1997 Komatsu D31E-20, D31P-20, D31PL-20, D31PLL-20, D31P-20A, D31S-20, D31Q-20, D37E-5, D37P-5A Bulldozer Shop Manual (P/N SEBM001007)

The 1997 Komatsu shop manual SEBM001007 covers D31E-20, D31P-20, D31PL-20, D31PLL-20, D31P-20A, D31S-20, D31Q-20, D37E-5 and D37P-5A machines. It includes the standard dozer configurations, D31S/Q dozer shovels and a dedicated trimming dozer section.

• Engine diagnosis and service: Compression and blow-by testing, valve-clearance adjustment, fuel-injection timing, and engine, cylinder-head and injection-pump removal/installation.

• Hydroshift transmission: Internal clutch and carrier disassembly/reassembly, modulating and selector/inching valve service, and powertrain oil-pressure checks.

• Steering and final drives: PPC valve and steering-clutch overhaul, brake adjustment, bevel-gear setup, and final-drive disassembly/reassembly.

• Hydraulics and work equipment: Pump and control-valve service, cylinder overhaul, main-relief pressure testing, and steering- and angle-cylinder bleeding.

• Undercarriage: Track-frame removal, recoil-spring service, idler and roller rebuilding, and track-shoe work with component inspection standards.

• Electrical systems: Starting and charging circuits, engine-control diagrams, monitor-sensor test tables, and wiring-harness and connector inspection guidance.

Written for service personnel carrying out workshop repairs, the procedures call for pressure-test equipment, pullers and suitable lifting equipment.

Engine, Fuel System and Cooling

Separate testing and removal/installation procedures distinguish the 6D95L-1 from the turbocharged S4D102-1. Engine specifications separate D31 rated power at 2,350 rpm from D37 ratings at 2,500 rpm.

The repair sections cover nozzle holders, the turbocharger, engine oil cooler core, radiator, water pump and thermostat. This machine shop manual covers engine testing and assembly removal/installation; full internal engine overhaul requires the separate engine-series volume.

The injection-pump installation section warns that continuing to bar the engine with the positioning pin engaged can break the pin. The tool tables identify equipment such as barring gear 795-799-1130.

Powertrain Diagnosis and Overhaul

Power train skeletons and the Power Train Hydraulic Circuit Diagram explain the relationship between the damper, Hydroshift transmission, modulating valve and steering supply. Serial-specific control drawings help match the linkage and PPC arrangement before diagnosing shifting or steering faults.

Transmission assembly includes clutch-piston operational checks. Bevel-gear and final-drive work adds tooth-contact, backlash and bearing-preload information, supported by shim and wear-limit data.

Engine troubleshooting charts use S-mode symptom groups; hydraulic and mechanical troubleshooting uses H-mode charts. These cover problems such as hard starting, low engine output, delayed shifting, weak drawbar pull and blade drift.

Blade and Dozer-Shovel Hydraulics

Dedicated hydraulic circuit diagrams distinguish straight tiltdozers, power-angle/power-tilt dozers and D31S/Q dozer shovels. Cylinder procedures separate blade lift, tilt and angle work from bucket lift and dump assemblies.

Cylinder assembly precautions identify rod packings, dust seals and O-rings as parts that can be damaged during installation. Pressure testing involves pressurized oil, while raised work equipment and heavy assemblies require secure support.

Undercarriage and Workshop Reference Data

Separate track-roller procedures follow component serial breaks, while maintenance tables distinguish dry and lubricated track links. Inspection standards cover bushings, shafts, floating seals and frame components.

Reference tables include standard metric-bolt, split-flange and O-ring boss connector torques. Fluid tables distinguish specified system capacities from normal service refill quantities.

Electrical and Trimming-Dozer Details

Electrical Circuit Diagrams show starting, charging, lighting, warning and engine-stop circuits. Monitor-system coverage adds sensor resistance and switching tables.

The trimming dozer section separates inside- and outside-mounted lift cylinders and steel- or rubber-shoe arrangements. Its Work Equipment Hydraulic Circuit Diagram and system diagram accompany control-valve sections and wear standards; this material is used with the main machine chapters.

Examples of Fill Capacities and Valve-Clearance Data

A few entries from the capacity and adjustment tables show the detail provided in this manual.

Standard-model Hydroshift transmission tables distinguish a specified capacity of 16 liters from a refill quantity of 13 liters. Final-drive cases on D31E-20, D31S-20 and D31Q-20 machines are listed at 9.5 liters per side.

At normal temperature, valve-clearance standards are 0.35 mm intake and 0.50 mm exhaust for the 6D95L-1, compared with 0.25 mm intake and 0.51 mm exhaust for the S4D102-1.

Bookmarked PDF with Partial Text Search

Search, navigation and diagram detail: Text search is partial; several wiring and engine-control sheets have no searchable text. Embedded bookmarks cover the main sections and many components, although the legacy MAIN MENU entry links to an external HTML file. Dense wiring labels and connector numbers require zooming.

Supplied as one printable, 671-page English PDF, including the cover, four-page revised-page list, integrated 90-page Others/trimming-dozer section and one-page revision-request form. All 38 blank pages are already included in that total.