (34), and retainer (35).
a When loosening bolt (33), take care ex-
2) Remove the mounting bolts and case (36).
a Do not remove the retainer, spool, and
plug.
3. Lift control valve

1) Remove the mounting bolts, cases (37) and
(38), spring (39), retainer (40), spring (41),
retainer (42), and plug (43).
a When loosening plug (43), take care ex-
2) Remove the mounting bolts, cases (44) and
(45), bolt (46), spring (47), retainer (48),
spring (49), and retainer (50).
a Remove bolt (46) from the spool without
taking the spool out of the block.
a When loosening bolt (46) take care ex-
a Do not remove the spool and retainer.
30-68 D31/37/39EX, PX-21

(1)
D31/37/39EX, PX-21 30-69

(1)
ASSEMBLY 3) Install retainer (30) and spring (29) to the
3 Bolt: 6.9 – 9.8 Nm {0.7 – 1.0 kgm}

Assembly of main control valve assembly 1/2 block with bolt (28).
a Apply engine oil to the sliding surfaces before as-
sembling. 4) Fit the O-ring to case (27).
a As a result of disassembly, if the spool or block 5) Install case (27) to the block with the mount-
3 Bolt:
has any defect, replace the assembly. ing bolts.
a Degrease the plug and female screw of the spool
with DRYSOL, etc. and dry them completely be- 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
fore tightening. Do not apply pressure on them
for at least 2 hours after they are tightened.
1. Lift control valve

1) Install retainer (50), spring (49), retainer
(48), and spring (47) to the spool.
2) Tighten bolt (46) in the spool.
a Apply 1 drip (approx. 0.02 g) of LOC-
TITE (No. 638) to the bolt.
a Tighten the bolt without taking the spool
3 Bolt: 6.9 – 9.8 Nm {0.7 – 1.0 kgm}

out of the block.
3) Fit the O-ring to cases (45) and (44).

4) Install cases (45) and (44) to the block with
3 Bolt:
the mounting bolts.
11.8 – 14.7 Nm {1.2 – 1.5 kgm}

5) Fit the O-ring to plug (43) and install them to
the block.
6) Install retainer (42), spring (41), retainer
(40), and spring (39) to the block.
3 Plug:
7) Tighten plug (43).
14.7 – 19.6 Nm {1.5 – 2 kgm}

8) Fit the O-ring to cases (38) and (37).
9) Install cases (38) and (37) to the block with
3 Bolt:
the mounting bolts.
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
2. Tilt control valve

1) Fit the O-ring to case (36).
2) Install case (36) to the block with the mount-
3 Bolt:
ing bolts.
11.8 – 14.7 Nm {1.2 – 1.5 kgm}

3) Install retainer (35) and spring (34) to the
3 Bolt: 6.9 – 9.8 Nm {0.7 – 1.0 kgm}

block with bolt (33).

3 Bolt:
ing bolts.
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
3. Angle control valve

3 Bolt:
ing bolts.
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
30-70 D31/37/39EX, PX-21

(1)
D31/37/39EX, PX-21 30-71

(1)
Assembly of main control valve assembly 2/2 7. Unload valve

1) Install spring (10) to the block.
1. Plugs 2) Fit the O-ring to plug (9) and screw them
3 Plug:
1) Fit the O-ring and tighten plug (26). into the block
3 Plug:
a 2 sets
147 – 186.2 Nm {15 – 19 kgm}
147 – 186.2 Nm {15 – 19 kgm} 3) Fit the O-ring to plug (7).
3 Plug: 49 – 58.8 Nm {5 – 6 kgm}

2) Fit the O-ring and tighten plug (25). 4) Install spring (8) and plug (7) to sleeve (5).
3 Plug:
5) Screw plug (7) into sleeve (5).
3 Plug:
3) Fit the O-ring and tighten plug (24).
34.3 – 44.1 Nm {3.5 – 4.5 kgm}
147 – 186.2 Nm {15 – 19 kgm} 6) Fit the O-ring and ring (6) to sleeve (5).
3 Plug:
4) Fit the O-ring and tighten plug (23). 7) Screw unload valve assembly (4) into the
3 Unload valve assembly:

block.
19.6 – 27.5 Nm {2 – 2.8 kgm}
117.6 – 161.8 Nm {12 – 16.5 kgm}
2. Cooler bypass valve
1) Fit the O-ring to plug (20). 8. Plug (Pressure releasing)
2) Install spring (22) and valve (21) to the block 1) Fit the O-ring and backup rings (3) and (2)
3 Plug:
with plug (20). to plug (1).
2) Screw pressure releasing plug (1) into the
3 Plug:
147 – 186.2 Nm {15 – 19 kgm} block.
3. Check valve (Angle) 34.3 – 44.1 Nm {3.5 – 4.5 kgm}

1) Fit the O-ring to plug (17).
2) Install spring (19) and valve (18) to the block
with plug (17).
3 Plug:
a 2 sets
19.6 – 24.5 Nm {2 – 2.5 kgm}
4. Main relief valve assembly

1) Fit the O-ring and ring (16).
2) Screw main relief valve assembly (15) into
3 Main relief valve assembly:

the block.
137 – 157 Nm {14 – 16 kgm}
5. Suction valve
Fit the O-ring and screw suction valve (14) into
the block.
3 Suction valve:
a 3 sets
39.2 – 49 Nm {4 – 5 kgm}

1) Install 3 springs (13) and 3 springs (12) to
the block.
2) Fit 6 O-rings to 6 plugs (11).
3 Plug: 47 – 58.8 Nm {4.8 – 6 kgm}

3) Screw plug (11) into the block.
30-72 D31/37/39EX, PX-21

(1)
D31/37/39EX, PX-21 30-73

(1)
DISASSEMBLY AND ASSEMBLY BLADE
REMOVAL AND 6. Disconnect the following 6 cylinder hoses.

• (6): Tilt hose (Left side: 2)
INSTALLATION OF BLADE • (7): Angle hoses (Left side: 2, Right side: 2)
ASSEMBLY
REMOVAL
k Referring to TESTING AND ADJUSTING, Bleed-
ing air from hydraulic cylinder, release the pres-
sure from the piping, then loosen the oil filler cap
of the hydraulic tank to release the pressure from
the tank.
1. Lower the blade to level ground and set block [1]

under the work equipment frame.
7. Sling work equipment assembly (8) temporarily.

a Connect the rear hanging wires to a chain
block, etc. to balance the work equipment
assembly.
2. Sling lift cylinder (1) temporarily.

a Perform the following procedures up to 5 for
both right and left sides.
3. Remove lock plate (2) and pull out cylinder head

pin (3). [*1]
a Both sides
8. Remove lock plate (9) and pull out frame fitting
4. Secure the head side of lift cylinder (1) to the pin (10). [*2]
engine hood knob with ropes, etc. a Both sides
a The head side of the cylinder may be se-
cured to the knob of the cab or ROPS.
a Both sides
5. Remove covers (4) and (5).

a Both sides
30-74 D31/37/39EX, PX-21

(1)
DISASSEMBLY AND ASSEMBLY BLADE
9. Lift off work equipment assembly (8). INSTALLATION
4
Work equipment assembly: removal.
950 kg (D31EX-21)
1,050 kg (D31PX-21) [*1]
1,000 kg (D37EX-21) k When aligning the pin holes, use a bar.
1,100 kg (D37PX-21) Never insert your fingers in the pin holes.
1,150 kg (D39EX-21)
1,200 kg (D39PX-21) [*2]
k When aligning the pin holes, use a bar.
Never insert your fingers in the pin holes.

again.
• Greasing
a After assembling the blade assembly, apply
grease to the removed pins securely.
D31/37/39EX, PX-21 30-75

(1)
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
DISASSEMBLY AND 3) Pull out piston rod assembly (3).

a Place an oil receiving pan, etc. under the
ASSEMBLY OF HYDRAULIC cylinder bottom to receive the oil.
CYLINDER ASSEMBLIES
SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
790-502-1003 Repair stand t 1

1
790-101-1102 Pump t 1
2 790-330-1100 Wrench t 1
3 790-302-1270 Socket t 1
4 790-720-1000 Expander t 1
796-720-1650 Rubber band q 1 2. Piston assembly and head assembly
5 1) Set piston rod assembly (3) to tool U1.
07281-01029 Clamp q 1
2) Using tool U3, remove nylon nut (4).
U 790-201-1720 Push tool kit 1 a Width across flats: 50 mm (Common to all
790-201-1751 • Push tool t 1 cylinders)
6
790-101-5021 • Grip t 1 3) Remove piston assembly (5) and head
01010-50816 • Bolt t 1 assembly (6).
790-201-1500 Push tool kit 1
790-201-1560 • Plate t 1
7
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 wrench
and tool U2, disconnect head assembly (2).
4) Disassembly of piston assembly

i) Remove wear ring (7).
ii) Remove piston ring (8).
30-76 D31/37/39EX, PX-21

(1)
5) Disassembly of head assembly iii) Install snap ring (11).

i) Remove backup ring (9) and O-ring. iv) Install packing (10).
ii) Remove packing (10) v) Install backup ring (9) and O-ring.
iii) Remove snap ring (11) and dust seal a Warm the backup ring in water at 50
(12). – 60°C before installing it.
iv) Remove bushing (13).
2) Disassembly of piston assembly

i) Set piston ring (8) to tool U4.
ASSEMBLY ii) Rotate the handle by 8 – 10 turns to
(Blade lift, angle, and tilt cylinders) expand the piston ring.
a Apply engine oil to the sliding surfaces of each iii) Remove piston ring (8) from tool U4.
part and take care not to damage the rod, pack- iv) Install piston ring (8) to piston assembly
ing, dust seal, and O-ring. (5).
v) Using tool U5, reduce piston ring (8).
1. Head assembly and piston assembly
1) Assembly of head assembly
i) Press fit bushing (13) with tool U6.
vi) Install wear ring (7).
ii) Using tool U7, install dust seal (12).
D31/37/39EX, PX-21 30-77

(1)
2. Piston rod assembly 6) Using a hydraulic pump or a power wrench
3
1) Set the piston rod to tool U1. and tool U2, tighten head assembly (2).
2) Install head assembly (6) and piston assem-
bly (5).
Cylinder name Tightening torque of head
3
3) Using tool U3, tighten nut (4).
637 ± 63.7 Nm
Blade lift
{65 ± 6.5 kgm}
Cylinder Width Tightening 569 ± 56.9 Nm
name across flats torque of nut Blade angle
{58 ± 5.8 kgm}
785 ± 78.5 Nm 677 ± 67.5 Nm
Blade lift 46 mm Blade tilt
{80 ± 8 kgm} {69 ± 6.9 kgm}
785 ± 78.5 Nm
Blade angle 46 mm
{80 ± 8 kgm}
1,080 ± 108 Nm
Blade tilt 50 mm
{110 ± 11 kgm}
a Before installing the nut, degrease the
2 Threads of rod:
threads of the piston rod thoroughly.
Adhesive (LOCTITE N262)
4) Set cylinder (1) to tool U1.

5) Install piston rod assembly (3) to the cylin-
der.
30-78 D31/37/39EX, PX-21

(1)
DISASSEMBLY AND ASSEMBLY OPERATOR’S SEAT FRAME
REMOVAL AND 5. Remove rear covers (3), (4), and (5).
INSTALLATION OF
OPERATOR’S SEAT FRAME
ASSEMBLY
REMOVAL
k Loosen the heater hose valve (If the machine is
equipped with the heater or air conditioner).
k Close the fuel stop valve. 6. Disconnect rear lamp wiring connector (CN33)
(6).
1. Drain the hydraulic oil.
6 Hydraulic tank: 47 l

water.
7. Lift off ROPS guard (7). [*1]
4 ROPS guard: 340 kg

a Both sides
D31/37/39EX, PX-21 30-79

(1)
8. Remove the 2 mounting bolts and seat belt (8). 11. Remove the mounting bolts and cover (11).
12. Disconnect center brake limit switch connector

PB1 (12), brake potentiometer connector BP1
(13), and decelerator pedal potentiometer con-
nector DP1 (14).
9. Remove 2 pins (9).
13. Disconnect decelerator pedal linkage (17) and

fuel control linkage (18). [*2]
10. Lift off operator’s seat assembly (10).
4 Operator’s seat assembly: 45 kg
14. Remove the mounting bolts and lift off floor

cover (19).
4 Floor cover: 35kg
30-80 D31/37/39EX, PX-21

(1)
15. Disconnect the 4 wiring connectors of the 4- 17. Disconnect the 4 floor wiring harness connec-
spool solenoid valve. tors and floor ground wire.
• (20): Parking brake solenoid valve connec- • (36): CN7
tor S4 (Color band: Brown) • (37): CN6
• (21): Slow brake solenoid valve connector • (38): CN8
S3 (Color band: Blue) • (46): CN5
• (22): 3rd gear speed solenoid valve connec- • (47): Floor ground wire
tor S2 (Color band: Green)
• (23): 2nd gear speed solenoid valve con-
nector S1 (Color band: Yellow)
18. Disconnect centralized drain block hose (39).
19. Disconnect 2 heater hoses (40).

16. Disconnect the 6 work equipment PPC hoses. (Only the model equipped with the heater or air
• (30): Angle right (Hose color band: Green) conditioner)
• (31): Tilt left (Hose color band: White)
• (32): Lift raise (Hose color band: Red) 20. Remove 3 floor wiring harness clamps (41).
• (33): Angle left (Hose color band: Blue)
• (34): Tilt right (Hose color band: Brown) 21. Disconnect heater unit wiring connector (CN92)
• (35): Lift lower (Hose color band: Orange) (42).
(Only the model equipped with the heater or air
conditioner)
D31/37/39EX, PX-21 30-81

(1)
22. Remove the mounting bolts and lift off operator's INSTALLATION
seat frame assembly (45). • Carry out installation in the reverse order to
4
removal.
Operator's seat frame assembly: 170 kg
3 Mounting bolt:
[*1]
245 – 309 Nm {25.0 – 31.5 kgm}
[*2]
a Adjust the fuel control linkage and decelera-
tor pedal linkage. For details, see TESTING
AND ADJUSTING, Adjusting fuel control le-
ver linkage and decelerator pedal linkage.
• Refilling with coolant

a Add coolant through the coolant filler to the
specified level. Run the engine to raise the
coolant temperature. Then, check the cool-
ant level again.

again.

a Bleed air from the HST circuit. For details,
air from HST circuit.
30-82 D31/37/39EX, PX-21

(1)
DISASSEMBLY AND ASSEMBLY FUEL TANK
REMOVAL AND 8. Lift off fuel tank assembly (10).
INSTALLATION OF FUEL 4 Fuel tank assembly:

TANK ASSEMBLY 110 kg (Dry weight)
REMOVAL
1. Remove the operator’s cab frame assembly.

For details, see REMOVAL OF OPERATOR’S
CAB FRAME ASSEMBLY.
2. Close the fuel stop valve.
3. Distance 2 fuel return hoses (1).
4. Disconnect the 2 fuel tank hoses.

• Hose (2): From fuel tank to fuel filter
• Hose (3): From fuel tank to fuel drain valve INSTALLATION
5. Remove clamp (4) and disconnect fuel hose (5). removal.
a When removing the clamp, remove the fuel
drain valve bracket, too.
[*1]
6. Remove clamp (6) and disconnect the following

2 connectors.
• (7): (CN13) Fuel sensor connector
• (8): (CN14) Backup alarm relay connector
7. Remove cap (9) and eyebolts. [*1]
D31/37/39EX, PX-21 30-83

(1)
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
REMOVAL AND 4. Remove cap (7) and mounting bolts.
INSTALLATION OF
HYDRAULIC TANK
ASSEMBLY
REMOVAL
1. Remove the operator’s cab frame assembly.

For details, see REMOVAL OF OPERATOR’S 5. Remove battery cover bolt (8).
CAB FRAME ASSEMBLY. a After removing the bolt, move the battery
cover so that the hydraulic tank assembly
2. Disconnect the following 5 hoses. [*1] will come off easily.
• (1): Delivery hose
• (2): Work equipment valve return hose
• (3): Left travel motor return hose
• (4): Right travel motor return hose
• (5): HST pump return hose
6. Lift off hydraulic tank assembly (9).
4 Hydraulic tank assembly: 70 kg
3. Disconnect oil filter hose (6).
30-84 D31/37/39EX, PX-21

(1)
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
INSTALLATION
removal.
a Take extreme care that each hose will not be
twisted when connected.
3 Clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

[*1]

again.

tails, see INSTALLATION OF HST PUMP
ASSEMBLY.
D31/37/39EX, PX-21 30-85

(1)
DISASSEMBLY AND ASSEMBLY HST CONTROLLER

INSTALLATION OF HST removal.
CONTROLLER ASSEMBLY
a If the HST controller assembly was replaced, ad-
REMOVAL just the new HST controller assembly according
k Disconnect the cable from the negative (–) ter- to TESTING AND ADJUSTING, Special func-
minal of the battery. tions of monitor panel (EMMS), 8-SERVICE AD-
JUST MODE.
1. Fold the operator's seat forward.
2. Disconnect the 3 wiring connectors.

• (1): ST1
• (2): ST2
• (3): ST3
3. Remove HST controller assembly (4).
30-86 D31/37/39EX, PX-21

(1)
90 OTHERS
Hydraulic circuit diagram (1/2) .........................90- 3

Hydraulic circuit diagram (2/2) .........................90- 5
Electrical circuit diagram (1/4) ..........................90- 7
Electrical circuit diagram (4/4) ..........................90-13
Air conditioner circuit diagram..........................90-15
D31/37/39EX, PX-21 90-1

HYDRAULIC CIRCUIT DIAGRAM (1/2)
D31/37/39EX, PX-21 90-3

HYDRAULIC CIRCUIT DIAGRAM (2/2)
D31/37/39EX, PX-21 90-5

ELECTRICAL CIRCUIT DIAGRAM (1/4)
D31/37/39EX, PX-21 90-7

D31/37/39EX, PX-21 90-9

D31/37/39EX, PX-21 90-11

D31/37/39EX, PX-21 90-13

AIR CONDITIONER CIRCUIT DIAGRAM
D31/37/39EX, PX-21 90-15

Bulldozer D39ex, PX-21 (1501 and Up)

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SEBM035005

MACHINE MODEL SERIAL NUMBER

• D31, D37, D39EX, PX-21 mount the SAA4D102E-2 engine.

10 STRUCTURE AND FUNCTION,

20 TESTING AND ADJUSTING ................................................................................... 20-1

30 DISASSEMBLY AND ASSEMBLY ................................................................... 30-1

00-2 D31/37/39EX, PX-21

The affected pages are indicated by the use of the

q Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGES

D31/37/39EX, PX-21 00-2-1

Time of Time of Time of Time of Time of

00-2-2 D31/37/39EX, PX-21

Time of Time of Time of Time of Time of

D31/37/39EX, PX-21 00-2-3

Time of Time of Time of Time of Time of

00-2-4 D31/37/39EX, PX-21

Time of Time of Time of Time of Time of

D31/37/39EX, PX-21 00-2-5

SAFETY NOTICE (Rev. 2007/03)

1. General precautions 8) Before starting work, warm up your body

D31/37/39EX, PX-21 00-3

00-4 D31/37/39EX, PX-21

4. Precautions for sling work and making signs

D31/37/39EX, PX-21 00-5

00-6 D31/37/39EX, PX-21

8. Precautions for disconnecting and connect-

★ Example of O-ring (Fitted to every joint of hoses

★ For tightening torque, see the precautions for in-

D31/37/39EX, PX-21 00-7

HOW TO READ THE SHOP MANUAL

1. Composition of shop manual

10. STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

20. TESTING AND ADJUSTING

Testing and adjusting

30. DISASSEMBLY AND ASSEMBLY

90. OTHERS (chassis volume)/Repair and replacement of parts (engine volume)

2. Revision and distribution

00-8 D31/37/39EX, PX-21

Item number (10. Structure and Function, Maintenance Standard)

Example 2 (Engine volume):

Unit number (1. Engine)

• 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.

D31/37/39EX, PX-21 00-9

EXPLANATION OF TERMS FOR MAINTENANCE STANDARD

1. Standard size and tolerance

★ The tolerance may be indicated in the text

• Usually, the size of a hole and the size of the

00-10 D31/37/39EX, PX-21

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value

D31/37/39EX, PX-21 00-11

HOW TO READ ELECTRIC WIRE CODE

Indicates size of wire by nominal No.

Indicates type of wire by symbol.

1. Type, symbol, and material