D41e 6

SEBM007009
, -
012406
MACHINE MODEL SERIAL NUMBER

D41E-6 B20001 – B40000
D41P-6 B20001 – B40000
D41E-6 50001 and up
D41P-6 50001 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.
• D41E,P-6 mounts the S6D102-1 engine.

For details of the engine, see the 102 Series Engine Shop Manual.
C 2005 1
All Rights Reserved 00-1
Printed in Japan 06-05(03) (9)
CONTENTS
No. of page
01 GENERAL .............................................................................. 01-1
10 STRUCTURE AND FUNCTION ............................................ 10-1
20 TESTING AND ADJUSTING ................................................ 20-1
30 DISASSEMBLY AND ASSEMBLY ....................................... 30-1
40 MAINTENANCE STANDARD............................................... 40-1
012406
90 OTHERS ................................................................................ 90-1
00-2
1
The affected pages are indicated by the use of the
following marks. It is requested that necessary actions
Mark Indication Action required
must be taken to these pages according to the list
below.
fi Page to be newly added Add
‡ Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are not revised at this time.
LIST OF REVISED PAGES
Revision Revision Revision Revision Revision

Mark Pages Mark Pages Mark Pages Mark Pages Mark Pages
number number number number number
‡ 00- 1 (9) ‡ 01- 8 (9) ‡ 10- 32 (9) ‡ 10- 58 (9) ‡ 10- 89 (9)
00- 2 (1) ‡ 01- 9 (9) ‡ 10- 32 -1 (9) ‡ 10- 59 (9) ‡ 10- 91 (9)
‡ 00- 2 -1 (9) 01- 9 -1 (6) 10- 33 10- 59 -1 (6) ‡ 10- 92 (9)
‡ 00- 2 -2 (9) 01- 9 -2 (6) ‡ 10- 34 (9) ‡ 10- 60 (9) 10- 93
‡ 00- 2 -3 (9) 01- 9 -3 (6) 10- 35 10- 61 10- 94
‡ 00- 3 01- 9 -4 (6) 10- 36 ‡ 10- 62 (9) ‡ 10- 95 (9)
‡ 00- 4 ‡ 01- 10 (9) 10- 37 10- 63 (6) 10- 96
‡ 00- 5 01- 11 (1) 10- 38 ‡ 10- 64 (9) ‡ 10- 97 (9)
‡ 00- 6 10- 1 (6) 10- 39 ‡ 10- 65 (9) ‡ 10- 98 (9)
‡ 00- 7 10- 2 10- 40 10- 66 20- 1
012406
‡ 00- 8 ‡ 10- 3 (9) 10- 41 ‡ 10- 67 (9) ‡ 20- 2 (9)

‡ 00- 9 ‡ 10- 4 (9) 10- 42 ‡ 10- 68 (9) 20- 3 (7)
‡ 00- 10 10- 5 (6) 10- 43 ‡ 10- 69 (9) 20- 4 (2)
‡ 00- 11 10- 6 ‡ 10- 43 -1 (9) ‡ 10- 70 (9) 20- 5 (2)
‡ 00- 12 ‡ 10- 7 (9) ‡ 10- 43 -2 (9) ‡ 10- 71 (9) 20- 6 (7)
‡ 00- 13 ‡ 10- 8 (9) ‡ 10- 43 -3 (9) ‡ 10- 72 (9) 20- 7 (7)
‡ 00- 14 10- 9 (6) ‡ 10- 43 -4 (9) ‡ 10- 72 -2 (9) 20- 8
‡ 00- 15 ‡ 10- 10 (9) ‡ 10- 43 -5 (9) ‡ 10- 72 -3 (9) 20-101 (8)
‡ 00- 16 ‡ 10- 11 (9) ‡ 10- 43 -6 (9) ‡ 10- 72 -4 (9) ‡ 20-102 (9)
‡ 00- 17 10- 12 ‡ 10- 43 -7 (9) ‡ 10- 72 -5 (9) ‡ 20-103 (9)
‡ 00- 18 ‡ 10- 13 (9) ‡ 10- 43 -8 (9) ‡ 10- 72 -6 (9) 20-104
‡ 00- 19 10- 13 -1 (6) ‡ 10- 43 -9 (9) ‡ 10- 73 (9) ‡ 20-105 (9)
‡ 00- 20 10- 14 (6) 10- 43-10 (1) ‡ 10- 74 (9) ‡ 20-106 (9)
‡ 00- 21 10- 15 ‡ 10- 44 (9) ‡ 10- 75 (9) 20-107
‡ 00- 22 10- 16 (6) 10- 44 -1 (6) ‡ 10- 76 (9) 20-108
01- 1 ‡ 10- 17 (9) 10- 45 (6) ‡ 10- 77 (9) 20-109 (7)
01- 2 (1) 10- 18 ‡ 10- 46 (9) ‡ 10- 78 (9) 20-110 (7)
01- 3 (1) 10- 19 (6) ‡ 10- 47 (9) ‡ 10- 79 (9) ‡ 20-110-1 (9)
‡ 01- 4 (9) 10- 20 (6) ‡ 10- 48 (9) ‡ 10- 80 (9) 20-110-2 (7)
‡ 01- 5 (9) 10- 21 (6) 10- 49 ‡ 10- 81 (9) ‡ 20-111 (9)
‡ 01- 6 (9) 10- 22 (6) ‡ 10- 50 (9) 10- 82 ‡ 20-111-1 (9)
‡ 01- 7 (9) ‡ 10- 23 (9) ‡ 10- 51 (9) 10- 83 ‡ 20-111-2 (9)
01- 7 -1 (6) 10- 24 ‡ 10- 52 (9) 10- 84 ‡ 20-111-3 (9)
01- 7 -2 (6) ‡ 10- 25 (9) ‡ 10- 53 (9) 10- 85 (2) 20-111-4 (2)
01- 7 -3 (6) ‡ 10- 26 (9) ‡ 10- 54 (9) ‡ 10- 86 (9) ‡ 20-111-5 (9)
‡ 01- 7 -4 (9) ‡ 10- 27 (9) 10- 55 (1) 10- 86 -1 (6) 20-111-6 (7)
01- 7 -5 (6) ‡ 10- 28 (9) ‡ 10- 56 (9) ‡ 10- 86 -2 (9) 20-111-7 (7)
01- 7 -6 (6) ‡ 10- 29 (9) 10- 57 (1) 10- 86 -3 (6) 20-111-8 (7)
01- 7 -7 (6) ‡ 10- 30 (9) ‡ 10- 57 -1 (9) ‡ 10- 87 (9) 20-111-9 (7)
‡ 01- 7 -8 (9) 10- 31 (1) 10- 57 -2 (1) ‡ 10- 88 (9) 20-112 (7)
00-2-1
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20-113 (2) ‡ 20-222 (9) ‡ 20-309 (9) 20-510 (7) ‡ 30- 38 -1 (9)
‡ 20-113-1 (9) ‡ 20-223 (9) 20-309-1 (7) ‡ 20-511 (9) 30- 38 -2 (5)
‡ 20-113-2 (9) ‡ 20-224 (9) 20-309-2 (7) ‡ 20-512 (9) ‡ 30- 39 (9)
‡ 20-114 (9) ‡ 20-225 (9) ‡ 20-310 (9) ‡ 20-512-1 (9) 30- 40 (7)
20-115 (7) ‡ 20-226 (9) 20-311 (7) 20-512-2 (7) 30- 41
‡ 20-116 (9) ‡ 20-227 (9) 20-312 (7) 20-512-3 (7) 30- 42
‡ 20-116-1 (9) fi 20-228 (9) 20-313 (2) 20-512-4 (7) 30- 43
‡ 20-116-2 (9) fi 20-229 (9) ‡ 20-313-1 (9) 20-513 (7) 30- 44
‡ 20-116-3 (9) fi 20-230 (9) 20-313-2 (7) 20-514 30- 45
‡ 20-116-4 (9) fi 20-231 (9) 20-314 (7) 20-515 (7) 30- 46
‡ 20-116-5 (9) fi 20-232 (9) 20-315 (2) ‡ 20-515-1 (9) 30- 47
‡ 20-116-6 (9) fi 20-233 (9) ‡ 20-315-1 (9) ‡ 20-516 (9) 30- 48
‡ 20-116-7 (9) fi 20-234 (9) 20-315-2 (7) ‡ 20-517 (9) 30- 49
‡ 20-116-8 (9) fi 20-235 (9) 20-316 (7) 20-518 (7) 30- 50
‡ 20-117 (9) fi 20-236 (9) 20-317 ‡ 20-519 (9) 30- 51
20-118 fi 20-237 (9) ‡ 20-317-1 (9) 30- 1 (3) 30- 52
20-119 fi 20-238 (9) 20-317-2 (7) 30- 2 (8) 30- 53 (3)
20-120 fi 20-240 (9) 20-318 (2) 30- 2 -1 (8) 30- 54
20-121 fi 20-241 (9) 20-319 30- 3 30- 55
20-122 fi 20-242 (9) 20-320 ‡ 30- 4 (9) ‡ 30- 56 (9)
‡ 20-123 (9) ‡ 20-251 (9) 20-321 ‡ 30- 5 (9) ‡ 30- 57 (9)
‡ 20-124 (9) ‡ 20-252 (9) 20-322 ‡ 30- 6 (9) ‡ 30- 58 (9)
20-125 ‡ 20-253 (9) 20-323 30- 7 (7) ‡ 30- 59 (9)
20-126 ‡ 20-254 (9) 20-324 30- 8 (3) ‡ 30- 60 (9)
20-127 (8) ‡ 20-255 (9) 20-325 30- 9 (7) ‡ 30- 61 (9)
012406
20-128 (8) ‡ 20-256 (9) 20-401 ‡ 30- 10 (9) ‡ 30- 62 (9)
20-129 (8) ‡ 20-257 (9) 20-402 ‡ 30- 12 (9) fi 30- 62 -1 (9)
‡ 20-201 (9) ‡ 20-258 (9) 20-403 ‡ 30- 13 (9) 30- 63 (8)
20-202 ‡ 20-259 (9) 20-404 30- 14 30- 64 (8)
‡ 20-203 (9) ‡ 20-260 (9) 20-405 30- 15 30- 65 (8)
‡ 20-204 (9) ‡ 20-261 (9) 20-406 30- 16 30- 66 (8)
‡ 20-205 (9) ‡ 20-262 (9) 20-407 ‡ 30- 17 (9) 30- 67 (8)
‡ 20-206 (9) ‡ 20-263 (9) 20-408 30- 18 30- 68 (8)
‡ 20-207 (9) ‡ 20-264 (9) 20-409 ‡ 30- 18 -1 (9) 30- 69 (8)
‡ 20-208 (9) ‡ 20-265 (9) 20-410 30- 18 -2 (7) ‡ 30- 70 (9)
‡ 20-209 (9) ‡ 20-266 (9) 20-411 ‡ 30- 19 (9) ‡ 30- 71 (9)
‡ 20-210 (9) ‡ 20-267 (9) 20-412 30- 20 ‡ 30- 72 (9)
‡ 20-211 (9) ‡ 20-268 (9) 20-413 30- 21 ‡ 30- 73 (9)
20-212 ‡ 20-269 (9) 20-414 30- 22 ‡ 30- 74 (9)
‡ 20-213 (9) ‡ 20-270 (9) 20-415 30- 23 ‡ 30- 74 -1 (9)
‡ 20-214 (9) ‡ 20-271 (9) 20-416 30- 24 30- 75
20-215-1 (7) ‡ 20-272 (9) 20-417 30- 25 (7) 30- 76
20-215-2 (2) ‡ 20-273 (9) 20-418 30- 26 (7) 30- 77
‡ 20-215-3 (9) 20-301 ‡ 20-501 (9) 30- 27 ‡ 30- 78 (9)
‡ 20-215-4 (9) 20-302 20-502 30- 28 30- 79
‡ 20-215-5 (9) 20-303 (2) 20-504 (7) 30- 29 30- 80
‡ 20-215-6 (9) 20-304 (7) 20-505 (2) 30- 30 30- 81 (8)
‡ 20-215-7 (9) 20-305 (2) ‡ 20-505-1 (9) 30- 31 30- 82 (8)
‡ 20-215-8 (9) ‡ 20-305-1 (9) 20-505-2 (7) 30- 32 30- 83 (8)
‡ 20-216 (9) 20-305-2 (7) 20-506 (2) 30- 33 (7) 30- 84 (8)
‡ 20-217 (9) 20-306 (7) 20-507 (7) 30- 34 (7) 30- 85 (8)
‡ 20-218 (9) 20-307 20-508 (2) 30- 35 30- 86 (8)
‡ 20-219 (9) ‡ 20-307-1 (9) ‡ 20-508-1 (9) 30- 36 (7) 30- 87 (8)
‡ 20-220 (9) 20-307-2 (7) 20-508-2 (7) ‡ 30- 37 (9) 30- 88 (8)
‡ 20-221 (9) 20-308 (7) 20-509 (7) 30- 38 (7) 30- 89 (8)
00-2-2
(9)
30- 90 30-135 30-191 ‡ 40- 11 (9) 90- 9 (1)

30- 91 30-136 30-192 ‡ 40- 12 (9) ‡ 90- 9 -1 (9)
30- 92 30-137 30-193 ‡ 40- 13 (9) ‡ 90- 11 (9)
‡ 30- 94 (9) 30-138 30-194 ‡ 40- 14 (9) 90- 11 -2 (6)
‡ 30- 95 (9) 30-139 30-195 ‡ 40- 15 (9) 90- 11 -4 (6)
‡ 30- 96 (9) 30-140 30-196 ‡ 40- 16 (9) ‡ 90- 13 (9)
‡ 30- 97 (9) 30-141 30-197 40- 17 (1) ‡ 90- 15 (9)
30- 98 30-142 ‡ 30-198 (9) ‡ 40- 17 -1 (9) 90- 17 (6)
‡ 30- 99 (9) ‡ 30-143 (9) ‡ 30-199 (9) ‡ 40- 17 -2 (9)
‡ 30-100 (9) 30-144 30-200 40- 18 (6)
‡ 30-101 (9) 30-145 30-201 ‡ 40- 19 (9)
‡ 30-102 (9) 30-146 ‡ 30-202 (9) 40- 20
‡ 30-103 (9) 30-147 ‡ 30-203 (9) ‡ 40- 21 (9)
‡ 30-104 (9) 30-148 30-204 (8) ‡ 40- 22 (9)
‡ 30-108 (9) 30-149 30-205 ‡ 40- 24 (9)
‡ 30-110 (9) 30-150 ‡ 30-206 (9) 40- 25 (1)
‡ 30-111 (9) 30-151 ‡ 30-207 (9) ‡ 40- 25 -1 (9)
‡ 30-112 (9) 30-152 30-208 40- 25 -2 (6)
‡ 30-113 (9) 30-153 30-209 ‡ 40- 26 (9)
30-114 30-154 30-210 ‡ 40- 27 (9)
30-115 30-155 30-211 (8) ‡ 40- 27 -1 (9)
‡ 30-116 (9) 30-156 30-212 (8) ‡ 40- 27 -2 (9)
‡ 30-117 (9) 30-157 30-212-1 (8) ‡ 40- 28 (9)
‡ 30-118 (9) 30-158 30-212-2 (8) 40- 28 -1 (6)
‡ 30-119 (9) 30-159 30-212-3 (8) 40- 28 -2 (6)
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‡ 30-120 (9) 30-160 30-212-4 (8) 40- 29 (1)

‡ 30-121 (9) 30-161 30-212-5 (8) ‡ 40- 29 -1 (9)
‡ 30-122 (9) 30-162 30-212-6 (8) 40- 29 -2 (1)
‡ 30-123 (9) 30-163 30-212-7 (8) 40- 29 -3 (6)
30-124 30-164 30-212-8 (8) 40- 29 -4 (1)
30-125 30-165 30-212-9 (8) 40- 29 -5 (6)
‡ 30-126 (9) 30-166 30-212-10 (8) 40- 29 -6 (6)
30-127 (3) 30-167 30-212-11 (8) 40- 29 -7 (6)
‡ 30-127-1 (9) 30-168 30-213 (8) 40- 29 -8 (6)
‡ 30-127-2 (9) 30-169 30-214 (7) 40- 29 -9 (6)
‡ 30-127-3 (9) 30-170 ‡ 30-215 (9) 40- 29-10 (6)
‡ 30-127-4 (9) ‡ 30-171 (9) ‡ 30-216 (9) ‡ 40- 30 (9)
‡ 30-127-5 (9) ‡ 30-172 (9) ‡ 30-217 (9) ‡ 40- 31 (9)
‡ 30-127-6 (9) 30-173 30-218 (8) ‡ 40- 32 (9)
‡ 30-127-7 (9) 30-174 ‡ 30-219 (9) ‡ 40- 33 (9)
‡ 30-127-8 (9) 30-175 30-220 (8) ‡ 40- 34 (9)
‡ 30-127-9 (9) 30-176 ‡ 30-221 (9) ‡ 40- 35 -1 (9)
‡ 30-128 (9) 30-177 30-222 ‡ 40- 35 -2 (9)
‡ 30-129 (9) 30-178 ‡ 30-223 (9) ‡ 40- 35 -3 (9)
‡ 30-130 (9) 30-179 ‡ 30-224 (9) ‡ 40- 35 -4 (9)
‡ 30-131 (9) 30-180 ‡ 30-225 (9) ‡ 40- 35 -5 (9)
‡ 30-132 (9) 30-182 ‡ 30-226 (9) ‡ 40- 36 (9)
30-133 (4) 30-183 ‡ 40- 1 (9) 40- 37
‡ 30-133-1 (9) 30-184 40- 2 ‡ 40- 38 (9)
‡ 30-133-2 (9) 30-185 ‡ 40- 3 (9) ‡ 40- 39 (9)
‡ 30-133-3 (9) 30-186 ‡ 40- 5 (9) 40- 40
‡ 30-133-4 (9) 30-187 ‡ 40- 6 (9) ‡ 90- 1 (9)
‡ 30-133-5 (9) 30-188 40- 7 90- 3 (4)
‡ 30-133-6 (9) 30-189 (7) ‡ 40- 8 (9) 90- 5 (6)
30-134 30-190 ‡ 40- 9 (9) 90- 7 (1)
00-2-3
(9)
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is 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 cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
• Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
• Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11.When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.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, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance standards.
TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL REVISED EDITION MARK
VOLUMES When a manual is revised, an edition mark

Shop manuals are issued as a guide to carrying out ((1)(2)(3)....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
Each issued as one Revised pages are shown in the LIST OF REVISED
Electrical volume:
}
Attachments volume: · volume to cover all
models
PAGES next to the CONTENTS page.
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
k
Special safety precautions
Safety are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order. tions or other precautions
2. Following examples show how to read the page a Caution for preserving standards
number. are necessary when per-
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3
4
tems. Caution necessary
Weight when selecting hoisting
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
3
Places that require special
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
5
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
Places where oil or water
6
item.
Drain must be drained, and
quantity to be drained.
3. 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
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may cause

k Heavy parts (25 kg or more) must be lifted the rope to slip off the hook during hoisting, and
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol 4
• If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing
3) Do not sling a heavy load with one rope alone,
interference with the part to be removed.
but sling with two or more ropes symmetrically
wound onto the load.
k Slinging with one rope may cause turning
WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to of the load during hoisting, untwisting of
the table below: the rope, or slipping of the rope from its
original winding position on the load, which
Wire ropes can result in a dangerous accident.
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
Rope diameter Allowable load
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
mm kN tons with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6
vertically, at various hanging angles.
14 21.6 2.2
16 27.5 2.8
When two ropes sling a load vertically, up to
18 35.3 3.6 19.6 kN {2000 kg} of total weight can be sus-
20 43.1 4.4 pended. This weight becomes 9.8 kN {1000 kg}
22.4 54.9 5.6 when two ropes make a 120° hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150°.
★ The allowable load value is estimated to be one-

sixth or one-seventh of the breaking strength of
the rope used.
2) Sling wire ropes from the middle portion of the

hook.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
k Before carrying out the following work, release Type 1

the residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from 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.
Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
★ The adapter can be pushed in about 3.5
mm.
★ Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.

(See Fig. 3)
★ Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See 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. (See Fig. 5)
★ When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
★ For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q’ty Container Main applications, features
• Used to prevent rubber gaskets, rubber

LT-1A 790-129-9030 150 g Tube
cushions, and cock plug from coming out.
• Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyethylene,
LT-1B 790-129-9050
(2 pcs.) container polyprophylene, tetrafluoroethlene and
vinyl chloride), rubber, metal and non-
metal.
• Features:
Polyethylene Resistance to heat and chemicals
LT-2 09940-00030 50 g
container • Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for metal,
790-129-9060
1 kg glass and plastic.
(Set of adhesive
LT-3 Hardening Can
and hardening
agent:
agent)
Adhesives 500 g
Polyethylene • Used as sealant for machined holes.
LT-4 790-129-9040 250 g
container
Holtz • Used as heat-resisting sealant for
790-126-9120 75 g Tube
MH 705 repairing engine.
• Quick hardening type adhesive
Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of metals,
rubbers, plastics and woods.
• Quick hardening type adhesive
• Quick cure type
Aron-alpha Polyethylene
790-129-9130 2g (max. strength after 30 minutes)
201 container
• Used mainly for adhesion of rubbers,
plastics and metals.
• Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc • Used at joint portions subject to high
648-50 container
temperatures.
• Used as adhesive or sealant for gaskets
LG-1 790-129-9010 200 g Tube
and packing of power train case, etc.
• Used as sealant for various threads, pipe
joints, flanges.
LG-5 790-129-9080 1 kg Can
• Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
• Features: Silicon based, resistance to
heat, cold
LG-6 790-129-9020 200 g Tube • Used as sealant for flange surface, tread.
• Used as sealant for oil pan, final drive
Gasket case, etc.
sealant • Features: Silicon based, quick hardening
type
LG-7 790-129-9070 1 kg Tube • Used as sealant for flywheel housing,
intake manifold, oil pan, thermostat
housing, etc.
Three bond • Used as heat-resisting sealant for
790-129-9090 100 g Tube
1211 repairing engine.
• Features: Silicone type, heat resistant,
Three bond vibration resistant, and impact resistant
419-15-18131 100 g Tube
1207B sealing material
• Used as sealing material for transfer case
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q’ty Container Main applications, features
• Used as lubricant for sliding portion (to

LM-G 09940-00051 60 g Can
prevent from squeaking).
Molybdenum
disulphide • Used to prevent seizure or scuffling of the
lubricant thread when press fitting or shrink fitting.
LM-P 09940-00040 200 g Tube
• Used as lubricant for linkage, bearings,
etc.
SYG2-400LI • General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature, light load
SYG2-350CA bearing at places in contact with water or
G2-CA SYG2-400CA-A Various Various steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum • Used for heavy load portion
SYG2-400M 400 g × 10 Bellows type
disulphide
Grease SYG2-400M-A 400 g × 20 Bellows type
grease
SYGA-16CNM 16 kg Can
LM-G (G2-M)
Hyper White • Seizure resistance and heat resistance
SYG2-400T-A
Grease G2-T higher than molybdenum disulfide grease
SYG2-16CNT 400 g Bellows type
G0-T (*) • Since this grease is white, it does not
SYG0-400T-A (*) 16 kg Can
*: For use in stand out against machine body.
SYG0-16CNT (*)
cold district
Biogrease G2B • Since this grease is decomposed by
SYG2-400B
G2-BT (*) bacteria in short period, it has less effects
SYGA-16CNB 400 g Bellows type
*: For high on microorganisms, animals, and plants.
SYG2-400BT (*) 16 kg Can
temperature
SYGA-16CNBT (*)
and large load
SUNSTAR • Used as primer for cab side
Glass
PAINT PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
417-926-3910
SUNSTAR • Used as primer for glass side
Glass
GLASS PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
SUNSTAR • Used as primer for painted surface on
Glass
PAINT PRIMER 22M-54-27230 20 ml cab side
Primer container
435-95 (Using limit: 4 months)
• Used as primer for black ceramic-
SUNSTAR
coated surface on glass side and for
GLASS PRIMER 22M-54-27240 150 ml Can
hard polycarbonate-coated surface
435-41
(Using limit: 4 months)
SUNSTAR • Used as primer for sash (Alumite).
Adhesive for cab glass
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months)
container
GP-402
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months)
SUPER 560 container)
SUNSTAR • “S” is used for high-temperature
PENGUINE season (April - October) and “W” for
Adhesive Polyethylene
SEAL 580 417-926-3910 320 ml low-temperature season (November -
container
SUPER “S” or April) as adhesive for glass.
“W” (Using limit: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml
Sikaflex 256HV container (Using limit: 6 months)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months)
container
SEAL No. 2505
SEKISUI • Used to seal front window.
Caulking Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months)
material container
SEALANT
GE TOSHIBA • Used to seal joint of glasses.
SILICONES 22M-54-27220 333 ml Cartridge Translucent white seal.
TOSSEAL 381 (Using limit: 12 months)
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Tightening torque
Thread diameter Width across
of bolt flats
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 – 7.5
12 19 98 – 123 10 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5

18 27 320 – 400 33 – 41
20 30 455 – 565 46.5 – 58
22 32 610 – 765 62.5 – 78
24 36 785 – 980 80 – 100
27 41 1150 – 1440 118 – 147

30 46 1520 – 1910 155 – 195
33 50 1960 – 2450 200 – 250
36 55 2450 – 3040 250 – 310
39 60 2890 – 3630 295 – 370
Tightening torque
Thread diameter Width across
of bolt flats
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
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

★ In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below. SAD00483
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 24.5 ± 4.9 2.5 ± 0.5

18 24 49 ± 19.6 5±2
22 27 78.5 ± 19.6 8±2
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal 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 128 – 186 {13.0 – 19.0} 157 {16.0}
10, 12 33 connector. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1010 {76.0 – 103} 883 {90.0}
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

10 10 17 9.8 – 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} 124.4 {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}
00-13
TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 10 0 2 1.02 0 0.20
8 24 0 4 2.45 0 0.41
10 43 0 6 4.38 0 0.61
12 77 0 12 7.85 0 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 802 0.81 0 0.20
8 10 0 2 1.02 0 0.20
10 12 0 2 1.22 0 0.20
12 24 0 4 2.45 0 0.41
14 36 0 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 301 0.31 0 0.10
1/8 802 0.81 0 0.20
1/4 12 0 2 1.22 0 0.20
3/8 15 0 2 1.53 0 0.20
1/2 24 0 4 2.45 0 0.41
3/4 36 0 5 3.67 0 0.51
1 60 0 9 6.12 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) Face seal type
type
Nominal size Width across
of hose flats Nominal thread
Thread size size Root diameter
Range Target - Threads per
(mm) inch, Thread series (mm) (Reference)
9
34 – 54 {3.5 – 5.5} 44 {4.5} – — – 18UN 14.3
02 19 16
34 – 63 {3.5 – 6.5} 44 {4.5} 14 – –
11
22 54 – 93 {5.5 – 9.5} 74 {7.5} – — – 16UN 17.5
03 16
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 – –
13
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 — – 16UN 20.6
16
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
3
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1 — – 12UN 30.2
16
(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 – –
00-14
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands (mm2) (mm2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
Color White & Red — White & Black Red & White Rellow & Red Green & White Blue & White
Code WB — BY RB YB GR LR
3
Color White & Black — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL — BR RY YG GY LY
Auxi-
4 liary Yellow & Green &
Color White & Blue — Black & Red Red & Yellow Blue & Yellow
Green Yellow
Code WG — — RG YL GB LB
5
Color White & Green — — Red & Green Yellow & Blue Green & Black Blue & Black
Code — — — RL YW GL n
6
Color — — — Red & Blue Yellow & White Green & Blue n
00-15
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), 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 two lines cross as (C). This point (C) gives the value when converting from
millimeters 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 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.
(B)
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
(C)
(A) 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
00-16
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
00-17
Liter to U.S. Gallon

1l = 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
Liter to U.K. Gallon

1l = 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 7.969 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
00-18
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
00-19
kg/cm2 to lb/in2
1kg/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 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as 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 81 117.8

–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 0 140.0 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
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22 04-05
GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model D41E-6 D41P-6
Serial No. B20001 – B40000 B20001 – B40000
Bare tractor kg 8,380 8,810

Operating
weight
With power angle tiltdozer kg 10,500 10,700

With power angle tilt + winch
kg {11,780} {12,200}
+ ROPS cab
Min. turning radius m 2.4 2.6

Gradeability deg 30 30
Stability (front, rear, left, right) deg 35 35
Forward 1st km/h 2.4 2.4

Speed ranges
Forward 2nd km/h 4.4 4.4

Performance
Forward 3rd km/h 7.6 7.6

Reverse 1st km/h 3.0 3.0
Reverse 2nd km/h 5.5 5.5
Reverse 3rd km/h 9.4 9.4
Bare tractor KPa {kg/cm2} 32.36 {0.33} 22.56 {0.23}

pressure
012406
Ground
With power angle tiltdozer KPa {kg/cm2} 40.21 {0.41} 27.46 {0.28}
With power angle tilt +
KPa {kg/cm2} 45.11 {0.46} 31.38 {0.32}
winch + ROPS cab
Overall
length
Bare tractor mm 3,610 3,635

With power angle tiltdozer mm 4,880 4,895
Overall
width
Dimensions
Bare tractor mm 2,300 2,490

With power angle tiltdozer mm 3,045 3,045
To tip of exhaust pipe mm 2,700 2,720

Overall height
To top of operator's compartment mm 2,020 2,040

With ROPS cab installed mm 2,885 2,905
With ROPS canopy installed mm 2,885 2,905
With canopy installed mm 2,715 2,735
Note: The values for the weight and ground pressure in { } are reference values.
01-4
(9)
Serial No. B20001 – B40000 B20001 – B40000
Track gauge mm 1,790 1,790

Dimensions
Length of track on ground mm 2,485 2,745

Width of track shoe (standard) mm 510 700
Min. ground clearance mm 365 440
(to bottom of undercover)
Name S6D102-1 S6D102-1

Type 4-cycle, water-cooled, in- 4-cycle, water-cooled, in-
line, vertical type, direct line, vertical type, direct
injection, with turbocharger injection, with turbocharger
No. of cylinders – bore x stroke mm 6 – 102 x 120 6 – 102 x 120
Piston displacement ¬ {cc} 5.9 {5,900} 5.9 {5,900}
Rated horsepower KW/rpm {HP/rpm} 77.9/2,400 {104.5/2,400} 77.9/2,400 {104.9/2,400}
Performance
Max. torque Nm/rpm {kgm/rpm} 461/1,300 {47/1,300} 461/1,300 {47/1,300}

Engine
High idling speed rpm 2,650 2,650

Low idling speed rpm 825 825
012406
Min. fuel consumption

g/KWh{g/HPh} 211 {157} 211 {157}
ratio
Starting motor 24V, 5.5 KW 24V, 5.5 KW

Alternator 24V, 40A 24V, 40A
Battery 12V, 65Ah x 2 12V, 65Ah x 2
Radiator core type D-5 D-5
Planetary gear type, multiple disc clutch,

hydraulically actuated, lubrication gear pump,
Transmission force feed, forward 3 speed, reverse 3 speed,
Power train system
manual mechanical type
Bevel gear shaft Spiral bevel gear, splash type lubrication

and brake
Wet type, single disc, manually operated,

Steering clutch
Clutch
hydraulically actuated
Wet type, single disc, manual/pedal operated,
Steering brake
hydraulically actuated
Final drive 1-stage spur gear, splash type lubrication
01-5
(9)
Serial No. B20001 – B40000 B20001 – B40000
Suspension Rigid type
Carrier roller 1 on each side

Undercarriage
Track roller 6 on each side 7 on each side
Track shoe Assembly type,

single grouser,
510 mm —
41 on each side,
pitch: 171.5 mm
Assembly type, special
track shoe for swampy
700 mm —
areas, 44 on each side,
pitch: 171.5 mm
Power train pump Gear type (SAR(2)-28)
Hydraulic pump Gear type (SAR(2)-36)

Theoretical discharge amount ¬/min 90
2
Max. discharge pressure MPa{kg/cm } 20.6 {210}
012406
Main control valve
3-spool type, manually operated
Type (lift + tilt + angle)
Type Double-acting piston type
Blade lift cylinder
Cylinder bore mm 105

Work equipment hydraulic system
Outside diameter of piston rod mm 50

Pistron stroke mm 325
Max. distance between pins mm 973
Min. distance between pins mm 648

Blade tilt cylinder
Hydraulic cylinders

Max. distance between pins mm 749
Min. distance between pins mm 569
Blade angle cylinder

Max. distance between pins mm 1,844
Min. distance between pins mm 1,137
Hydraulic tank Box type (externally installed control valve)
01-6
(9)
Serial No. B20001 – B40000 B20001 – B40000
Hydraulic type angle tiltdozer

Type
(power angle, power tiltdozer)
Blade support method Hydraulic cylinder type
Max. lifting height (from ground) mm

Work equipment
1,010 1,085 (*1)

Performance
Max. lowering depth (from ground) mm 490 415 (*1)

Max. tilt mm Right: 485, Left: 645 Right: 485, Left: 645
Max. angle deg 25 25
(For transportation: Left 55) (For transportation: Left 30)
Dimensions
Blade width mm 3,045 3,045

Blade height mm 1.060 1.060
Blade cutting angle deg 57 57
*1. The values are dimension from tip of track shoe.

012406
01-7
(9)
GENERAL WEIGHT TABLE
WEIGHT TABLE
¤ This weight table is for use when handling components or when transporting the machine.
Unit: kg
Serial No. B20001 – B40000 B20001 – B40000
Engine, damper assembly 515 515
• Engine assembly 485 485
• Damper assembly 26 26
• Engine mount parts (wiring) 1.5 1.5
Radiator assembly (including oil cooler) 80 80
• Oil cooler assembly (for power train) 3.5 3.5
Fuel tank assembly 105 105
Universal joint 7 7
Transmission assembly (including valve) 275 275
012406
Transmission valve assembly 12 12
Steering clutch, brake assembly 780 780
Steering piston assembly 15 15
Priority valve assembly 2 2
Brake valve assembly 10 10
Parking brake cylinder assembly 15 15
Final drive assembly (each side) 440 440
Frame assembly 2,155 2,280
• Track frame 1,435 1,490
• Idler assembly 50 x 2 50 x 2
• Track roller assembly 35 x 12 35 x 14
• Carrier roller assembly 15 x 2 15 x 2
01-8
(9)
GENERAL WEIGHT TABLE
Unit: kg
Serial No. B20001 – B40000 B20001 – B40000
Track shoe assembly (each side)
• 510 mm,shoe (wet type link) 840 —
• 700 mm,shoe (wet type link) — 1,030
Hydraulic tank assembly 40 40
Main control valve 25 25

(Lift + tilt + angle)
Operator's seat 35 35
Power angle tiltdozer assembly 1,475 1,475
• Blade 716 716
• Dozer frame 573 573
• Tilt cylinder assembly 30 30

012406
• Angle cylinder assembly 95 95
Blade lift cylinder assembly 35 x 2 35 x 2
Hydraulic, power train pump assembly 13 13
ROPS cab assembly 250 250
FLoor frame assembly 240 240
Cab assembly 285 285
ROPS canopy assembly 340 340
Canopy assembly 105 105
01-9
(9)
GENERAL TABLE OF FUEL, COOLANT AND LUBRICANTS
TABLE OF FUEL, COOLANT AND LUBRICANTS
KIND OF AMBIENT TEMPERATURE CAPACITY (¬)

RESERVOIR –22 –4 14 32 50 68 86 104°F
FLUID –30 –20 –10 0 10 20 30 40°C Specified Refill
SAE 30CD,CE,CF-4
SAE 10WCD,CE,CF-4
Engine oil pan 26.8 22.8
SAE 10W-30CD,CE,CF-4
SAE 15W-40CD,CE,CF-4
Damper case 1.1 1.1
Transmission case SAE 30CD 22 19
80 (Serial No.:
B20001 – B40000)
Steering clutch case Engine SAE 10WCD 80 74 (Serial No.:
50001 and up)
oil
Final drive case (each) 13 13
SAE 10WCD
Hydraulic oil system SAE 10W-30CD 73 37
SAE 15W-40CD
Serial No.: B20001 – B40000

Serial No.: 50001 – 50200
Idler (each) SAE 30CD
012406
0.15 0.15
Serial No.: 50201 and up
0.165 0.165
Serial No.: B20001 – B40000
Serial No.: 50001 – 50074
Track roller (each) 0.16 0.16
GO 140
Gear oil Serial No.: 50075 and up
0.255 0.255
Carier roller (each) 0.20 0.20
Diesel ASTM D975 No. 2

Fuel tank 225 —
fuel ASTM D975 No.1
Cooling system Coolant Add antifreeze —

(including sub tank) 30
01-10
(9)
STRUCTURE AND FUNCTION RADIATOR, OIL COOLER
ª1. Serial No.: B20001 – B20500
ª2. Serial No.: B20501 – B40000

012406
Specifications
Outline Power train
Radiator oil cooler
• A sub-tank is installed to the radiator to
make it possible to check the radiator water Core type D-5 PTO-OL
level.
• The power train oil cooler is built into the Fin pitch (mm) 3.0 —
lower tank. Heat dissipation
capacity (kcal/h) 83,700 13,450
Heat dissipation
area (m2) 30.08 0.409
10-3
(9)
STRUCTURE AND FUNCTION ENGINE CONTROL
ENGINE CONTROL
Serial No.: B20001 – B40000
Serial No.: 50001 – 50200
w 2
1 q
012406
3
SLD00792
1. Decelerator pedal Outline

2. Throttle lever • The control of the engine speed is carried
3. Clutch out with the throttle lever (2) or decelerator
4. Cable pedal (1).
5. Loose spring
6. Fuel injection pump
Lever positions
[1]: Low idling
[2]: High idling
[3]: High idling
[4]: Low idling
10-4
(9)
STRUCTURE AND FUNCTION POWER TRAIN SYSTEM
POWER TRAIN SYSTEM

ª1. Serial No.: B20501 – B40000
012406
1. Engine (S6D102-1) 8. Bevel gear

2. Damper 9. Bevel gear shaft
3. Universal joint 10. Steering clutch
4. Power train pump (SAR028) 11. Steering brake
5. Hydraulic pump (SAR036) 12. Final drive
6. PTO 13. Sprocket
7. Transmission 14. Track
10-7
(9)
STRUCTURE AND FUNCTION POWER TRAIN HYDRAULIC PIPING DRAWING
POWER TRAIN HYDRAULIC PIPING DRAWING

Serial No.: B20001 – B40000
Serial No.: 50001 – 50200
012406
1. Central pressure pickup port A. Transmission modulating pressure

2. Brake valve (main relief pressure) pickup port (B)
3. Power train oil filter B. Inching pressure pickup port (A)
4. Steering piston C. Right steering clutch pressure pickup
5. Priority valve port (RC)
6. Steering PPC valve D. Left steering clutch pressure pickup
7. Transmission valve port (LC)
8. Hydraulic + power train pump E. Right steering brake pressure pickup
(SAR36+28) port (RB)
9. Power train oil cooler F. Left steering brake pressure pickup
(built into radiator lower tank) port (LB)
10. Shuttle valve
10-8
(9)
STRUCTURE AND FUNCTION POWER TRAIN HYDRAULIC PIPING DRAWING

012406
1. Central pressure pickup port A. Transmission modulating pressure

2. Brake valve (main relief pressure) pickup port (B)
3. Power train oil filter B. Inching pressure pickup port (A)
4. Steering piston C. Right steering clutch pressure pickup
5. Priority valve port (RC)
6. Steering PPC valve D. Left steering clutch pressure pickup
7. Transmission valve port (LC)
8. Hydraulic + power train pump E. Right steering brake pressure pickup
(SAR36+28) port (RB)
9. Power train oil cooler F. Left steering brake pressure pickup
(built into radiator lower tank) port (LB)
10. Shuttle valve
11. PPC last chance filter
10-9
6
STRUCTURE AND FUNCTION POWER TRAIN HYDRAULIC SYSTEM DIAGRAM
POWER TRAIN HYDRAULIC SYSTEM DIAGRAM

Engine at LOW IDLING, speed and steering lever at NEUTRAL, brake pedal at RELEASED
fl For details of this page, see page 90-3.
012406
10-10
(9)
012406
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM

20. Steering piston

20A. Right steering clutch piston
20B. Right steering brake piston
20C. Left steering clutch piston
20D. Left steering brake piston
21. Brake valve
21A. Parking valve
21B. Brake valve

1. Engine 22. Parking brake cylinder
2. Joint 23. Central pressure pickup port
3. PTO 14. REVERSE clutch
4. Transmission case 15. Oil cooler bypass valve A. Transmission modulating pressure
5. Oil strainer Set pressure: 0.8MPa (main relief pressure) pickup port (B)
6. Hydraulic + power train {8kg/cm2} B. Inching pressure pickup port (A)
pump F1,R1: 2.94±0.15MPa 9D. Inching valve 16. Oil cooler C. Right steering clutch pressure pickup
(SAR36+28) 9. Transmission control valve {30.0±1.5kg/cm2} 9E. Directional valve 17. Transmission lubrication valve port (RC)
7. Power train oil filter 9A. Modulating valve F2,R2,F3,R3: 2.99±0.15MPa 10. 1st clutch Set pressure: 0.3MPa D. Left steering clutch pressure pickup po
8. Priority valve Set pressure: {30.5±1.5kg/cm2} 11. 2nd clutch {3kg/cm2} E. Right steering brake pressure pickup
Set pressure: 2.75±0.1MPa N1: 2.89±0.15MPa 9B. Quick return valve 12. 3rd clutch 18. Transmission lubrication port (RB)
{28±1kg/cm2} {29.5±1.5kg/cm2} 9C. Speed valve 13. FORWARD clutch 19. Steering PPC valve F. Left steering brake pressure pickup por
(9)
10-11
STRUCTURE AND FUNCTION DAMPER, UNIVERSAL JOINT
DAMPER, UNIVERSAL JOINT
1 12
2
11
3 4
10
012406
6 5
8
7 13
SDD00798
1. Damper case Outline

2. Bearing • A wet type, friction spring type is used for
3. Coupling the damper.
4. Universal joint The damper stopper angle is set to 4.5° and
5. Cross pin the stopper torque (when the stopper angle
6. Shaft is 4.5°) is set to 1,451 Nm (148 kgm).
7. Friction spring
8. Hub
9. Stopper pin
10. Torsion spring
11. Drive plate
12. Oil filler plug
13. Inspection plug
10-12
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
TRANSMISSION CONTROL
Serial No.: B20001 – B40000
Serial No.: 50001 – 50200
i q
u
y
t
e
3
w
r
2
012406
SLD00799
Lever positions 1. Safety lever (parking lever)

[1]: Neutral 2. Brake valve
[2]: FORWARD 3. Steering, directional, speed lever
[3]: REVERSE 4. Steering PPC valve
[4]: Left swing 5. Transmission control valve
[5]: Right swing
[6]: 1st Outline
[7]: 2nd • Control of the transmission is carried out
[8]: 3rd using the steering, directional, and speed
lever.
10-13
(9)
STRUCTURE AND FUNCTION TRANSMISSION
1. Input coupling No. of plates and discs

2. Input shaft
3. PTO cover Clutch No. No. of plates No. of discs
4. No. 1 clutch housing No. 1 clutch 6 5
5. No. 1 carrier No. 2 clutch 6 5
6. No. 1 clutch piston
No. 3 clutch 4 3
7. Pinion shaft
8. Plate No. 4 clutch 3 2
9. Lubrication valve piston No. 5 clutch 4 3
10. Lubrication valve spring
12. No. 2, 3 carrier Speed range and path of transmission
13. No. 2, 3 clutch housing
14. No. 3 clutch piston Direction Speed range Clutches used (engaged)
15. Pinion shaft 1st No. 2, No. 5
16. No. 4 clutch piston FORWARD 2nd No. 2, No. 4
17. No. 4 clutch housing
3rd No. 2, No. 3
18. Pinion shaft
19. Transmission case 1st No. 1, No. 5
20. Plate REVERSE 2nd No. 1, No. 4
21. No. 4 carrier 3rd No. 1, No. 3
22. No. 5 clutch housing
012406
24. Bushing
25. Output shaft (bevel pinion)
26. Seal cage
27. Bearing cage
28. Cage Outline
29. Rear housing • The transmission has 3 forward speeds and
30. No. 5 clutch spring 3 reverse speeds and uses a combination of
31. No. 4 clutch spring disc clutches with planetary gear systems.
32. No. 3 clutch spring • The transmission uses 4 sets of planetary
33. No. 2 clutch spring (small) gear system and disc clutch and one rotat-
33a.No. 2 clutch spring (large) ing clutch (for 1st). The control valve sends
34. No. 1 clutch spring (small) hydraulic pressure to lock two of these
34a.No. 2 clutch spring (large) clutches in position to provide the selected
35. Clutch plate speed and direction of rotation.
36. Clutch disc • The No. 1 clutch locks REVERSE, the No. 2
37. Tie bolt clutch locks FORWARD, the No. 3 clutch
38. Strainer locks 3rd, the No. 4 clutch locks 2nd, and
the No. 5 clutch locks 1st.
• When the transmission is at neutral, both
the No. 1 clutch and No. 2 clutch are disen-
gaged.
(One of the No. 3, 4, or 5 clutches is en-
gaged.)
10-17
(9)
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
TRANSMISSION CONTROL VALVE

P4
D D
a P1
C C
B B
A
012406
SDD00810
Outline
• The transmission control valve sets the main
relief pressure as follows.
a. From priority valve (inlet port)
Set pressure
P1. Modulating valve pressure pickup plug Speed range
P4. Inching valve pressure pickup plug (MPa {kg/cm2})
2.89 ± 0.15
N1
{29.5 ± 1.5}
2.94 ± 0.15
F1, R1
{30.0 ± 1.5}
2.99 ± 0.15
F2, R2, F3, R3
{30.5 ± 1.5}
(when the engine is at rated)
• Furthermore, there is an inching valve in-
stalled in the circuit between the speed valve
and directional valve, and this makes it pos-
sible to carry out fine adjustment of the
travel speed.
10-23
(9)
1 2 3 4 5 6 7 8 9 10
11
12
13
012406
A-A
14
15 16 17 18
B-B 19 SDD00811
10-24
012406 STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
1. Cover 12. Stopper 23. Spring

2. Stopper 13. Cover 24. Piston
3. Load piston 14. Valve body 25. Spring
4. Spring (small) 15. Valve body 26. Inching valve
5. Spring (large) 16. Detent 27. Piston
6. Modulating valve 17. Plug 28. Piston spring
7. Piston 18. Directional valve spool 29. Piston
8. Piston spring 19. Speed valve spool 30. Plug
9. Piston 20. Inching valve spool 31. Detent
10. Stopper 21. Cover
11. Quick return valve 22. Stopper
10-25
(9)
MODULATING VALVE
Outline • Modulating graph

• The modulating valve consists of a modu-
lating valve and a quick return valve, and
acts to modulates the pressure.
• When the gear shift lever is operated to shift
gear, the clutch is pushed into close contact
by the piston. However, if high pressure is
suddenly applied, the piston will suddenly
engage the clutch. This will make the ma-
chine start suddenly, and it will cause an
excessive shock.
To prevent this, the modulating valve is in-
stalled. When the gear shift lever is oper-
ated to shift gear, it gradually raises the
pressure on the piston to the set pressure
and the clutch is engaged smoothly. This
allows the machine to start without any
shock, thereby improving the durability of
the power train and at the same time pro-
viding a comfortable ride for the operator.
• The figure on the right shows the relation-
ship between the time and the increase in
the hydraulic pressure of the modulating
012406
valve.
For example, when the gear is shifted from
R1 to R2, the oil from the pump passes
through the speed valve spool, flows to the
2nd clutch and fills the circuit up to the clutch
piston port.
The time taken for the circuit to be filled up
to the clutch piston port is called the “filling
time”.
When the circuit up to the clutch piston port
is filled with oil, the oil pressure starts to
rise. The time taken for the pressure to rise
to the set pressure is called the “build-up
time”. The filling time and build-up time
together are called the “modulating time”.
10-26
(9)
OPERATION
1. While traveling
• The oil from the power train pump enters
chamber B from port A.
The oil passes through orifice "b" and enters
chamber F to fill the two sets of clutch pis-
ton ports of the speed valve and directional
valve.
The pressure in this circuit is always set to
the set pressure by the action of modulat-
ing valve (1).
• When the pressure inside the circuit be-

comes higher, modulating valve (1) moves
to the left. It opens the passage between
chamber B and chamber E, so the oil from
the pump is relieved to chamber E.
If the pressure inside the circuit drops be-
cause of leakage of oil from the clutch pis-
012406
ton or valve, modulating valve (1) moves to

the right. This closes the passage between
chamber B and chamber E, so the oil from
the pump all flows to the clutch piston port.
2. Immediately after shifting gear shift lever

• When the gear shift lever is moved, the cir-
cuit from the power train pump to the clutch
piston port is switched and oil flows to the
desired clutch piston port.
When this happens, a difference in pressure
is generated between port A and chamber F
because the oil is restricted by orifice "b".
Because of the pressure at port A, quick
return valve (2) moves to the right.
At the same time, the oil in chamber D
passes through port G and is drained. This
relieves the back pressure on load piston
(3).
When this happens, modulating valve (1) is
moved to the right by the tension of springs
(4) and (5), and load piston (3) is returned to
the left.
10-27
(9)
3. While clutch pressure is rising

• When the oil sent under pressure from the
pump fills the circuit from port A to the
clutch piston port, the oil pressure starts to
rise.
When this happens, the difference in pres-
sure on both sides of orifice "b" is removed.
The quick return valve (2) moves to the left
and the passage between chamber D and
drain port G is closed.
At the same time, the oil passing from ori-
fice "c" of the quick return valve then passes
through orifice "d" and enters chamber D.
• The oil becomes the back pressure of load
012406
piston (3), compresses tension springs (4)
and (5) and moves the load piston (3) to the
right to close the passage between cham-
ber B and chamber E.
This operation repeatedly opens and closes
chamber B and chamber E to balance the
back pressure of chamber H and chamber D
with the tension of tension springs (4) and
(5). As a result, the pressure inside the cir-
cuit gradually rises and finally load piston
(3) comes into contact with the valve body
and cannot move any further.
When this happens, the rise in pressure of
modulating valve (1) is completed and the
pressure becomes the set pressure.
Modulating valve (1) repeatedly opens and
closes the passage between chamber B and
chamber E to let the oil from the pump flow
into chamber F and keep the clutch oil pres-
sure at the set pressure of modulating valve
(1).
The oil relieved from chamber B to cham-
ber E flows from chamber E into the oil
cooler circuit.
10-28
(9)
INCHING VALVE
Outline
• The inching valve is in the circuit between
the speed valve and directional (F-R) valve.
The amount that the inching pedal is oper-
ated adjusts the amount of oil (oil pressure)
sent from the speed valve to the directional
valve. The inching pedal changes the pres-
sure of the FORWARD or REVERSE clutch
to partially or fully disengage the clutches
and allow fine control of the travel, or to
make it possible to stop the machine.
• To reduce the shock when operating the
inching pedal, an inching valve with modu-
lation is employed.
Operation
1. Inching pedal not operated
Spool (1) is connected to the inching pedal,
so when the inching pedal is not being op-
erated, it is pushed fully to the right by the
inching control return spring. As a result,
valve (2) is pushed to the right by sleeve (3)
012406
together with spool (1).

The oil sent under pressure from the pump
passes through modulating valve (4) and
the speed valve and enters port B from port
A.
The oil at port B then passes through the
directional valve and flows to the FORWARD
or REVERSE clutch.
The oil at port B passes through orifice "a",
enters chamber C, and tries to move valve
(2) to the left through piston (5). However,
sleeve (3) is pushed to the right, so valve (2)
cannot move to the left. Therefore, throttle
"b" between ports A and B is kept fully open.
As a result, the oil from the inching valve
flows at the set pressure of modulating valve
(4), and engages the FORWARD or REVERSE
clutch.
When this happens, the oil in chamber D of
modulating valve (4) is stopped by spool
(1), so it does not flow to drain port E.
10-29
(9)
2. Fine operation of inching pedal

When the inching pedal is partially de-
pressed, spool (1) moves to the left by an
amount which corresponds to the amount
the pedal is depressed. When this happens,
sleeve (3) separates from valve (2).
Valve (2) is pushed by piston (5) and moves
to the left, but if the oil pressure in chamber
C is greater than the tension of springs (6)
and (7), valve (2) closes throttle "b" and the
oil pressure in chamber C is drained from
orifice "e". If the oil pressure in chamber C is
smaller than the tension of springs (6) and
(7), valve (2) opens throttle "b", main pres-
sure is brought in from modulating valve
(4), and the pressure in chamber C rises.
In this way, valve (2) balances the oil pres-
sure in chamber C with the tension of
springs (6) and (7).
The oil pressure in chamber C passes
through orifice "a", port B, and the direc-
tional valve, and becomes the pressure for
the FORWARD or REVERSE clutch. In other
words, the FORWARD or REVERSE clutch
pressure is reduced to the pressure set by
012406
springs (6) and (7), and the clutch is par-
tially engaged.
When this happens, the passage between
chamber D of modulating valve (4) and drain
port E opens, so the oil from chamber D is
drained through orifice d. Load piston (8) of
modulating valve (4) moves to the position
of orifice "d", and the main pressure is kept
lowered.
3. Inching pedal fully depressed

When the inching pedal is fully depressed,
spool (1) moves to the left until it contacts
cover (9). In this condition, the tension of
springs (6) and (7) becomes the minimum,
and the FORWARD or REVERSE clutch pres-
sure is lowered to 0.07 – 0.09 MPa (0.7 – 0.9
kg/cm2). When this happens, the force of
the clutch piston return spring is greater
than the hydraulic pressure pushing the
clutch piston, so the clutch is disengaged
and the machine stops.
The passage between chamber D of modu-
lating valve (4) and drain port E is opened,
so the main pressure is kept lowered.
10-30
(9)
4. Inching pedal depressed → released

If the inching pedal is released after it has
been depressed, spool (1) is pulled back to
the right by the inching control return spring.
The inching valve is placed in the “Inching
pedal not operated” condition, and outputs
the same hydraulic pressure as modulating
valve (4). When this happens, the passage
between chamber D of modulating valve (4)
and drain port E is closed by spool (1), so
load piston (8) of modulating valve (4)
moves from the position of orifice "d" to the
end of its stroke. The main pressure rises to
the set pressure, and the FORWARD or RE-
VERSE clutch is engaged smoothly by this
modulation.
012406
10-31
1
STRUCTURE AND FUNCTION STEERING, BRAKE, INCHING CONTROL
STEERING, BRAKE, INCHING CONTROL

Serial No.: B20001 – B40000
Serial No.: 50001 – 50200
012406
Lever and pedal positions 1. Brake pedal

[1]: Neutral 2. Rod (brake pedal)
[2]: Left clutch disengaged 3. Parking brake cylinder
[3]: Left clutch disengaged 4. Safety lever (parking lever)
Left brake applied 5. Brake valve
[4]: Right clutch disengaged 6. Steering, directional, speed lever
[5]: Right clutch disengaged 7. Steering piston
Right brake applied 8. Steering PPC valve
[6]: Brake released 9. Priority valve
[7]: Brake applied 10. Rod (inching pedal)
[8]: Free 11. Inching pedal
[9]: Lock 12. Shuttle valve
10-32
(9)

012406
Lever and pedal positions 1. Brake pedal

[1]: Neutral 2. Rod (brake pedal)
[2]: Left clutch disengaged 3. Parking brake cylinder
[3]: Left clutch disengaged 4. Safety lever (parking lever)
Left brake applied 5. Brake valve
[4]: Right clutch disengaged 6. Steering, directional, speed lever
[5]: Right clutch disengaged 7. Steering piston
Right brake applied 8. Steering PPC valve
[6]: Brake released 9. Priority valve
[7]: Brake applied 10. Rod (inching pedal)
[8]: Free 11. Inching pedal
[9]: Lock 12. Shuttle valve
13. PPC last chance fillter
10-32-1
(9)
Outline
• Steering, directional, speed lever (6) oper-
ates the steering and brake through steer-
ing PPC valve (8) and steering piston (7). In
addition, brake pedal (1) operates only the
brake through rod (2).
• Safety lever (4) is interconnected with the
parking brake valve, and acts also as a park-
ing brake.
• If steering, directional, speed lever (6) is
moved slightly to the left, the left steering
clutch is partially disengaged and the ma-
chine will turn gradually to the left.
• If steering, directional, speed lever (6) is
moved fully to the left, the left steering clutch
is completely disengaged, and the left steer-
ing brake is applied, so the machine turns
sharply to the left.
• If inching pedal (11) is depressed, the inch-
ing valve is actuated through rod (10), and
the directional clutch of the transmission is
disengaged, so the transmission of power
to the track is cut off. The inching pedal is
interconnected with the brake, and if the
012406
pedal is depressed further after the trans-

mission of power to the tracks is cut off, the
brake is actuated to stop the machine.
10-33
STRUCTURE AND FUNCTION BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE
BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE

Serial No.: B20001 - B20500
2 1 3
012406
B C
A A
Y
Z
B C
SDD00824
1. Steering piston
2. Steering unit
3. Breather
10-34
(9)
Serial No.: B20501 – B40000

012406
1. Steering piston
2. Steering unit
3. Breather
10-43-1
10-42
(9)
012406 STRUCTURE AND FUNCTION BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE
10-43-2
10-43
(9)
012406
1. Bevel gear shaft 11. Bevel gear shaft cage

2. Reaction receiving pin 12. Planet pinion
3. Brake backup plate 13. Bevel gear shaft bearing
4. Brake lining 14. Reaction receiving pin
5. Brake cam case 15. Clutch backup plate
6. Clutch hub 16. Clutch lining
7. Sun gear 17. Clutch plate
8. Carrier 18. Brake plate
9. Ring gear 19. Clutch cam case
10. Bevel gear 20. Brake hub
10-43-3
10-44
(9)
21. Steering case

22. Top cover
23. Needle bearing
24. Eccentric camshaft
25. Torque receiving pin
10-43-4
10-45
(9)
Outline
1. Bevel gear shaft 3. Steering brakes
• The power transmitted from the engine • The steering brakes are used to stop or
→ damper → transmission is transmit- turn the machine by braking the power
ted to the bevel pinion (transmission from the steering clutches to the final
output shaft) and bevel gear (10), which drive.
are meshed by the bevel gear shaft sys- • The steering brakes are a wet, single
tem. From here, it is sent at right angles disc, hydraulically boosted type. They
to the left and right by the bevel gear are hydraulically operated by the steer-
shaft, and the rotation speed is reduced ing PPC valve, which is actuated by op-
at the same time. eration of the steering lever, and the
• The bevel gear shaft system uses a spi- brake valve, which is actuated by the
ral bevel gear for the bevel pinion and brake pedal, and they are interconnected
bevel gear, and lubrication is carried out with the clutches. Lubrication is carried
by splash lubrication. out by splash lubrication.
• The bevel gear shaft system consists of • The steering brakes have two functions
bevel gear (10) and the following parts (parking brake and brakes to stop the
which form the planetary gear reduc- machine when traveling). The steering
tion system: ring gear (9), planetary pin- brakes are used as the parking brake by
ion (12), carrier (8), bevel gear shaft (1), setting the safety lever to the LOCK po-
bevel gear shaft bearing (13), and bevel sition.
gear shaft cage (11). • The steering brake consists of the fol-
lowing parts: brake hub (20), which is
2. Steering clutch joined by a spline to bevel gear shaft
012406
• In the planetary gear reduction system, (1), brake plate (18), brake lining (4),
sun gear (7) and bevel gear shaft (1) are brake cam case (5), brake backup plate
joined by a spline, and the power sent (3), eccentric camshaft (24) which sup-
from bevel gear shaft (1) to the left and ports the brake cam case, reaction re-
right final drives is transmitted or cut ceiving pin (2), which is secured to the
off in order to change the direction in steering case, and torque receiving pin
which the machine turns. (25).
• The steering clutches are a wet, single Eccentric camshaft (24) is supported to
disc, hydraulically boosted type. They the top cover and steering case by nee-
are hydraulically operated by the steer- dle bearing (23), and the brake lever is
ing PPC valve, which is actuated by op- installed to the top of the shaft.
eration of the steering lever, and they
are interconnected with the brakes. Lu-
brication is carried out by splash lubri-
cation.
• The steering clutches consist of the fol-
lowing parts: clutch hub (6), which is
joined by a spline to sun gear (7) of the
planetary gear reduction system, clutch
plate (17), clutch lining (16), clutch cam
case (19), clutch backup plate (15), ec-
centric camshaft (24), which supports the
clutch case, reaction receiving pin (14),
which is secured to the steering case,
and torque receiving pin (25).
Eccentric camshaft (24) is supported to
the top cover and steering case by nee-
dle bearing (23), and the clutch lever is
installed to the top of the shaft.
10-43-5
10-46
(9)
OPERATION OF STEERING CLUTCH

012406
1. Steering clutch engaged

When the steering lever is at the neutral
position, hydraulic pressure acts on the
clutch piston, and the clutch piston pushes
the clutch lever installed to the top of ec-
centric camshaft (24).
In this condition, clutch cam case (19) pushes
clutch lining (16) against clutch plate (17)
through eccentric camshaft (24), and locks
sun gear (7) of the planetary gear reduction
system.
Therefore, the power entering from the bevel
pinion passes through bevel gear (10), ring
gear (9), planetary pinion (12), and carrier
(8), is transmitted to bevel gear shaft (1),
and from here is output to the final drive.
10-43-6
10-47
(9)
012406
2. Steering clutch disengaged

When the steering lever is operated, the When the steering lever is released, the
steering PPC valve is switched and the hy- steering PPC valve returns to its original po-
draulic pressure stops acting on the clutch sition, so the hydraulic pressure acts on the
piston. As a result, the clutch lever installed clutch piston and engages the steering
to the top of eccentric camshaft (24) is re- clutch.
turned by the lever return spring. If the left steering clutch is disengaged, the
In this condition, the force pushing clutch power is transmitted only to the right steer-
lining (16) and clutch plate (17) together is ing clutch, so the machine will turn to the
lost, so sun gear (7) of the planetary gear left.
reduction system is not held in position.
Therefore, the power entering from the bevel
pinion only rotates bevel gear (10), ring gear
(9), planetary pinion (12), and sun gear (7),
and the power is not transmitted to bevel
gear shaft (1).
10-43-7
10-48
(9)
OPERATION OF STEERING BRAKE

012406
1. Steering brake released

If the steering lever is at the neutral posi-
tion and the brake pedal is released, hy-
draulic pressure does not act on the brake
piston, so the brake lever is installed to the
top of eccentric camshaft (24A) is returned
by the lever return spring.
In this condition, there is no force acting to
push brake lining (4) and brake plate (18)
together.
10-43-8
10-49
(9)
012406
2. Steering brake applied
(steering lever operated)
If the steering lever is operated fully, the
steering PPC valve is switched, and the steer-
ing clutch is disengaged. At the same time,
hydraulic pressure acts on the brake piston,
and the brake piston pushes the brake lever
installed to the top of eccentric camshaft
(24A).
In this condition, brake cam case (5) pushes
brake lining (4) into contact with brake plate
(18) through eccentric camshaft (24A), and
stops the rotation of bevel gear shaft (1).
The hydraulic force applied to the brake pis-
ton can be controlled by the amount that
the steering lever is operated. This makes it
possible to control the braking force and
thereby control the turning radius and turn-
ing time.
10-43-9
10-50
(9)
3. Brake applied (steering lever at neutral,

brake pedal depressed)
When the brake pedal is depressed, the
brake valve is switched. Hydraulic pressure
acts on the brake piston, and the brake pis-
ton pushes the brake lever installed to the
top of eccentric camshaft (24A).
The steering clutch remains engaged, while
the brake is actuated to stop the rotation of
bevel gear shaft (1).
10-43-10
10-51
1
STRUCTURE AND FUNCTION STEERING PPC VALVE
STEERING PPC VALVE A C

Serial No.: B20001 – B40000
Serial No.: 50001 – 50200
A C
D B
012406
a D b B
f
c
SAD00833
a. Port P (from power train pump) Outline
b. Port P1 (to right steering clutch piston) • The steering PPC valve is in the circuit be-
c. Port T (to transmission case) tween the power train pump and steering
d. Port P3 (to right steering brake piston) clutch piston and brake piston.
e. Port P2 (to left steering clutch piston) • The steering PPC valve is interconnected
f. Port P4 (to left steering brake piston) with the steering, directional, and speed le-
ver, and when the lever is operated to the
right or left to turn the machine, the steer-
ing PPC valve is actuated and sends hy-
draulic pressure to the steering clutch pis-
ton or brake piston.
• It is possible to control the amount of oil
discharged from the steering PPC valve by
adjusting the amount the lever is operated.
This makes it possible to control the turning
speed.
10-44
(9)
OPERATION OF STEERING PPC VALVE

1. At neutral
Brake piston A is connected from PPC valve
port P3 to drain chamber D.
Clutch piston B is connected from PPC valve
port P1 to pump pressure chamber PP.
D
Pp
PP
P T
2. Clutch neutral → clutch disengaged

If the lever is operated to raise portion "a" P3 P1
of link (1), piston (2) is pushed by centering
spring (3) and moves up. When this hap-
pens, valve (4) is also moved up by meter- A B
012406
ing spring (5).
As a result, the notch in valve (4) is shut off
from pump pressure chamber PP. At almost SAD00835
the same time, it is connected to drain cham-

ber D and allows the pressurized oil at port
P1 to escape. 1
When the pressure at port P1 goes down,
valve (4) is pushed back down by metering a
spring (5), and the opening of valve (4) is 2
shut off from drain chamber D. At almost 6
the same time, it is connected with pump
3
pressure chamber PP, so pressure oil is sup-
D 5
plied from port P1 to clutch piston B.
In this way, valve (4) moves up and down 4
to balance the force of metering spring (5) PP
Pp
and the pressure at port P1. P T
The relationship of the position of valve (4)
and body (7) does not change until valve (4)
contacts retainer (6).
Therefore, metering spring (5) extends in
proportion to the amount that the control
lever is moved, so the pressure at port P1 7
also goes down in proportion to the amount
that the control lever is moved. P3 P1
As a result, the pressure of clutch piston B
becomes the same as the pressure at port
P1. In addition, if retainer (6) pushes valve A B
(4) up, the connection between port P1 and
pump pressure chamber PP is cut off, and
SAD00836
port P1 is connected to drain chamber D.
10-46
(9)
3. Clutch disengaged → full stroke

(brake applied)
If the clutch is disengaged and portion "a"
of link (1) is moved up further (portion "b"
is moved down), piston (8) goes down, and
valve (9) is also moved down by metering
spring (10).
As a result, the opening of valve (9) is shut
off from drain chamber D. At almost the
same time, the notch is connected with
pump pressure chamber PP, so pressure oil
is supplied from port P3 to brake piston A.
When the pressure at port P3 goes up, valve
(9) is pushed back and the connection with
pump pressure chamber PP is shut off. At
almost the same time, it is connected to
drain chamber D and allows the pressurized 1
oil at port P3 to escape.
In this way, valve (9) moves up and down b
to balance the force of metering spring (10) 8 a
and the pressure at port P3.
The relationship of the position of valve (9) D
and body (7) does not change until retainer 11
(11) contacts valve (9).
Pp
PP
012406
Therefore, metering spring (10) is com- 10

pressed in proportion to the amount that
the control lever is moved, so the pressure 9 T
at port P3 also goes up in proportion to the

P
amount that the control lever is moved.
As a result, the pressure of brake piston A
becomes the same as the pressure at port
P3.
In addition, if retainer (11) pushes valve (9) 7
down, the connection between port P3 and
P3 P1
is drain chamber D cut off, and port P3 is
connected to pump pressure chamber PP.
A B
SAD00838
10-47
(9)
STRUCTURE AND FUNCTION STEERING PISTON
STEERING PISTON
012406
1. Brake piston
2. Clutch piston
Outline
• The steering piston consists of clutch piston • The brake piston is actuated by hydraulic
(2) and brake piston (1). pressure from the steering PPC valve which
• Clutch piston (2) is actuated by the hydrau- is actuated by the operation of the steering
lic pressure from the steering PPC valve, lever and brake, which is actuated by the
which is actuated by the operation of the brake pedal. The brake piston controls the
steering lever. The clutch piston controls the brake lever installed to the top of the brake
clutch lever installed to the top of the clutch eccentric camshaft of the steering unit.
eccentric camshaft of the steering unit.
10-48
(9)
STRUCTURE AND FUNCTION PRIORITY VALVE
PRIORITY VALVE
A B
C
A
012406
1 2 3 4
1. Return spring (large)

2. Return spring (small)
3. Valve
4. Plug
5. Valve spring
6. Valve
7. Spool
8. Shim
9. Valve body
10. Plug
10 9 8 7 6 E 5 A. Drain port
A-A SDD00840
B. To brake valve
C. To transmission valve
D. To steering PPC valve
E. From power train pump
10-49
STRUCTURE AND FUNCTION PRIORITY VALVE
Outline
• The priority valve is in the circuit from the
power train pump to the steering PPC valve,
brake valve, and transmission valve. It pre-
vents the hydraulic pressure in the steering
and brake circuit from dropping momentar-
ily when the transmission is shifted.
Operation
• When the transmission is not being shifted,
transmission valve port A of priority valve
spool (1) is opened, and the circuit from the
pump to the steering PPC valve and brake
valve becomes the pressure set by the trans-
mission valve.
• When the transmission is shifted, if the pres-
sure at transmission valve port A of the pri-
ority valve momentarily drops, priority valve
spool (1) closes port A, and the circuit pres-
sure from the pump to the steering PPC
valve and brake valve is set to the pressure
determined by the priority valve in order to
prevent the pressure from dropping.
• Relief set pressure:
2.7 MPa (28 kg/cm2) (65 ¬/min)
012406
10-50
(9)
STRUCTURE AND FUNCTION BRAKE VALVE
BRAKE VALVE
A 1
A
2
A 3 4 B C D 5
012406
11 10 9 E 8 7 6
1. Parking brake valve A-A
SDD00842
2. Main brake valve
3. Body
4. Return spring
5. Plug
6. Return spring
7. Valve
8. Piston Outline
9. Shaft • The brake valve is in the circuit between the
10. Modulating spring brake piston and power train pump through
11. Guide the transmission modulating valve and pri-
ority valve. It consists of the main brake
A. Port Br (R) (to right brake piston) valve and the parking brake valve.
B. Port P (pump port) • When the brake pedal is depressed, oil flows
C. Port T2 (main brake valve drain) to the brake piston, and the brake piston
D. Port Br (L) (to left brake piston) presses the disc and plate together to apply
E. Port T1 (parking brake valve drain) the brake.
10-51
(9)
OPERATION
1. Brake released (safety lever free, brake pedal released)
012406
• When the brake pedal at the “released” po- • When safety lever (14) is at the “free” posi-
sition (not being depressed), brake pedal tion, the oil entering from port A passes
(12) pushes the rod, and guide (11), shaft through port B, enters parking brake cylin-
(9), and brake valve (7) are pushed to the der (15), and pushes the cylinder piston to
right. the right. This pushes the brake cylinder rod
The oil from the power train pump enters to the right, but no force is brought to bear
port A and is stopped at port C. The oil on brake eccentric camshaft (16) because of
from brake piston (13) is drained from port the oblong portion provided in the lever.
D to port E, and the brake is released.
10-52
(9)
2. Brake applied (safety lever free, brake pedal depressed)

012406
• When the brake pedal (12) is depressed, between port D and drain port E opens, and
guide (11) and shaft (9) are returned to the the pressure beyond port D is maintained
left, and the force of modulating spring (10), and prevented from rising.
which was acting on brake valve (7), be- If the pedal is depressed further, the above
comes weaker, so brake valve (7) also moves action is repeated, and when the valve
to the left. When this happens, the passage reaches the end of its stroke, the brake is
between port C and port D opens, and the completely applied.
passage between port D and drain port E • The pressure beyond port D is determined
tries to close. The oil from the power train by the tension of return spring (6), which
pump enters port A, passes through ports receives a load in accordance with the
B, C, and D, and flows to the back pressure amount that the brake pedal is depressed.
port of brake piston (13). • Therefore, if the brake pedal is depressed
Some of the oil from port D passes through slightly, the hydraulic pressure beyond port
orifice and enters port H. When the pres- D is set low and the brake is partially ap-
sure of the oil entering port H rises, the plied. If the brake pedal is depressed a long
force pushing brake valve (7) to the right way, the hydraulic pressure is set high and
increases. When it becomes greater than the the brake is fully applied.
tension of return spring (6), the passage
10-53
(9)
3. Safety lever LOCK (brake pedal released, safety lever at LOCK)
012406
• If safety lever (14) (parking lever) is set to

the LOCK position, brake valve (1) is pulled
to the left. When this happens, the passage
between port A and port B closes, and the
passage between port B and port G opens.
The oil from the power train pump enters
port A and stops.
• If the oil flowing to parking brake cylinder
(15) and forming the back pressure flows
from port B through port G and is drained,
parking brake spring (17) extends and pulls
the brake cylinder rod to the left. Brake ec-
centric camshaft (16) is turned by the lever
and the brake is applied.
10-54
(9)
STRUCTURE AND FUNCTION POWER TRAIN OIL FILTER
POWER TRAIN OIL FILTER
X
A
2
X
B
012406
X-X
SED00846
Specifications
1. Power train oil filter
Performance
2. Head
0.2 ± 0.02 MPa
3. Filter cartridge Cracking pressure {2.0 ± 0.2 kg/cm2}
Mesh size 10 µm
A. To power train circuit
B. From power train pump Filtering area 3,600 cm2
Filter flow 80 ¬/min
10-55
1
STRUCTURE AND FUNCTION FINAL DRIVE
FINAL DRIVE
Serial No.: B20001 - B20500 fl The diagram shows the D41P-6.
012406
Outline
1. Sprocket • The final drive uses a single-stage spur gear
2. Final drive case reduction system. It is lubricated by splash
3. Pinion (No. of teeth: 11) type lubrication using the rotation of the
4. Gear (No. of teeth: 81) gear.
5. Cover The final drive is designed so that it can be
6. Floating seal removed or installed as a single unit.
7. Sprocket shaft • Floating seal (6) is installed to the rotating
8. Hub and sliding portion of the sprocket to pre-
vent entry of soil or sand from outside and
to prevent leakage of oil.
10-56
(9)
012406 STRUCTURE AND FUNCTION FINAL DRIVE
Path for transmission of power

The power from the steering clutch and bevel
gear shaft is transmitted to pinion (3). It then
passes through gear (4), which is meshed with
pinion (3), sprocket shaft (7), and sprocket hub
(8), and is transmitted to sprocket (1).
10-57
1
STRUCTURE AND FUNCTION FINAL DRIVE
Serial No.: B20501 – B40000

Serial No.: 50001 and up fl The diagram shows the D41P-6.
012406
Outline
1. Sprocket • The final drive uses a single-stage spur gear
2. Final drive case reduction system. It is lubricated by splash
3. Pinion (No. of teeth: 11) type lubrication using the rotation of the
4. Gear (No. of teeth: 81) gear.
5. Cover The final drive is designed so that it can be
6. Floating seal removed or installed as a single unit.
7. Sprocket shaft • Floating seal (6) is installed to the rotating
8. Hub and sliding portion of the sprocket to pre-
vent entry of soil or sand from outside and
to prevent leakage of oil.
10-57-1
10-62
(9)
012406 STRUCTURE AND FUNCTION FINAL DRIVE
Path for transmission of power

The power from the steering clutch and bevel
gear shaft is transmitted to pinion (3). It then
passes through gear (4), which is meshed with
pinion (3), sprocket shaft (7), and sprocket hub
(8), and is transmitted to sprocket (1).
10-57-2
10-63
1
STRUCTURE AND FUNCTION FRAME ASSEMBLY
FRAME ASSEMBLY fl The diagram shows the D41P-6.
ª1. Serial No.: B20501 – B40000

012406
1. Engine mount Outline

2. Frame assembly The frame assembly uses a hull frame structure
3. Power train unit mount with the main frame, track frame, and under-
guard forming an integrated unit.
10-58
(9)
STRUCTURE AND FUNCTION TRACK FRAME
TRACK FRAME fl The diagram shows the D41E-6.
Serial No.: B20001 – B40000

Serial No.: 50001 – 50200
012406
1. Idler • Track roller

2. Carrier roller
Qt'y Flange type and arrangement
3. Track frame
4. Sprocket D41E-6 6 S, S, S, S, S, S
5. Track roller guard
D41P-6 7 S, S, S, S, S, S, S
6. Track roller
10-59
(9)
STRUCTURE AND FUNCTION RECOIL SPRING
RECOIL SPRING
D41E Serial No.: B20001 – B20980
D41P Serial No.: B20001 – B20983
(ª) D41E Serial No.: B20981 – B40000

D41P Serial No.: B20984 – B40000
012406
1. Support connection
2. Housing
3. Nut
3A. Spacer (ª)
4. Rod
5. Dust seal, oil seal
6. Recoil spring Outline
7. Cylinder • The recoil spring moves rod (4) forward or
8. Piston (rod and piston form integrated unit) backward to adjust the track tension. The
9. U-packing recoil spring is moved by pumping in or
10. Wear ring releasing grease from lubricator (12). Recoil
11. Bushing spring (6) also acts to absorb any sudden
12. Lubricator shock applied to the idler.
10-60
(9)
STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM

POWER ANGLE TILTDOZER
6
5
4
3
2
1
012406
9
SLD00853
1. Blade angle cylinder 6. Hydraulic tank

2. Blade lift cylinder 7. Hydraulic, power train pump
3. Slow return valve (SAR36+28)
4. Main control valve 8. Hydraulic oil cooler
5. Hydraulic filter 9. Blade tilt cylinder
10-61
STRUCTURE AND FUNCTION WORK EQUIPMENT CONTROL
WORK EQUIPMENT CONTROL

POWER ANGLE TILTDOZER i
Serial No.: B20001 – B40000
Serial No.: 50001 – 50200 u
r
y q
t
w
e
2
012406
o
!0
SLD00854
Lever positions Outline

[1]: Blade HOLD • Control of the work equipment is carried
[2]: Blade LOWER out by operating work equipment control
[3]: Blade FLOAT lever (2), which moves a rod to move the
[4]: Blade RAISE spool of the main control valve (3).
[5]: Blade left tilt • If work equipment safety lever (1) is placed
[6]: Blade right tilt at the LOCK position, work equipment con-
[7]: Blade left angle trol lever (2) cannot be moved from the
[8]: Blade right angle HOLD position to the RAISE, TILT, or AN-
[9]: FREE GLE positions.
[10]: LOCK • If the blade is at the FLOAT position, work
equipment safety lever (1) cannot be placed
1. Work equipment safety lever at the LOCK position, so return work equip-
2. Work equipment control lever ment control lever (2) to the HOLD position,
3. Main control valve then place work equipment safety lever (1)
at the LOCK position.
10-62
(9)

012406
Lever positions Outline

1: Blade HOLD • Control of the work equipment is carried
2: Blade LOWER out by operating work equipment control
3: Blade FLOAT lever (2), which moves a rod to move the
4: Blade RAISE spool of the main control valve (3).
5: Blade left tilt • If work equipment safety lever (1) is placed
6: Blade right tilt at the LOCK position, work equipment con-
7: Blade left angle trol lever (2) cannot be moved from the
8: Blade right angle HOLD position to the RAISE, TILT, or AN-
9: FREE GLE positions.
0: LOCK • If the blade is at the FLOAT position, work
equipment safety lever (1) cannot be placed
1. Work equipment safety lever at the LOCK position, so return work equip-
2. Work equipment control lever ment control lever (2) to the HOLD position,
3. Main control valve then place work equipment safety lever (1)
at the LOCK position.
10-63
6
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM

Engine running, Hydraulic control lever at HOLD
012406
10-64
(9)
012406 STRUCTURE AND FUNCTION

1. Hydraulic tank
2. Hydraulic, power train pump
(SAR36+28)
3. Main control valve
3A. Main relief valve
Set pressure: 20.6MPa
{210kg/cm2}
3B. Unload valve
3C. Blade lift valve
3D. Blade tilt valve
3E. Blade angle valve
3F. Pressure compensation valve
3G. Suction valve
3H. Suction & safety valve
Set pressure: 24.5MPa
{250kg/cm2}
4. Slow return valve
5. Blade lift cylinder
6. Blade angle cylinder
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
7. Blade tilt cylinder

8. Oil cooler
9. Hydraulic filter
10. Breather
(9)
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
10-65
STRUCTURE AND FUNCTION HYDRAULIC TANK, FILTER
HYDRAULIC TANK, FILTER
2 B B
1 A-A
012406
A
A
SAD00857
1. Drain plug
2. Hydraulic filter
3. Hydraulic tank
4. Hydraulic tank oil filler cap
4A. Key cylinder
4B. Vacuum valve
4C. Pressure valve
A. From main control valve

B. To hydraulic tank
10-66
STRUCTURE AND FUNCTION HYDRAULIC TANK, FILTER
4 4A
4C 4B
B-B
B
A
012406
C
C
C-C SED00858
Specifications
Item Specified value
Capacity of hydraulic tank 60 ¬

Pressure valve 38.3 ± 14.7 KPa
Hydraulic cracking pressure {0.39 ± 0.15 kg/cm2}
tank cap Vacuum valve 0 – 3.9 KPa
actuating pressure {0 – 0.046 kg/cm2}
102.9 ± 19.6 KPa
Cracking pressure {1.05 ± 0.2 kg/cm2}
Hydraulic Mesh size 10 µm

filter
Filtering area 3,400 cm2
Filter flow 100 ¬/min
10-67
(9)
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
MAIN CONTROL VALVE

3-SPOOL VALVE (BLADE LIFT, TILT, ANGLE)
D41E,P-6
(1/5)
012406
a. Pump pressure pickup plug

b. Port B1 (to lift cylinder bottom)
c. Port B2 (to tilt cylinder head)
d. Port B3 (to angle cylinder bottom)
e. Safety valve circuit pressure release plug
f. Port A3 (to angle cylinder head)
g. Port A2 (to tilt cylinder bottom)
h. Port A1 (to lift cylinder head)
j. Port P (from hydraulic pump)
k. LS pressure pickup plug
m. Port TS (to hydraulic tank)
n. Port T (to hydraulic tank)
10-68
(9)
(2/5)
2
6
5 3
A-A
4
012406
10
11
B-B
SAD00860
1. Suction valve (angle cylinder head) 7. Auxiliary valve port plug (angle)
2. Suction valve (tilt cylinder bottom) 8. Angle spool
3. Auxiliary valve port plug (lift) 9. Tilt spool
4. Suction & safety valve 10. Lift spool
5. Suction valve (lift cylinder bottom) 11. Main relief valve
6. Auxiliary valve port plug (tilt)
10-69
(9)
(3/5)
1 2
9 3
8 4
012406
6 C-C
11
10
12
E-E
D-D
SAD00861
1. Pump pressure pickup plug 7. Pressure compensation valve F (lift)

2. Pressure compensation valve R (angle) 8. Pressure compensation valve F (tilt)
3. Pressure compensation valve R (tilt) 9. Pressure compensation valve F (angle)
4. Pressure compensation valve R (lift) 10. Check valve (angle)
5. LS selector piston 11. Safety valve circuit pressure release plug
6. Unload valve 12. LS pressure pickup plug
10-70
(9)
(4/5)
3
5
012406
F-F 4
6 7
G-G
10 9
SAD00862
1. Suction & safety valve 6. Suction valve (lift cylinder bottom)

2. Main relief valve 7. Auxiliary valve port plug
3. LS selector piston 8. Lift spool
4. LS bypass plug 9. Pressure compensation valve F
5. Unload valve 10. Pressure compensation valve R
10-71
(9)
(5/5)
1 2
H-H
5 4
012406
6 7
10 J-J 9
SAD00863
1. Auxiliary valve port plug 6. Auxiliary valve port plug

2. Suction valve (tilt cylinder bottom) 7. Suction valve (angle cylinder head)
3. Tilt spool 8. Angle spool
4. Pressure compensation valve R 9. Pressure compensation valve R
5. Pressure compensation valve F 10. Pressure compensation valve F
10-72
(9)
(9)
(9)
(9)
(9)
(9)
STRUCTURE AND FUNCTION CLSS
CLSS
OUTLINE
Features
CLSS stands for Closed center Load Sens-
ing System, and has the following features.
1) Fine control performance that is not af-
fected by the load.
2) Flow dividing control using a pressure
compensation valve to enable division
of the oil flow regardless of any differ-
ence in load. (Possible to operate lift,
tilt, and angle at the same time)
Structure
The CLSS consists of a fixed displacement
gear pump, control valve, and the actua-
tors.
012406
BASIC PRINCIPLE
1. Flow control
The flow of oil to the actuators is controlled
by the unload valve, which keeps ∆PLS con-
stant. (∆PLS is the difference in pressure
between pump discharge pressure PP and
control valve outlet pressure PLS (actuator
load pressure)).
ª Differential pressure ∆PLS =
pump discharge pressure PP – control
valve outlet pressure PLS
If ∆PLS becomes lower than the set pres-
sure of the unload valve, the oil supply is
increased; if it becomes higher than the set
pressure, oil is drained from the unload
valve to the tank to reduce the oil supply.
fl For details of the operation, see OPERA-
TION OF UNLOAD VALVE.
10-73
(9)
2. Pressure compensation control

A valve (pressure compensation valve) is
installed to the inlet port side of the main
control valve spool to balance the load.
If more than one actuator is operated at the
same time, the difference in pressure ∆PLS
between the upstream (inlet port) and down-
stream (outlet port) pressure at the notched
part of each spool is made equal by this
spool.
As a result, the flow of oil from the pump is
divided in proportion to the areas of open-
ing S1 and S2 of each valve.
012406
10-74
(9)
FUNCTIONS, OPERATION OF VALVE

Hydraulic circuit diagram and names of valves
012406
1. Unload valve 7. LS bypass plug

2. Suction & safety valve 8. Angle spool
Set pressure: 24.5 MPa {250 kg/cm2} 9. Tilt spool
3. Pressure compensation valve 10. Lift spool
4. Suction valve 11. Angle cylinder
5. Main relief valve 12. Tilt cylinder
Set pressure: 20.6 MPa {210 kg/cm2} 13. Lift cylinder
6. Check valve
10-75
(9)
1. Unload valve
Function
• When the work equipment control lever of oil sent to the actuators in proportion
is at HOLD, the unload valve relieves all to the area of opening of the spool.
the oil discharged from the pump at low • The unload valve is controlled by the
pressure (cracking pressure: 0.35 MPa difference in pressure on both sides of
{3.6 kg/cm2}) to the tank circuit to reduce the spool, so it also acts as a pressure
the loss of pressure from the pump to compensation valve to reduce the
the tank. change in the oil flow caused by the
• The unload valve controls the amount load pressure.
012406
Operation
1) Control lever at HOLD (unload valve set
to low pressure)
• When the work equipment spool is MPa {0 kg/cm2}. In this way, pump
at HOLD, the LS circuit is connected pressure PP acting on the lower side
to port TS through the throttle of LS of unload valve (1) is set only by
bypass plug (5), so LS circuit pres- load F1 of spring (2). (SA (area at
sure PLS = PTS = . 0 MPa {0 kg/cm2}. end of spool) x PP = F1)
.
Chamber A and chamber A1 are con- • If pump discharge pressure PP rises
nected through the orifice, but cham- and reaches the load of spring (2),
ber A1 is connected to port TS from unload valve (1) moves up and the
the drill hole in sleeve (3) through oil discharged from the pump flows
the drill hold in selector piston (4). from drill hole "b" in unload valve
Therefore, chamber A1 = PTS = . 0 (1) to tank circuit T.
.
10-76
(9)
fl The diagram shows the operation for blade lift RAISE.

012406
2) Work equipment control lever operated

(unload valve set to high pressure)
fl Introduction of LS pressure of un- • At the same time, pressure compen-
load valve sation valve R (6), which is pushed
(Reduction of pump pressure PP to by pressure compensation valve F
the same pressure as actuator cir- (7), also moves up, so pump pres-
cuit pressure D by pressure compen- sure PP, which is introduced from
sation valve R (6), and introduction passage C, is reduced by the pres-
as LS circuit pressure PLS) sure loss at notch "d" and goes to
fl Because of the action of the unload LS circuit PLS. It also goes to spring
valve, the amount of oil flowing to chamber PLS1.
the cylinder corresponds to the open- • When this happens, LS circuit pres-
ing of the spool. (Proportional con- sure PLS is connected to tank circuit
trol) TS from LS bypass plug (5).
fl The unload valve is controlled by the • The area at both ends of pressure
difference in the pressure on both compensation valve R (6) is the same
sides of the spool, so there is little (SC = SCLS), so actuator circuit pres-
change in the amount of oil due to sure PA acts on the SC side, and the
the load pressure. reduced pressure of pump pressure
• When spool (8) is operated, notched PP acts on the SCLS side on the op-
portion "a" of spool (8) is the open- posite side. For this reason, pressure
ing, so part of the oil discharged compensation valve R (6) is balanced
from the pump pushes pressure at a position where actuator circuit
compensation valve F (7) up and PA is the same as spring chamber
flows to the cylinder from port A. PLSI. Pump pressure PP, which was
However, in this condition, the oil reduced at notch "d", becomes ac-
discharged from the pump is almost tuator circuit pressure A and goes to
all unloaded. LS circuit PLS.
10-77
(9)
• Pressure PLS acts on chamber B at

the upper side of unload valve (1),
and when the hydraulic pressure
rises, it pushes selector piston (4)
up. This separates tank circuit TS
from the chamber of spring (2), so
the pressure in the chamber of
spring (2) becomes pressure PP.
Therefore, the force moving unload
valve (1) up becomes pump pres-
sure PP x area receiving pressure
SB, and unload valve (1) is balanced
in a position where PP x SB = load
of spring (2) + PLS x SB.
• Unload valve (1) is balanced by dif-
ferential pressure ∆PLS between
pump pressure PP and LS circuit
pressure PLS (in other words, the
meter-in pressure loss (spool notch
"a") and the load of spring (2)). The
unload flow of unload valve (1) is
determined by the position of bal-
ance. Of the oil discharged from the
pump, the oil which is not unloaded
is supplied to the cylinder. The me-
012406
ter-in pressure loss is determined by
the area of the opening of notch "a"
of spool (8), so the flow of oil to the
cylinder corresponds to the area of
opening, and has no relation to the
load pressure.
10-78
(9)
012406 STRUCTURE AND FUNCTION CLSS
3) Blade operated to FLOAT

fl When the lift valve is in the FLOAT interconnected by port T and port
condition, the cylinder port and drain TS to the tank, so all the oil dis-
port T are interconnected, and the charged from the pump is drained
circuit is under no load. to the tank from unload valve (1).
fl To make it possible to operate the • For this reason, if any external force
other work equipment (tilt, angle, is applied to the blade, the blade will
etc.) even when the lift valve is at move up or down freely.
FLOAT, the pump circuit and cylin- • In the FLOAT position, portion "a" of
der circuit are separated. spool (8) is closed. Therefore, if the
• If the work equipment control lever other work equipment (tilt, angle,
is set to the FLOAT position, spool etc.) is operated, the pump pressure
(8) is kept at the fully operated posi- will rise, and it will be possible to
tion by detent (9). In this condition, carry out compound operation.
ports D and E, and the LS circuit are
10-79
(9)
fl The diagram shows the condition immediately after the lift cylinder has reached the end of its
stroke.
012406
4) At relief
• When spool (8) is operated, the oil • In this condition, all of the oil dis-
discharged from the pump flows charged from the pump is sent to
from port D to the cylinder. When the cylinder, but the cylinder is
this happens, LS circuit pressure PLS stopped, so the pressure in the pump
goes to chamber B. circuit rises.
• When the cylinder reaches the end • When pump pressure PP reaches the
of its stroke and stops, PP = . P1 =. set pressure of relief valve (10), the
. .
PLS, and unload valve (1) is pushed relief valve is actuated, and the pres-
down by the load of spring (2), so sure is set to the maximum set pres-
the unload flow becomes 0. sure for the pump circuit.
10-80
(9)
fl This diagram shows the condition when port A1 is under heavy load and port A2 is under
light load.
012406
5) Pressure compensation function during

compound operation
fl During compound operation, if a dif- cuit PP and pressure compensation
ference appears in the load pressure, valve spool (12) upstream PPA2, and
and the oil flow to the side under pressure loss is generated between
light pressure starts to increase, PP and PPA2.
pressure compensation is carried • The condition balances at the posi-
out. tion where the difference in pressure
• During compound operation, if the between pressure PLS1 and PA2 act-
load pressure at port A1 becomes ing on both ends of pressure com-
higher, pressure PP also becomes pensation valve R (reducing valve)
higher, and the oil starts to flow to (6A) and the differential pressure loss
port A2, which is under a lighter between pressure PPA2 and pressure
load. (Large difference between pres- PP on both sides of pressure com-
sure PP and pressure PA2) pensation valve F (flow control valve)
• If this happens, the LS pressure PLS (7A) are the same.
at the side under heavy load acts on • In this way, the difference in pres-
spring chamber PLS1 on the side sure between the downstream pres-
under light load, and pressure com- sure and upstream pressure of both
pensation valve R (reducing valve) the spools being used for compound
(6A) and pressure compensation operation becomes the same (PPA1
valve F (flow control valve) (7A) are – PA1 = PPA2 – PA2), so the oil flow
pushed down. from the pump is divided in propor-
• Pressure compensation valve F (flow tion to the area of opening of
control valve) (7A) throttles the area notches a1 and a2 of each spool.
of the opening between pump cir-
10-81
(9)
STRUCTURE AND FUNCTION AIR CONDITIONER
AIR CONDITIONER
AIR CONDITIONER PIPINT
Serial No.: B20001 – B40000
Serial No.: 50001 – 50200
012406
1. Hot water pickup piping A. Fresh air

2. Receiver tank B. Recirculated air
3. Air conditioner unit C. Hot air/cold air
4. Condenser
5. Refrigerant piping
6. Air conditioner compressor
7. Hot water return piping
8. Blower motor
10-86
(9)
STRUCTURE AND FUNCTION AIR CONDITIONER

012406
1. Hot water pickup piping A. Fresh air

2. Receiver tank B. Recirculated air
3. Air conditioner unit C. Hot air/cold air
4. Condenser
5. Refrigerant piping
6. Air conditioner compressor
7. Hot water return piping
8. Blower motor
10-86-1
6
STRUCTURE AND FUNCTION ACTUAL ELECTRIC WIRING DIAGRAM
ACTUAL ELECTRIC WIRING DIAGRAM

fl For details of this page, see page 90-9-1.
D41P-6 Serial No.: B20984 – B40000
*1. D41E-6 Serial No.: B20981 – B40000
012406
10-86-2
(9)
STRUCTURE AND FUNCTION ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM

WITH CAB

*1. Serial No.: 20501 – B40000
012406
Serial No.: B20001 – B40000

Serial No.: 50001 – 50200
10-87
(9)
STRUCTURE AND FUNCTION ELECTRICAL CIRCUIT DIAGRAM
WITHOUT CAB
D41E, P-6
*1. Serial No.: 20501 – B40000
012406
Serial No.: B20001 – B40000
Serial No.: 50001 – 50200
10-88
(9)
(9)
STRUCTURE AND FUNCTION ENGINE CONTROL SYSTEM
ENGINE CONTROL SYSTEM

SAFETY MECHANISM WHEN STARTING ENGINE
Function
• A limit switch is installed which is intercon-
nected with the safety lever (parking lever).
If the safety lever is not at the LOCK posi-
tion, the starting circuit is not switched ON
and the engine cannot be started.
• When the safety lever is set to the LOCK
position, the steering, directional, and speed
lever is automatically returned to the Neu-
tral position.
012406
10-91
(9)
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
MACHINE MONITOR SYSTEM
012406
• The machine monitor system uses sensors • The machine monitor system consists of the
installed at various parts of the machine to monitor panel, sensors, warning buzzer and
observe the machine condition. It processes power source.
this information swiftly and displays it on The monitor panel and sensors are con-
the panel to keep the operator informed of nected with wiring harnesses, and the power
the machine condition. supply for the monitor panel is taken from
The information displayed on the panel can the battery. If any abnormality occurs in the
be broadly divided into the following cat- machine (detected by the sensor), the moni-
egories: tor and warning lamp flash and the buzzer
sounds to protect the machine. The buzzer
1. The monitor group, which informs the can be stopped temporarily by operating the
operator when there is an abnormality cancel switch.
in the machine.
2. The gauge group (coolant temperature,
power train oil temperature, fuel level),
which always displays the condition of
the machine.
10-92
(9)
STRUCTURE AND FUNCTION MACHNE MONITOR SYSTEM
Monitor panel display (monitor group)
LED lamp Caution

Display Display item Display lamp Buzzer
Symbol Remarks
category range Display Display display output
color
Below
102°C Turn off Turn off OFF
Engine
coolant 102–107°C Flashes Red Flashes OFF
temperature
SKD00622 Above
107°C Flashes Flashes ON
Below
Turn off Turn off OFF
120°C
Power
train oil 120-130°C Flashes Red Flashes OFF
temperature
Above
Flashes Flashes ON
130°C
Warning
When ON
there is (when engine Turn off
Battery defective is stopped)
Red OFF
charge charging Flashes
(below (when engine Flashes
SKD00624
10V) is running)
ON
(when engine Turn off OFF
Engine oil Below is stopped)
pressure specified Red
value Flashes
SKD00625
(when engine Flashes ON
is running)
012406
Pilot Preheating When ON Green Turn off OFF

preheating
SKD00629
Service 0– — — — — Time on
meter 99999.9h the clock
Service
meter
Flashes
When
Service when
service — —
meter service Green
meter is
indicator meter is
running
running
Buzzer Flashes
When
Switches cancel while buzzer —
buzzer is Yellow OFF
switch remains
canceled
indicator canceled
SKD00633
Switches
Items Actuation Symbol
Buzzer cancel OFF ↔ ON
SKD00634
10-95
(9)
STRUCTURE AND FUNCTION SENSORS
SENSORS
• The signal from the sensor is input directly
to the machine monitor panel.
• The engine oil pressure sensor signal is
judged to be normal when the contacts are
open and the signal wire is separated from
the chassis ground
Display category Type of sensor When normal When abnormal

Sensor method
Engine oil pressure Constant OFF (open) ON (closed)
Caution Engine coolant temperature Resistance — —
Power train oil temperature Resistance — —
Gauge Fuel level Resistance — —
012406
10-96
ENGINE OIL PRESSURE SENSOR
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Thermistor
Function
• The engine oil pressure sensor is installed fied pressure, the curve of the diaphragm
at the front on the left side of the cylinder becomes smaller, so the contact and con-
block. When the engine oil pressure is above tact link come into contact and the circuit is
the specified value, diaphragm (4) bends, turned ON. The monitor panel display and
so contact (3) and contact ring (2) are sepa- warning lamp flash, and the alarm buzzer
rated and the circut is turned OFF. When sounds.
the engine iol pressure goes below the speci-
012406
ENGINE COOLANT TEMPERATURE SENSOR

POWER TRAIN OIL TEMPERATURE SENSOR
1. Connector
2. Plug
3. Thermistor
Function
• The engine coolant temperature sensor is
installed to the thermostat housing on the
right side of the engine. It detects the tem-
perature with thermistor (3) and sends a
signal to the monitor panel.
The monitor panel moves the gauge indica-
tor to the range that corresponds to the sig-
nal, and if it is above the specified tempera-
ture, and monitor panel display and warn-
ing lamp flash, and the buzzer sounds.
10-97
(9)
FUEL LEVEL SENSOR
012406
1. Connector Function
2. Float • The fuel level sensor is insalled to the center
3. Arm of the front face of the fuel tank. Float (2)
4. Body moves up and down in accordance with the
5. Spring level of the remaining fuel.
6. Contact The movement of the float passes throgh
7. Spacer arm (3), which actuates a variable resist-
ance, and this sends a signal to the monitor
panel to display the level of the remaining
fuel.
10-98
(9)
20 TESTING AND ADJUSTING
Standard value table for engine

related parts ........................................ 20- 2
Standard value table for chassis
related parts ........................................ 20- 3
Standard value table for machine
monitor ................................................ 20- 6
Testing and adjusting ............................... 20-101
Troubleshooting ........................................ 20-201

012406
fl The following precautions are necessary when using the standard value tables for testing and
adjusting, or for troubleshooting.
1. The values in the table are for new machines, and are obtained from reference to values when
shipping from the factory. Therefore, they should be used as target values for judging the
progress of wear, or when repairing the machine.
2. The standard values for judging failures are based on the results of various tests when shipping
the machine from the factory. These values should be used as reference together with the repair
condition and operating record of the machine to make judgements on failures.
3. The values in the table should not be used for judging claims.
¤ When carrying out testing, adjusting or troubleshooting, stop the machine on level ground,
install the safety pins and block the tracks.
¤ When carrying out work together with other workers, use agreed signals and do not allow
unauthorized persons near the machine.
¤ 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.
¤ Be careful not to get caught in the fan or other rotating parts.
20-1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
Machine type D41E,P-6
Engine S6D102-1
Standard value
Item Measurement conditions Unit Service limit value
for new machine
High idling 2,650 ± 50 2,650 ± 50
Engine speed Low idling rpm 825 ± 25 825 ± 25
Rated speed 2,400 2,400
At sudden acceleration Bosch Max. 3.5 4.5

Exhaust gas color
At high idling index Max. 1.0 2.0
(normal temperature)
Valve clearance Intake valve mm 0.25 —
Exhaust valve 0.51 —
(SAE30 oil)
Oil temperature: MPa
Compression pressure 2 — —
40 – 60°C {kg/cm }
(Engine speed)
012406
(Water temperature:
Operating range) KPa
Blow-by pressure {mmH2O} Max.0.50{50.8} —
(SAE30 oil)
At rated output
(SAE15W-40 oil)
(Oil temperature:Min80°C)
MPa
Oil pressure At high idling 0.275 – 0.516 0.275 – 0.516
{kg/cm2}
{2.81 – 5.27} {2.81 – 5.27}
At low idling Min. 0.124 0.069

{Min. 1.26} {0.7}
Oil temperature Whole speed range

°C 90 – 110 120
(inside oil pan)
Before compression
Fuel injection timing ° 13.5 13.5
top dead center
20-2
(9)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Cate-
gory Item Measurement conditions Unit Standard value Permissible value
Fuel control lever Tip of lever knob

Engine slow
mm
153 – 187 153 – 187
↔ Full 135 – 165 135 – 165
• Engine slow N ↔ FORWARD 40 ± 10 40 ± 10

Directional lever • Center of lever knob mm
N ↔ REVERSE 40 ± 10 40 ± 10
1st ↔ 2nd 15 ± 2.5 15 ± 2.5

• Engine slow deg
Gear shift lever
• Lever twisting angle
2nd ↔ 3rd 16 ± 2.5 16 ± 2.5
• Engine slow
Steering lever mm 90 ± 15 90 ± 15
• Center of lever knob
• Engine slow
Inching pedal 105 ± 15 105 ± 15
Travel
• Center of pedal
mm
• Engine slow
Brake pedal 77 ± 12 77 ± 12
• Center of pedal
• Engine stopped
Decelerator pedal mm 57 ± 10 57 ± 10
• Center of pedal
HOLD ↔ RAISE 65 ± 10 65 ± 10
• Engine stopped HOLD ↔ LOWER 65 ± 10 65 ± 10

• Center of lever knob mm
Work equipment • Lever twisting angle HOLD ↔ FLOAT 125 ± 20 125 ± 20
control lever for angldozer
HOLD ↔
012406
Left, right tilt 45 ± 10 45 ± 10

HOLD ↔Left,
deg 15 ± 2.5 15 ± 2.5
right angle
63.7 ± 24.5 98
{6.5 ± 2.5} {10}
Engine slow
→ Full 72.4 ± 24.5 110
{7.4 ± 2.5} {11}
Fuel control lever • Engine stopped N
• Center of lever knob {kg} 33.3 ± 20 63.7
{3.4 ± 2.0} {6.5}
Engine full
→ Slow 37.8 ± 20 72.4

{4.0 ± 2.0} {7.4}
• Engine slow N → FORWARD N 34.3 ± 19.6 63.7
Directional lever
• Center of lever knob N → REVERSE {kg} {3.5 ± 2.0} {6.5}
3.2 ± 1.0 4.9
• Engine slow 1st ↔ 2nd {0.33 ± 0.1} {0.5}
Nm
Gear shift lever
Operating effort
• Center of lever knob {kgm} 3.2 ± 1.0 4.9

2nd ↔ 3rd
{0.33 ± 0.1} {0.5}
• Engine slow N 44.1 ± 19.6 78.5
Steering lever
• Center of lever knob {kg} {4.5 ± 2.0} {8.0}
225.6 ± 49.0 323.6
Inching pedal
• Engine slow N {23 ± 5.0} {33}
• Center of pedal {kg} 510 ± 98 726
Brake pedal
{52 ± 10} {74}
N 98.0 ± 19.6 137.3
Decelerator pedal • Center of pedal
{kg} {10 ± 2.0} {14}
HOLD ↔ RAISE 24.5 ± 9.8 47.1
HOLD ↔ LOWER {2.5 ± 1.0} {4.8}
N 58.8 ± 14.7 106
HOLD ↔ FLOAT {6.0 ± 1.5} {10.8}
• Engine slow {kg}
Work equipment
control lever • Center of lever knob HOLD ↔ 29.4 ± 9.8 35.3
Left, right tilt {3.0 ± 1.0} {3.6}
HOLD ↔ Left, Nm 4.4 ± 1.0 6.4
right angle {kgm} {0.45 ± 0.1} {0.65}
Serial No. B20001 – B30000, 50001 – 50200
Serial No. B30001 and up, 50201 and up
20-3
7
Cate-
• Engine at rated 2.89 ± 0.15

Neutral
• Power train oil {29.5 ± 1.5}
Modulating relief temperature: 2.94 ± 0.15
F1, R1 {30.0 ± 1.5}
pressure 70 – 80°C
2.99 ± 0.15
F2•3, R2•3
Hydraulic pressure
{30.5 ± 1.5}
Steering actuating 3.5 ± 0.34 3.0
pressure • Engine at high idling MPa {36 ± 3.5} {30.5}
Brake actuating • Power train oil {kg/cm2}
temperature: 2.65 ± 0.25 2.2
pressure (Brake
70 – 80°C {27 ± 2.5} {22}
pedal operated)
Pedal 0.08 ± 0.01
Inching circuit operated {0.8 ± 0.1} —
actuating
Pedal 2.55
pressure
not operated 2.7 +0.4
0 {28+40 } {26}
Hydraulic pump • Engine at high idling +8 17.7
20.6 +0.8
0 {210 0}
relief pressure • Hydraulic oil temperature: 45 – 55°C {180}
FORWARD 1st 2.4 ± 0.2 2.4 ± 0.2

• Level road surface
• Engine at high idling
• Engine water FORWARD 2nd 4.4 ± 0.3 4.4 ± 0.3
Power train
temperature:
Within operating FORWARD 3rd 7.6 ± 0.5 7.6 ± 0.5
Travel speed
012406
range km/h
• Run-up distance: REVERSE 1st 3.0 ± 0.3 3.0 ± 0.3
10 – 30 m
• Measurement
REVERSE 2nd 5.5 ± 0.5 5.5 ± 0.5
distance: 20 m
REVERSE 3rd 9.4 ± 0.8 9.4 ± 0.8
• Posture of work equipment

RAISE
2.2 ± 0.2 2.7
Blade lift speed Sec.

• Hydraulic oil temperature:
45 – 55°C
LOWER
• Blade: No load
1.9 ± 0.2 2.3
• Ground level → Max. lifting
Work equipment
height

LEFT TILT
2.0 ± 0.2 2.4
Blade tilt speed Sec.

RIGHT TILT

45 – 55°C
2.0 ± 0.2 2.4
• Blade: No load
• Left tilt ↔ Right tilt
20-4
2
Cate-
LEFT ANGLE
6.1 ± 0.3 6.6
Blade angling
Sec.
speed
• Engine at full throttle
RIGHT ANGLE
45 - 55°C
• Blade: No load 4.5 ± 0.3 5.0
• Time taken to angle blade
from max. left angle to max.
right angle
Work equipment
Hydraulic drift mm/

Max. 50 Max. 100
(Blade lift) 15 min
• Engine stopped
• Hydraulic oil temperature: 45 - 55°C
012406
• Raise center cutting edge of blade

300 mm, then measure downward
movement for 15 minutes (h)
Hydraulic drift mm/ Max. 100 Max. 200

(Blade tilt) 15 min
• Engine stopped
• Hydraulic oil temperature:45 – 55°C
• Tilt blade to max. tilt, lower to
ground, then measure
downward movement for 15
minutes (h)
Blade lift • Engine at full throttle
2.0 8
oil leakage
cylinder • Hydraulic oil temperature: 45 - 55°C

Internal
• Fully extend piston rod of cylinder

Blade tilt cc/min 2.3 9
to be measured, then disconnect
cylinder
hose at head end
Blade angle • Measure leakage at relief for 1 8
1.9
cylinder minute
20-5
2
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR MACHINE MONITOR
STANDARD VALUE TABLE FOR MACHINE MONITOR

Sys- Name of Con- Inspect- Measurement
tem component
nector ion Judgement table conditions
No. method
Check, caution If the condition is as shown in Tables 1 and 2, the monitor
portion buzzer panel is normal.
signal
Table 1 (Check, caution portion) 1) Start engine.
The H and L in the 2) Insert
sensor signal
Monitor item
table above are the Monitor auxiliary signal output T-adapter.
Signal
following voltages. Engine oil Starting Alternator
Monitor
display
ª 1 Engine oil presure signal signal
pressure signal signal
H: 3.5 – 30V Monitor ª1 ª2 ª3
L: Approx. 0V item CN49 8 CN49 5 CN49 4 ª 4
ª 2 Starting signal
H: 3 – 30V Preheating H ON
— —
L: Approx. 0V CN49 6 L OFF
Once the starting
signal is H, even if Engine oil L ON
pressure H H —
it then changes to CN49 8 H OFF
L, the starting signal
is stored in memory Battery charge L ON
H H —
inside the monitor CN49 4 H OFF
panel as H until the
starting switch is Table 2 (Buzzer signal)
turned OFF.
ª 3 Alternator Starting switch ON
signal CN49 1 – 2 20 – 30V
A Starting switch OFF
H: 27.5 – 30V (+24V input)
012406
0V
L: Max. 5V
Machine monitor
ª 4 Sensor signal When connector CN15 is

Machine panel
CN50 7 (alarm buzzer removed, buzzer sounds

H: 3.5 – 30V output) – 4
L: Approx. 0V or the following cycle is
repeated.
B Disconnect CN15 Over 20V: 0.8 sec
(coolant temperature 3V: 0.8 sec
sensor) ↔ connect
short connector to When short connector is
CN15 connected, buzzer stops
or voltage is 20 – 30V
Coolant Sensor 1) Turn starting

temperature resistance switch OFF,
50°C Approx. 17 kΩ insert dummy
resistance, or
90°C Approx. 5 kΩ measure
102°C(104°C)* Approx. 3.7 kΩ resistance of
sensor.
120°C Approx. 2.3 kΩ
Measure resistance
2) Turn starting
Display portion
switch ON and
check display.
Coolant CN15 3) Connect
temperature 1–2 socket.
* Serial No. B20001 – B30000, 50001 – 50200: 102˚C, Serial No. B30001 and up, 50201 and up: 104˚C
20-6
7

component
tem No. method
Power Sensor 1) Turn starting

train oil resistance switch OFF,
temperature
insert dummy
50°C Approx. 17 kΩ resistance, or
measure
Measure resistance
resistance of
120°C Approx. 2.3 kΩ sensor.
2) Turn starting
Power train oil CN58 switch ON and
temperature 1–2 50°C 90°C 102°C check display.
3) Connect
socket.
Display portion
Machine panel
BDD00073
Fuel level Sensor

resistance
E Approx. 82 Ω
1/10 Approx. 70 Ω
Measure resistance
012406
F Approx. 12 Ω
Machine monitor
CN3
Fuel level E 1/10 F
1–2
SYD00340
If the condition is as shown in the table 1) Turn starting

below, it is normal switch OFF.
2) • Disconnect
Measure resistance
Coolant temperature Oil temperature or When normal CN15 (cool-

sensor coolant temperature
CN15 ant tempera-
(Coolant temperature (male) 100°C Approx. 3.8 kΩ ture sensor).
gauge) l l • Disconnect
Power train oil CN58 90°C Approx 5 kΩ CN58 (power
temperature sensor (male) l l train oil
(Power train oil 35°C Approx. 29 kΩ
l l temperature
temperature gauge) sensor).
20°C Approx. 52 kΩ
l l
If the condition is as shown in the table 1) Start engine.

below, it is normal
Continuity
Engine oil pressure 0.05

Engine oil pressure No continuity
— MPa (0.5 kg/cm2) or above
sensor
Engine oil pressure below
Continuity
0.05 MPa (0.5 kg/cm2)
20-7
7

tem component
No. method
Measure resistance
If the condition is as shown in the table 1) Turn starting
below, the sensor is normal switch OFF.
(normal temperature: 25°C)
Fuel level sensor CN3
CN3 (male) 1 – 2
(fuel gauge) (male)
Machine monitor
Full Approx. 12 Ω or below

Empty Approx. 85 – 110 Ω
Between alternator
When engine is running (1/2 throttle or 1) Start engine.

Measure voltage
terminal R and
above) → 27.5 – 29.5V

ª If the battery is old, or after starting in
chassis
cold areas, the voltage may not rise for

Alternator some time.
012406
20-8
Tools for testing, adjusting and troubleshooting .............................................................................. 20-102

Adjusting valve clearance ..................................................................................................................... 20-103
Measuring blow-by .................................................................................................................................20-104
Testing and adjusting fuel injection timing ........................................................................................ 20-105
Measuring exhaust color ...................................................................................................................... 20-106
Measuring engine oil pressure ............................................................................................................ 20-107
Measuring engine speed ....................................................................................................................... 20-108
Adjusting fuel control linkage .............................................................................................................. 20-109
Adjusting decelerator pedal linkage .................................................................................................... 20-110
Adjusting engine stop solenoid ........................................................................................................... 20-111
Adjusting steering, directional, gear shift lever ................................................................................. 20-112
Testing main brake and parking brake ............................................................................................... 20-114
Testing wear of brake lining and clutch lining .................................................................................. 20-116
Adjusting brake, clutch lever assembly and lining clearance ....................................................... 20-116-1
Adjusting brake pedal linkage ........................................................................................................... 20-116-5
Adjusting inching pedal linkage ........................................................................................................ 20-116-6
Adjusting parking brake linkage ....................................................................................................... 20-116-7
012406
Adjusting work equipment control linkage and safety lever linkage .............................................. 20-117
Measuring power train oil pressure .................................................................................................... 20-118
Testing and adjusting work equipment circuit pressure .................................................................. 20-122
Testing and adjusting track shoe tension ........................................................................................... 20-123
Measuring leakage inside cylinder ...................................................................................................... 20-124
Bleeding air from hydraulic cylinder ................................................................................................... 20-125
Procedure for releasing parking brake ................................................................................................ 20-126
Testing and adjusting operator's cab .................................................................................................. 20-127
Testing and adjusting "open" and "close" lock and steady rest of operator's cab door .............. 20-128
20-101
(8)
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING

Check, measurement item Symbol Part Number Part Name Remarks
Engine speed A 799-205-1100 Tachometer KIT Digital display: 6 – 99,999.9 rpm
Coolant, oil temperatures B 799-101-1502 Thermometer —
Analog hydraulic Pressure 2.5,5.9,39.2,58.8 MPa

799-101-5002 gauge: {25,60,400,600 kg/cm2}
tester
Pressure 58.8 MPa
1 790-261-1204 Digital hydraulic tester gauge: {600 kg/cm2}
Oil pressure C 799-401-2320 Hydraulic gauge 1.0 MPa {10 kg/cm2}
790-261-1311 Adapter —
2
790-261-1321 Adapter —
Blow-by pressure
Blow-by pressure E 799-201-1504 4.9 KPa {500 mmH2O}
gauge
F Commercially —
Valve clearance Feeler gauge
available
1 799-201-9001 Handy smoke checker Bosch index: 0 – 9

Exhaust color G
2 Commercially —
Smoke meter
available
012406
79A-264-0020 Push-pull scale 0 – 290 N {0 – 30 kg}
Operating effort I
79A-264-0090 Push-pull scale 0 – 490 N {0 – 50 kg}
Stroke, hydraulic drift J Commercially —

Scale
available
Work equipment speed K Commercially Stop watch —
available
M Commercially —
Voltage, resistance Tester
available
Fuel injection timing
N 790-799-1130 Gear —
valve clearance
20-102
(9)
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE
CLEARANCE
1. Remove the cylinder head cover. 1
2. Set cranking tool N to the flywheel.
3. Rotate the crankshaft in the normal direction to
a point where timing pin (1) enters the hole in
the gear.
fl Push pin (1) in lightly while cranking. N
4. At the position in Step 3, adjust the clearance
of the valves marked ‡ in the valve arrange-
ment chart. At the same time, make match marks
on the crankshaft pulley and timing gear case,
then remove timing pin (1). BED00024
5. Next, rotate the crankshaft one turn (360°) in

the normal direction, align the match marks
made in Step 4 accurately, then adjust the valve
clearance of the remaining valves marked fi.
fl To adjust the valve clearance, loosen locknut
(4) of adjustment screw (3), then insert feeler
gauge F between valve stem (5) and rocker
arm (6), and turn adjustment screw (3) until
the clearance is a sliding fit.
6. Tighten the locknut to hold the adjustment screw
in position.
Locknut: 23.5 Nm (2.4 kgm)
012406
fl The firing order is as follows: 1-5-3-6-2-4
BED00026
5 6 3 4
BED00027
20-103
(9)
TESTING AND ADJUSTING MEASURING BLOW-BY
MEASURING BLOW-BY
fl Raise the coolant temperature to the operating
range before measuring.
1. Install blow-by checker E to the tip of engine 1

breather hose (1).
2. Run the engine at rated output, and measure

the blow-by pressure.
¤ When measuring, be careful not to touch
any hot parts or rotating parts.
fl The blow-by should be measured with the E
engine running at rated output. BED00028
• If it is impossible to check at rated output or
stall speed, measure at high idling.
In this case, the blow-by value will be about
80% of the value at rated output. E 1
012406
BED00029
fl Blow-by varies greatly according to the con-

dition of the engine. Therefore, if the blow-
by value is considered abnormal, check for
problems connected with defective blow-by,
such as excessive oil consumption, defec- E
tive exhaust gas color, and prematurely dirty
or deteriorated oil.
TLD00021
20-104
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING

FUEL INJECTION TIMING
1. Testing 1
1) Using cranking tool N, rotate the crankshaft
in the normal direction to a point where
timing pin (1) enters the hole in the gear.
2) Remove plug (2), turn over timing pin (3),
and check that timing pin (3) meshes with N
timing pin pointer (4) at the injection pump
end.
BED00024
2. Adjusting
• If timing pin does not mesh.
1) Remove the injection pump.
For details, see REMOVAL OF FUEL INJEC-
TION PUMP.
2) Rotate the camshaft of the injection pump
to align timing pin (3) with timing pin pointer
(4).
3) Install the injection pump.
For details, see INSTALLATION OF FUEL IN-
012406
JECTION PUMP.
20-105
(9)
TESTING AND ADJUSTING MESURING EXHAUST COLOR
MEASURING EXHAUST COLOR

• When measuring in the field where there is no
air or electric power supply, use tool G1; when
recording formal data, use tool G2.
fl Raise the coolant temperature to the operating
range before measuring.
¤ Be careful not to touch any hot parts when re-

moving or installing the measuring tools.
G1
Measuring with G1
1) Install filter paper to tool G1.
2) Insert the exhaust gas suction port into the BED00033
exhaust pipe, accelerate the engine sud-
denly, and operate the handle of tool G1 at
the same time to collect the exhaust gas on
the filter paper.
3) Remove the filter paper and compare it with
the scale supplied to judge the condition.
012406
Measuring with G2
1) Insert probe [1] into the outlet port of ex-
haust pipe, and tighten the clip to secure it
to the exhaust pipe.
2) Connect the air hose, the socket of the ac-
celerator switch, and the probe hose to tool q
G2.
fl Keep the pressure of the air supply be-
low 1.5 MPa (15 kg/cm2).
3) Connect the power cord to the AC socket.
fl When connecting the cord, check that
the power switch of tool G2 is OFF. BED00034
4) Loosen the cap nut of the suction pump,
and fit the filter paper.
fl Fit the filter paper securely so that the
exhaust gas cannot leak.
G2
5) Turn the power switch of tool G2 ON.
6) Accelerate the engine suddenly, and depress
the accelerator pedal of tool G2 at the same
time to collect the exhaust gas color on the
filter.
7) Place the filter paper used to catch the ex-
haust gas color on top of at least 10 sheets
of unused filter paper inside the filter paper
holder, and read the value shown.
TLD00140
20-106
(9)
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL LINKAGE
ADJUSTING FUEL CONTROL LINKAGE

Serial No. B20001 – B30000, 50001 – 50200
1. Place fuel control lever (1) at the low idling po-

sition, set distance between pins "a" of rod (2) 1
to the standard dimension, then connect.
fl Standard distance "a": 325 mm
6
2. In the above position, connect cable (3).
3. Place fuel control lever (1) at the high idling

position, then adjust distance between pins "b",
012406
"c", "d", "e" of each rod to the dimensions be- 8

low. 7
fl Distance between pins "b": 256 mm BED00059
"c": 232.5 mm
"d": 242.6 mm
"e": 254 mm
fl Connect so that the loose spring is not com-
pressed.
4. Place fuel control lever (1) at the low idling po-

sition, and adjust with rod (5) so that governor
lever (4) of the injection pump contacts the stop-
per.
5. In the above position, set the clearance to 0

between lever (7) and stopper bolt (6) at the
low idling end of the lever assembly, then turn
back 2 turns and secure in position with the
locknut.
6. Pull fuel control lever (1) to a point where gov-

ernor lever (4) contacts the FULL stopper, set
the clearance to 0 between lever (7) and stop-
per bolt (8) at the high idling end of the lever
assembly, then turn back 2 turns and secure in
position with the locknut.
20-109
7
TESTING AND ADJUSTING ADJUSTING DECELERATOR PEDAL LINKAGE
ADJUSTING DECELERATOR PEDAL LINKAGE

Serial No. B20001 – B30000, 50001 – 50200
1. Adjust the fuel control linkage to the specified

dimensions.
2
1) Ajust distance between pins "a" of rod (1) to
the following dimension.
fl Dimension "a": 87.5 mm
2) Adjust installed length "b" of cable (3) at the

pedal end to the following dimension. 4
fl Dimension "b": 273 mm
012406
3) Adjust installed length "c" of cable (5) at the
engine end to the following dimension. 1 a
BED00061
fl Dimension "c": 232.5 mm
2. Start the engine and set the fuel control lever to

the high idling position.
fl Check that the high idling speed is 2650 ±
50 rpm.
In this condition, depress decelerator pedal (2)

fully and turn stopper bolt (4) to adjust to the
following speed.
fl Speed when decelerator pedal is fully de-
pressed: 1100 ± 50 rpm
fl Turn the stopper bolt to adjust as follows.
To DECREASE speed, move bolt IN
To INCREASE speed, move bolt OUT
20-110
7

ADJUSTING DECELERATOR PEDAL LINKAGE
Serial No.: B30001 – B40000, 50201 and up
012406
1. Set lever assembly (1) to the low idling position

(Clearance a is 0 mm at this time) and adjust
installed dimension C of rod (3) so that fuel
control lever (2) will be at the idling position.
• Dimension A of lever (2) (at idling position):
26 mm
• Dimension C of rod (3): 405 mm
2. Connect cable (4).
3. Set fuel control lever (2) to the FULL side and
adjust installed dimension D of the loose spring.
• Dimension D: 231 mm
• Adjust dimension D by adjusting the cable
anchor. Do not compress the loose spring,
however.
4. Set fuel control lever (2) to the low idling posi-
tion and adjust installed dimension E of rod (5)
so that governor lever (6) will be at the idling
position.
• Dimension E: 224 mm
20-110-1
7
(9)
5. Move fuel control lever (2) until governor lever

(6) comes to the FULL position and tighten stop-
per bolt (7) to reduce clearance b between lever
assembly (1) and stopper bolt (7) to 0 mm, then
return stopper bolt (7) by 2 turns and fix it.
6. Set fuel control lever (2) to the low idling posi-

tion and adjust installed height c of stopper
bolt (9) of decelerator pedal (8) to 21 mm, then
press decelerator pedal (8) until it touches stop-
per bolt (9). At this time, install cable (11) and
yoke (10) so that clearance d in the oblong hole
of yoke (10) will be 0 mm and governor lever
(6) will not move from the idling position.
012406
7. Set fuel control lever (2) to the FULL position

and adjust clearance e in bumper (12) used to
adjust the decelerator pedal stroke.
• Clearance e: 1 mm
8. Set fuel control lever (2) to the FULL position
and press decelerator pedal (8). Adjust the height
of stopper bolt (9) so that engine speed will be
1,100 ± 50 rpm when the decelerator pedal (8)
touches stopper bolt (9).
20-110-2
7
TESTING AND ADJUSTING ADJUSTING ENGINE STOP SOLENOID
ADJUSTING ENGINE STOP

SOLENOID
1. Testing operating effort of fuel injection
fl If the engine stop solenoid has been removed pump cut-off lever
or replaced, carry out adjustment in the order
shown in the chart on the right.
Operating effort Operating effort

normal abnormal
(less than 9.8 N (less than 9.8 N
1. Testing operating effort of fuel injection pump {1.0 kg}) {1.0 kg})
cut-off lever
1) Install bolt (2) to the rod end mount of cut-
off lever (1). 2. Reducing
fl Do this with the engine stop solenoid operating
rod not connected. effort
2) Fit a spring balance to bolt (2), pull cut-off 3. Replacing and adjusting solenoid
lever (1) in the installation direction of the
solenoid and measure the operating effort.
fl Use a spring balance with a maximum 4. Checking after replacing solenoid and
measurement of 98 N {10 kg}. installing to machine
• If the operating effort is less than 9.8 N
{1.0 kg}:
The operating effort is normal, so
012406
go on to Step 3. Replacing and

adjusting solenoid.
• If the operating effort is more than 9.8 N
{1.0 kg}:
The operating effort is abnormal, so
go on to Step 2. Reducing operating
effort.
2. Reducing operating effort

1) To reduce the friction between the inside of
cut-off lever (1) and the bearing boss portion,
insert screwdriver [1] into the contacting por-
tion and move cut-off lever (1) to the out-
side.
fl Move the lever lightly.
2) Use a torque wrench to check the tightening

torque of bolt (3).
• Standard value for tightening torque:
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
3) Return to Step 1 and test the operating effort

of the fuel injection pump cut-off lever again.
20-111
(9)
fl If the operating effort does not become

normal with the above procedure, carry out
the following procedure.
4) Remove bolt (4).
fl Oil will flow out from the bolt hole, so
after disconnecting cut-off lever (1),
temporarily assemble the bolt again
quickly.
5) Remove bolt (3), then remove cut-off lever
(1) from the fuel injection pump.
fl Be careful not to drop washer (5) inside
the cut-off lever.
6) Correct any twisting or deformation of the
left and right mounting holes of cut-off lever
(1).
7) Install cut-off lever (1) in the reverse order
to removal.
fl Do not forget to install the washer.
Bolt : 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
8) Return to Step 1 and test the operating effort
of the fuel injection pump cut-off lever again.
012406
3. Replacing and adjusting solenoid
1) Install ball joint (7) to solenoid (6), then
secure with locknut (8).
fl Check that the starting switch is OFF
before doing this.
Locknut:
2.94 – 4.90 Nm {0.3 – 0.5 kgm}
2) Install solenoid (6) to bracket (9).
fl Check that the paint on the solenoid
mounting surface of the bracket (hatched
portion in View Z) has been removed. If
there is any paint remaining, remove it
completely.
20-111-1
(9)
3) Fit 2 locknuts (10) to rod (11), adjust rod (11)

and rod end (12) to mounting dimension a,
and assemble temporarily.
before starting, and do not connect to
the cut-off lever.
8 Thread portion:
Thread tightener (LT-2)
(Do not coat the area 5 mm from the
tip of the rod.)
• Mounting dimension a:
132 mm (reference value)
fl Standard depth for screwing in rod:
Solenoid end: 13 mm
Rod end: 10 mm
012406
4) Turn the starting switch ON, set solenoid (6)

to attraction, and check dimension b when
there is attraction.
• Dimension b when there is attraction:
302 mm (reference value)
fl When the solenoid is fully extended
(FREE position in the diagram on the
right) with the starting switch OFF, if the
solenoid is not attracted when the
starting switch is turned ON, push the
rod in towards the solenoid.
fl Be sure to turn the starting switch OFF
again. If the rod is not connected to the
cut-off lever and the starting switch is
left ON, the solenoid will burn out
prematurely.
20-111-2
(9)
5) Turn the starting switch ON and set solenoid

(6) to attraction.
6) Pull cut-off lever (1) up, adjust the rod length
at the position where the operating effort
changes, and install bolt (2).
fl The position where the operating effort
of the cut-off lever changes is the cancel
spring contact position shown in the
graph on the right.
fl After adjusting the rod length, check
clearance c between cut-off lever (1) and
outside stopper (13).
• Clearance c: Approx. 2 mm
7) Tighten 2 locknuts (10).
Locknut:
2.94 – 4.90 Nm {0.3 – 0.5 kgm}
012406
8) Turn the starting switch OFF and measure
actuation dimension d of cut-off lever (1).
• Actuation dimension d: 25 mm
20-111-3
(9)
9) To check the influence of the thrust play of

the cut-off lever, turn the starting switch ON
again and check clearance c between cut-off
lever (1) and outside stopper (13) when cut-
off lever (1) is pulled (in the direction of the
arrow).
• Clearance c: Approx. 2 mm
4. Checking after replacing solenoid and installing

to machine
1) Always check clearance c between cut-off
lever (1) and outside stopper (13).
fl Clearance c varies slightly at the cancel
spring contact position, but the target
value for the clearance is approx. 2 mm.
2) Check that the surface temperature of the
solenoid during operation is approx. 40°C.
fl The surface temperature varies slightly
according to the ambient temperature,
but if it is not adjusted properly, the
temperature may rise to an abnormally
012406
high temperature (the surface cannot be

touched by hand), and this will lead to
premature burning out.
3) Check the engine high idling speed.
• High idling speed: 2,650 ± 50 rpm
20-111-4
2
ADJUSTING ENGINE STOP

SOLENOID
Serial No.: B30001 – B40000, 50201 and up 1. Testing operating effort of fuel injection
pump cut-off lever
fl If the engine stop solenoid has been removed
or replaced, carry out adjustment in the order
shown in the chart on the right.
Operating effort Operating effort
normal abnormal
1. Testing operating effort of fuel injection pump (less than 9.8 N (less than 9.8 N
cut-off lever {1.0 kg}) {1.0 kg})
1) Install bolt (2) to the rod end mount of cut-
off lever (1).
fl Do this with the engine stop solenoid 2. Reducing
rod not connected. operating
effort
2) Fit a spring balance to bolt (2), pull cut-off
lever (1) as indicated arrow direction and 3. Replacing and adjusting solenoid
measure the operating effort.
fl Use a spring balance with a maximum
measurement of 98 N {10 kg}. 4. Checking after replacing solenoid and
• If the operating effort is less than 9.8 N installing to machine
{1.0 kg}:
The operating effort is normal, so
go on to Step 3. Replacing and ad-
012406
justing solenoid.
• If the operating effort is more than 9.8 N
{1.0 kg}:
The operating effort is abnormal, so
go on to Step 2. Reducing operating
effort.
2. Reducing operating effort

1) To reduce the friction between the inside of
cut-off lever (1) and the bearing boss por-
tion, insert screwdriver [1] into the contact-
ing portion and move cut-off lever (1) to the
outside.
fl Move the lever lightly.
2) Use a torque wrench to check the tighten-

ing torque of bolt (3).
• Standard value for tightening torque:
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
3) Return to Step 1 and test the operating ef-

fort of the fuel injection pump cut-off lever
again.
20-111-5
(9)
fl If the operating effort does not become nor-

mal with the above procedure, carry out the
following procedure.
4) Remove bolt (4).
fl Oil will flow out from the bolt hole, so
after disconnecting cut-off lever (1), tem-
porarily assemble the bolt again quickly.
5) Remove bolt (3), then remove cut-off lever
(1) from the fuel injection pump.
fl Be careful not to drop washer (5) inside
the cut-off lever.
6) Correct any twisting or deformation of the
left and right mounting holes of cut-off le-
ver (1).
7) Install cut-off lever (1) in the reverse order
to removal.
fl Do not forget to install the washer.
3 Bolt : 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
8) Return to Step 1 and test the operating ef-
fort of the fuel injection pump cut-off lever
again.
012406
3. Replacing and adjusting solenoid

1) Install ball joint (7) to solenoid (6), then se-
cure with locknut (8).
before doing this.
3 Locknut:
2.94 – 4.90 Nm {0.3 – 0.5 kgm}
2) After installing the ball joint to solenoid (6),
install solenoid assembly {(6) + (7)} to the
bracket.
fl Keep the starting switch at the "OFF"
position.
fl Before installing solenoid (6), make sure
that all paint (coating) has been removed
from face "a" of the bracket to fit sole-
noid assembly {(6) + (7)} (Hatched part:
Opposite face of the solenoid). If there
is any paint remaining, remove it com-
pletely.
20-111-6
7
3) Install locknuts (9) and (10) and adjust and

assemble temporarily with rod 2 (11) and
ball joint (12) so that the installed dimen-
sion will be "b".
fl Keep the starting switch at the "OFF"
position.
fl Do not connect ball joint (12) to the fuel
cut-off lever.
2 Threads of rod 2 and ball joint:
Liquid adhesive (LT-2)
fl Do not apply liquid adhesive (LT-2) to
the part of 5 mm from the thread end.
fl Dimension b: 135 mm (For reference)
fl Tightening depth: c = 10 mm, d = 13 mm
012406
4) Turn the starting switch to the "ON" posi-
tion to turn on solenoid (7) and measure
dimension "e" when solenoid (7) operates,
then fix rod 2 (11) with the locknuts
fl Dimension "e" when solenoid operates:
307 mm
fl When the starting switch is turned to
the "ON position, solenoid (7) may not
be turned on [if rod 2 (11) was fully ex-
tracted (to position "A" = FREE position)
when the starting switch was turned to
the "OFF" position previous time].
In this case, push rod 2 (11) toward so-
lenoid (7). (If the starting switch is kept
at the "ON" position with the rod ex-
tracted, solenoid (7) will burn. Take care.)
fl Part C: Left-handed screw, Part D: Right-
handed screw
20-111-7
7
5) Pull fuel cut-off lever (14) in the direction of

Y. At the position where the operating effort
changes as shown in Fig. 1, adjust the length
of rod (13) and fix it with the locknuts.
fl The position where the operating effort
of fuel cut-off lever (14) changes means
the "position where the cancel spring
comes in contact" in the graph.
fl Keep the starting switch at the "ON" po-
sition.
2 Threads of locknuts (9) and (10):
Liquid adhesive (LT-2)
3 Locknut (9) and (10):
2.9 - 4.9 Nm {0.3 - 0.5 kgm}
fl After adjusting, make sure that clearance
"g" between fuel cut-off lever (14) and
outside stopper (16) is in the standard
range.
fl Clearance "g" (Standard value): Approx.
2.0 mm
6) Turn the starting switch to the "OFF" posi-
tion and make sure that fuel cut-off lever
(14) moves from engine stop position "E" to
engine start position "F" (Moving distance:
012406
"h").
fl Dimension h: 25 mm
20-111-8
7
4. Inspection after replacing solenoid

1) Turn the starting switch to the "ON" posi-
tion, make sure that clearance "g" between
fuel cut-off lever (14) and outside stopper
(16) is in the standard range.
fl Clearance "g" (Standard value): Approx.
2.0 mm
2) Make sure that the surface temperature of
the solenoid is about 40˚C during operation.
fl The surface temperature of the solenoid
varies more or less according to the at-
mosphere condition. If the solenoid is
not adjusted perfectly or adjusted
wrongly, its temperature may rise ab-
normally (so high that you cannot touch
the solenoid) and may burn in a short
time.
3) Check the high idling speed of the engine.
• High idling speed: 2,650 ± 50 rpm
012406
20-111-9
7
TESTING AND ADJUSTING ADJUSTING STEERING, DIRECTIONAL, GEAR SHIFT LEVER
ADJUSTING STEERING,
DIRECTIONAL, GEAR SHIFT
LEVER
Serial No. B20001 – B30000, 50001 – 50200
fl Tighten the locknuts of the rods and cables se-

curely, and bend the cotter pins securely.
fl The gear shift lever and directional lever are
installed to the transmission control valve. Each
speed position and directional position is set by
the detent inside the valve.
1. Adjusting steering linkage

1) Adjust distance between pins "a" of rod (1)
to the following dimension.
2) Start the engine and check the oil pressure a
1
when the steering lever is operated fully to
the left or right.
012406
BDD00071
2. Adjusting speed and directional linkage

3 4 2
1) Adjusting valve spool stopper
(1) Speed valve spool stopper
i) Set speed valve spool (2) to the 3rd
position.
ii) Put stopper bolt (3) in contact with
spool (2), then turn back 90°. (Turn
6 7 5
to the left.)
iii) Tighten locknut (4).
(2) Directional valve spool stopper
i) Set directional valve spool (5) to the
R position. BED00056
to the left.)
20-112
7
ADJUSTING STEERING,
DIRECTIONAL, GEAR SHIFT
LEVER

fl The gear shift lever and directional lever are
installed to the transmission control valve. Each
speed position and directional position is set by
the detent inside the valve.
1. Adjusting steering linkage

1) Adjust distance between pins "a" of rod (1)
to the following dimension.
2) Start the engine and check the oil pressure a
1
when the steering lever is operated fully to
the left or right.
012406
BDD00071
2. Adjusting speed and directional linkage

3 4 2
1) Adjusting valve spool stopper
(1) Speed valve spool stopper
i) Set speed valve spool (2) to the 3rd
position.
6 7 5
to the left.)
(2) Directional valve spool stopper
i) Set directional valve spool (5) to the
R position. BED00056
to the left.)
20-113-1
(9)
(3) Gear shift and forward-reverse shift cable b 9

i) Adjust installed length "b" of cables
(8) and (9) on the control valve side
to the following value.
fl Dimension b: 158.5 mm
BED00057
ii) Adjust installed length "c" of cables

(10) and (11) on the lever side to the
following value.
fl Dimension c: 205.2 mm
012406
3. Adjustment of limit switches

1) The deviation of the cam center of lever (12)
from the roller center of the limit switch (13)
in the "2nd" position must be 0.5 mm maxi-
mum (2 places).
2) When lever (14) comes to the operating po-

sition of limit switch (15), limit switch (15)
must move by the stroke of y mm.
fl Stroke y: 2.8 mm
4. After adjusting, make sure that each gear speed

is selected securely.
20-113-2
(9)
TESTING AND ADJUSTING TESTING MAIN BRAKE AND PARKING BRAKE
TESTING MAIN BRAKE AND PARKING BRAKE

Serial No. B20001 – B30000, 50001 – 50200
1. Testing effect of main brake
¤ Never place the gear shift lever in 1st when
testing.
1) Depress inching pedal (1) fully.
2) Start the engine.
fl Set the directional lever at neutral.
3) Set safety lever (2) to the FREE position,
then operate work equipment control lever
(3) to raise the blade.
fl Leave the safety lever at the FREE
position.
4) Set parking brake lever (4) to the FREE
position.
5) Operate fuel control lever (5) and run the Serial No. B30001 – B40000, 50201 and up
engine at low idling.
6) Depress brake pedal (6), set gear shift lever
(7) to 2nd, and operate to FORWARD.
fl Check the speed range display window
to confirm that the transmission is in
2nd.
7) Keep brake pedal (6) depressed and slowly
release inching pedal (1).
8) If the machine does not move and the engine
stops with the above operation, the effect of
the main brake is normal.
012406
fl If the inching pedal is released suddenly
in Step 7), the machine may move
momentarily, but if the machine does
not move when it is released slowly, the
braking effect is normal.
20-114
(9)
TESTING AND ADJUSTING TESTING MAIN BRAKE AND PARKING BRAKE
2. Testing effect of parking brake

fl Although the parts around the operator's
seat, shape of the control lever, etc. on D41E-
6 and D41P-6, Serial No. 50201 and up, are
different from this illustration, they can be
inspected basically by the procedure ex-
plained here.
fl Carry out the check on a slope.
1) Set the blade at the downhill end, drive up
the slope in reverse, lower the blade to the
ground, and stop the machine securely.
fl With the engine still running, set the
directional lever at neutral and depress
brake pedal (6).
2) With the machine stopped by the blade,

release brake pedal (6) and lock parking
brake lever (4).
012406
3) Operate work equipment control lever (3) to

raise the blade slowly.
4) If the machine does not move even when

the blade is raised from the ground in the
above operation, the effect of the parking
brake is normal.
20-115
7
TESTING AND ADJUSTING TESTING WEAR OF BRAKE LINING AND CLUTCH LINING
TESTING WEAR OF BRAKE LINING AND CLUTCH LINING

1. Testing wear of brake lining
1) Start the engine and set the parking brake
lever to the FREE position.
¤ Check that the directional lever is at
neutral. Never operate the lever to the
forward or reverse direction or make the
machine move during operation.
2) Operate the steering lever fully on the left
side (or right side), and measure protrusion
a of brake piston (1) from the end face of
the case.
fl If dimension a > 39 mm:
The brake lining is worn, so replace
the lining.
fl If dimension a < 39 mm:
The lining has not reached the wear
limit, so it can be used until
dimension c = 39 mm, but consider
the remaining life and decide if it is
necessary to replace the lining.
012406
2. Testing wear of clutch lining
1) Start the engine and set the parking brake
lever to the FREE position.
¤ Check that the directional lever is at
neutral. Never operate the lever to the
forward or reverse direction or make the
machine move during operation.
2) Set the steering lever to the neutral position
and measure protrusion b of clutch piston
(2) from the end face of the case.
fl If dimension b is greater than 39 mm,
the clutch lining is worn, so replace the
lining.
20-116
(9)
ADJUSTING BRAKE, CLUTCH LEVER
TESTING AND ADJUSTING ASSEMBLY AND LINING CLEARANCE
ADJUSTING BRAKE, CLUTCH LEVER ASSEMBLY AND LINING

CLEARANCE
fl If the brake lining or clutch lining have been
replaced, adjust the assembly of the lever and
the clearance of the lining as follows.
1. Assembly of brake lever

1) Turn brake shaft (1) of the steering case in
the direction shown in the diagram on the
right until it stops.
fl Turn COUNTERCLOCKWISE for left side,
and CLOCKWISE for right side.
fl Set the punch mark on the end face of
the shaft facing the front of the machine.
2) Tighten left and right adjustment screws (2)
of the lever assembly fully in the direction
of the arrow, then turn back 1.5 turns to
adjust temporarily.
fl Do not tighten the locknut.
012406
3) Tighten lever assembly (3) to brake shaft

(1).
4) Align the serration of the shaft and lever
when installing to make clearance a between
brake piston (5) and roller (4) of the lever
assembly as small as possible.
fl Check that the protrusion of brake piston
(5) is 4.5 mm (when pulled in fully)
before starting adjustment.
fl Make the maximum value of clearance
a less than 14 mm.
If it is more than 14 mm, turn the
meshing of the serration one notch and
install again.
5) Push the lever fully into the serration, then
tighten lock bolt (6).
Lock bolt:
53.9 – 122.5 Nm {5.5 – 12.5 kgm}
20-116-1
(9)
2. Assembly of clutch lever

1) Turn clutch shaft (7) of the steering case in
the direction shown in the diagram on the
right until it stops.
fl Turn CLOCKWISE for left side, and
COUNTERCLOCKWISE for right side.
fl Set the punch mark on the end face of
the shaft facing the front of the machine.
2) Tighten adjustment screw (8) of the left and

right lever assemblies fully in the direction
of the arrow, then turn back 1.5 turns to
adjust temporarily.
fl Do not tighten the locknut.
012406
3) Assemble left and right lever assemblies (9)
to clutch shaft (7).
4) Align the serration of the shaft and lever
when installing to make clearance b between
clutch piston (11) and roller (10) of the lever
assembly as small as possible.
fl Check that the protrusion of clutch piston
(11) is 3.0 mm (when pulled in fully)
before starting adjustment.
fl Make the maximum value of clearance
b less than 14 mm.
If it is more than 14 mm, turn the
meshing of the serration one notch and
install again.
5) Push the lever fully into the serration, then
tighten lock bolt (12).
Lock bolt:
53.9 – 122.5 Nm {5.5 – 12.5 kgm}
20-116-2
(9)
3. Adjusting lining clearance

fl The adjustment bolt at the brake end is for
adjustment when assembling.
If the brake lining is worn and the braking
effect or steering efficiency is poor, replace
the lining.
¤ Never use the adjustment screw to adjust
the clearance if the lining has not been
replaced.
1) Adjusting brake lining clearance
Pull lever (13) in the direction of the arrow
at approx. 19.6 N {2 kg} and adjust with
adjustment screw (2) so that clearance a
between brake piston (5) and roller (4) is
the value given below.
• Clearance a: 1.7 ± 0.3 mm
fl When adjusting, keep the lever pulled,
insert a 1.7 mm clearance gauge be-
tween the roller and brake piston, and
turn the adjustment screw until there is
no play.
Locknut :
46.55±12.25Nm {4.75±1.25kgm}
2) Adjusting clutch lining clearance
Pull lever (14) in the direction of the arrow
012406
at approx. 19.6 N {2 kg} and adjust with

adjustment screw (8) so that clearance b
between brake piston (11) and roller (10) is
the value given below.
• Clearance b: 3.5±0.3mm
fl When adjusting, keep the lever pulled,
insert a 3.5 mm clearance gauge be-
tween the roller and clutch piston, and
turn the adjustment screw until there is
no play.
Locknut :
46.55±12.25Nm {4.75±1.25kgm}
3) Installation of springs
After adjusting the clearance at the brake
and clutch, install 2 springs (15).
20-116-3
(9)
[Reference] Reason for prohibition of adjustment

of clearance with adjustment bolt
• Even if the braking effect of the main brake
becomes poor when the brake lining is worn,
the structure is designed so that the parking
brake always works properly. (See the diagram
on the right.)
a: Max. stroke of parking brake cylinder

b: Max. link stroke made by parking cylinder
c: Max. stroke of main brake
d: Max. stroke of main brake piston
Even if the main brake piston reaches
max. stroke d (= main brake is max. stroke
c), and the main brake loses its effect,
max. link stroke b made by the parking
cylinder is larger, so if the parking brake
cylinder is actuated, the parking brake
takes effect.
012406
• Because of the structure of the link, if the
clearance is adjusted with the adjustment bolt
after the brake lining is worn, the main brake is
adjusted, but the parking brake is not adjusted.
(See the diagram on the right.)
If adjustment bolt (2) is tightened in the

direction of the arrow to carry out adjustment,
lever (16) is automatically moved in the di-
rection of the arrow by the link, so clearance
e is formed between lever (16) and yoke (17).
This changes the initial
setting for the parking brake adjustment, and
the effect of the parking brake becomes poor.
¤ The main brake will become effective but the

parking brake will lose its braking effect. The
operator cannot detect this abnormality, so once
the assembly has been assembled, the
adjustment bolt must not be used to adjust the
brake.
20-116-4
(9)
TESTING AND ADJUSTING ADJUSTING BRAKE PEDAL LINKAGE
ADJUSTING BRAKE PEDAL LINKAGE
fl Tighten the locknuts of the rods and cables se- a

1
1. Adjust the height of bumper (2) so that the travel
of brake pedal (1) is dimension "a".
6
fl Brake pedal travel "a": 77 mm
fl Standard height of bumper: 24 mm
2. Adjust the length of rod (3) to dimension "c",

2
then install to lever (4).
fl Dimension "c": 358 mm
012406
BED00041
3. Adjust the length of rod (5) to dimension "d",
fl Dimension "d": 175 mm
4. Turn only joint (7) and connect rod (3) and rod
(5).
fl If both (7) and (8) are turned at the same
time, they will act as a turnbuckle.
5. With brake pedal (1) at the brake RELEASED

position, adjust the length of the rod so that the
play of the brake pedal is 3 – 8 mm at the center
of the pedal.
fl Turn joints (7) and (8) in the same direction
at the same time to adjust the length of the
rod.
6. With brake pedal (1) at the brake RELEASED

position, check that lever (6) contacts bumper
(2).
7. Check that the stroke of the brake valve spool is

14 mm when the brake pedal is depressed fully.
20-116-5
(9)
TESTING AND ADJUSTING ADJUSTING INCHING PEDAL LINKAGE
ADJUSTING INCHING PEDAL LINKAGE
5 7 3
6 4
BED00043

1. Adjust the length of rod (3) to dimension "c",

2. Adjust the length of rod (5) to dimension "d",

012406
3. Turn only joint (7) and connect rod (3) and rod
(5).
4. After connecting rods (3) and (5), check that the

overall dimension of the rod is 543 mm.
5. Check that the following conditions are fulfilled

when inching pedal (1) is depressed.
Travel of pedal Check item
Inching valve stroke: 23.5 mm

75 ± 5 mm
Start of movement of brake valve
105 ± 5 mm Brake valve stroke: 14 mm
20-116-6
(9)
TESTING AND ADJUSTING ADJUSTING PARKING BRAKE LINKAGE
ADJUSTING PARKING BRAKE LINKAGE

012406
fl If the main brake clearance has been ad- 5. If the pin holes are not aligned, adjust as
justed, always adjust the parking brake link- follows.
age as follows. i) Remove pin (5) and disconnect the link-
age.
1. Start the engine and set the parking brake ii) Stop the engine and set the parking brake
lever to the FREE position. lever to the LOCK position.
¤ Check that the directional lever is at neu- iii) Loosen cylinder nut (6) and locknut (7)
tral. Never operate the lever to the for- to make it possible for joint (8) to turn.
ward or reverse direction or make the iv) Install pin (2) and lock with the split pin.
machine move during operation. fl Bend the split pin fully to prevent it
fl Check that the protrusion of brake piston from protruding from the outside of
(1) is 4.5 mm (when pulled in fully). the washer.
v) Start the engine and set the parking brake
2. Remove pin (2). lever to the FREE position.
vi) Turn joint (8) to adjust so that the pin
3. Check that the pin holes of lever (4) and holes of lever (4) and yoke (9) are aligned
yoke (3) are aligned when yoke (3) is pushed when yoke (3) is pushed fully in the di-
fully in the direction of the arrow. rection of the arrow, then install pin (5).
fl Each turn of the joint moves approx.
4. If the pin holes are aligned, install pin (2) 1.5 mm.
and lock with a split pin.
fl Bend the split pin fully to prevent it from
protruding from the outside of the
washer.
20-116-7
(9)
TESTING AND ADJUSTING ADJUSTING PARKING BRAKE LINKAGE
vii) Lock joint (8) with locknut (7), then tighten

cylinder nut (6).
Locknut, cylinder nut:
53.9 – 88.2 Nm {5.5 – 9.0 kgm}
viii)Check that there is no stiffness between le-
ver (4) and yoke (9), then lock with the split
pin.
fl Bend the split pin fully to prevent it from
protruding from the outside of the
washer.
012406
20-116-8
(9)
ADJUSTING WORK EQUIPMENT CONTROL
TESTING AND ADJUSTING LINKAGEAND SAFETY LEVER LINKAGE
ADJUSTING WORK EQUIPMENT

CONTROL LINKAGE AND
SAFETY LEVER LINKAGE
2 1 3
1. Adjusting rod at control lever end a
1) Adjust so that distance between pins "a" of
lift spool rod (1) is the dimension below.
fl Dimension "a": 96 mm c 8
2) Adjust so that distance between pins "b" of
b
tilt spool rod (2) is the dimension below.
g
7
fl Dimension "b": 145 mm
3) Adjust so that distance between pins "c" of
angle spool rod (3) is the dimension below. 9 BDD00063
2. Adjusting rod at spool end

1) Adjust so that distance between pins "d" of c
lift spool rod (4) is the dimension below.
2) Adjust so that distance between pins "e" of
tilt spool rod (5) is the dimension below.
fl Dimension "e": 104.6 mm b
3) Adjust so that distance between pins "f" of
angle spool rod (6) is the dimension below.
fl Dimension "f": 104.6 mm
012406
3. Adjusting safety lever rod a

BDD00064
1) Adjust so that distance between pins "g" of
safety lever (7) is the dimension below.
fl Dimension "g": 345.9 mm
2) Set the safety lever in the LOCK position,
8 6
and check that pin (8) enters plate (9). 7
9
4
e,f d
5
BDD00065
20-117
(9)
TESTING AND ADJUSTING TESTING AND ADJUSTING TRACK SHOE TENSION

TRACK SHOE TENSION
¤ The machine is moved when carrying out the
adjustment, so always set the work equipment
safety lever to the LOCK position.
1. Stop the machine on a horizontal surface.

fl Travel forward and stop the machine with-
out using the brake.
2. Put a straight rod between the idler and carrier

roller, and adjust so that the clearance from the
grouser at the center point is dimension "a"
below.
fl Dimension "a": 20 – 30 mm
3. Increasing the tension

Pump in grease through lubricator (1). 1
fl If the grease does not go in easily, move
the machine backwards or forwards slowly.
When doing this, do not use the brake to
stop the machine.
4. Reducing the tension

Loosen lubricator (1) slowly.
012406
¤ There is danger that the lubricator may fly CED00225
out under the high internal pressure of the

grease, so never loosen the lubricator more
than 1 turn. If the grease does not come out
easily, move the machine backwards or for-
wards slowly.
20-123
(9)
TESTING AND ADJUSTING MEASURING LEAKAGE INSIDE CYLINDER
MEASURING LEAKAGE INSIDE

CYLINDER
• If the hydraulic drift exceeds the standard value,
check if the cause of the hydraulic drift is in the
cylinder or in the control valve.
fl Hydraulic oil temperature when measuring:
45 – 55°C
1. Measurement posture
1) Blade lift cylinder
• Set the front of the track on a block,
then fully extend the cylinder rod.
2) Blade tilt cylinder
• Fully extend the cylinder rod, and lower
the tip of the blade to the ground.
3) Blade angle cylinder
• Fully extend the angle cylinder rod, and
lower the blade to the ground.
2. Measuring
1) Disconnect the head piping, and block the
piping at the chassis end with a blind plug.
¤ Be careful not to disconnect the piping
at the bottom end.
012406
2) Start the engine, run the engine at high
idling, and apply the relief pressure to the
bottom end of the cylinder.
3) Wait for 30 seconds, then measure the
amount of leakage over the next 1 minute.
20-124
(9)
TESTING AND ADJUSTING TESTING AND ADJUSTING OPERATOR'S CAB

OPERATOR'S CAB
Check after installing cab assembly
1. Measuring pressure in cab

• Criterion:
Measured value (Negative pressure):
0 – 4.9 Pa {0 – 0.5 mmH2O}
• Engine speed: High idling
• Fan speed: 100% mode
(See the User adjustment mode of the moni-
tor panel)
• Fan switch of air conditioner: OFF
• EXTERNAL/INTERNAL air changeover switch
of air conditioner:
Fresh air position (EXTERNAL)
fl If the measured value is lower than the
standard value, check the seals of the holes
for wiring harnesses and optional parts in
the cab.
1) A simple method of measuring the internal

pressure is as follows.
i) Prepare a transparent vinyl hose (1).
• Inside diameter: 6 – 10 mm,
012406
Length: 3,000 mm
ii) Secure the inside end of the hose to the
top of the back seat (2) with a tape.
iii) Remove the lock lever of the sash glass
on the side of the cab.
iv) Insert the other end of the hose in the
bolt hole and take it out.
v) Seal the hole of sash glass with tape.
vi) Bend the hose in the shape of letter U
and fill the hose with water up to about
the half level.
vii) Set the water level in the vinyl hose out
of the cab to that in the cab.
viii)Run the engine at high idling and meas-
ure water level difference.
(Pa {mmH2O})
fl Inside of cab: ”Negative pressure”
Out of cab: ”Atmospheric pressure”
2. Check of searing performance

1) Close the all openings of the cab.
2) Splash water around the hatched part of the
cab at the rate of about 19 ¬/min for 10
minutes.
• At this time, it is not necessary to splash
pressurized water.
3) Splash water horizontally from a hose over
sealing surface (C).
4) Check around the dashboard carefully.
fl If water leaks, caulk the leaking part with
Three bond (1207B) and check again.
20-127
(8)
TESTING AND ADJUSTING "OPEN" AND "CLOSE" LOCK AND
TESTING AND ADJUSTING STEADY REST OF OPERATOR'S CAB DOOR

STEADY REST OF OPERATOR'S CAB DOOR
1. Testing door lock
• Close the door and check the relationship
between the operator's cab and door. If there
is any fault, repair it.
1) Check of condition
i) Check the installed height of damper
rubber (1). (Check both sides, 4 pieces
on each.)
• Stick adhesive tape 1, etc. to the
contact face of damper rubber (1)
and open and close the door 2 - 3
times. Then, check the contact face
of adhesive tape 1 against the op-
erator's cab.
Normal: When the door is closed, the
damper rubber comes in con-
tact lightly.
Abnormal: When the door is closed, the
damper rubber does not come
in contact or comes in contact
so strongly that the adhesive
tape is removed.
ii) Check the relationship between the door
notch and striker (on both sides).
012406
• Close door (2) and check the engag-
ing condition of latch (3) and striker
(4).
fl Check deviation a of latch center
x and striker center y from each
other from the direction of A.
2) Adjusting
i) Adjusting height of damper rubber
• Increase or decrease of shims (5)

under damper rubber (1) to adjust
the height of damper rubber (1) prop-
erly.
ii) Adjusting height of latch and striker
(1) Tighten the mounting bolt of striker
(4) temporarily and open and close
the door 2 - 3 times to align latch (3)
and striker (4) with each other.
(2) Check the engaging condition of
latch (3) and striker (4).
(3) Tighten the mounting bolt of striker
(4) securely.
20-128
(8)
TESTING AND ADJUSTING STEADY REST OF OPERATOR'S CAB DOOR
(4) Open and close the door and check

that it is locked and unlocked
smoothly. If the door is not locked
and unlocked smoothly (If the knob
is heavy), perform the adjustment
procedure from the first.
fl Operating effort of knob:
68.6 ± 19.6 N {7 ± 2 kg}
iii) Apply grease (GII-LI) to latch (3).
fl If latch (3) is not greased, the knob
becomes heavy. Accordingly, apply
grease sufficiently.
2. Testing open lock

• Lock the door open and check the relation-
ship between the operator's cab and door.
If there is any fault, repair it.
1) Check of condition
i) Check the relationship between open
lock latch (3) and striker (4) from the
direction of B.
fl Check part b to see if the claw of
latch (6) rides over the bent part of
striker (4). (If normal, the claw does
012406
not ride over the bent part.)

fl Check parts c and b to see if the
body of latch (6) interferes with
striker (4). (If normal, the latch does
not interfere.)
ii) Check the installed height of the stopper
rubber. (Check both sides, 4 pieces on
each.)
(1) Lock the door (2) open and shake it
in the forward and reverse directions
to see if it has any play.
(2) Check that the operating effort of
unlock lever (7) is not heavy.
20-129
(8)
TROUBLESHOOTING
Points to remember when troubleshooting ........................................................................................ 20-202

Sequence of events in troubleshooting ............................................................................................... 20-203
Points to remember when carrying out maintenance ....................................................................... 20-204
Checks before troubleshooting ............................................................................................................. 20-212
Method of using troubleshooting charts ............................................................................................. 20-213
Connector types and mounting locations ........................................................................................ 20-215-1
Connector arrengement diagram ...................................................................................................... 20-215-3
Connection table for connector pin numbers ..................................................................................... 20-216
T-adapter table ........................................................................................................................................ 20-240
Troubleshooting of engine system (S mode) ..................................................................................... 20-251
Troubleshooting of electrical system (E mode) .................................................................................. 20-301
Troubleshooting of hydraulic, mechanical system (H mode) ........................................................... 20-401
Troubleshooting of machine monitor system (M mode)................................................................... 20-501
012406
20-201
(9)
2
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

 Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
 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.
 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.
 Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
 When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
 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 function.
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 3) Other inspection items.

to disassemble the components. 4) Other maintenance items can be checked ex-
If components are disassembled immediately any ternally, so check any item that is considered
failure occurs: to be necessary.
• Parts that have no connection with the fail- 4. Confirming failure
012406
ure or other unnecessary parts will be disas- Confirm the extent of the failure yourself, and
sembled. judge whether to handle it as a real failure or as
• It will become impossible to find the cause a problem with the method of operation, etc.
of the failure. fl When operating the machine to reenact the
It will also cause a waste of manhours, parts, or troubleshooting symptoms, do not carry out
oil or grease, and at the same time, will also lose any investigation or measurement that may
the confidence of the user or operator. make the problem worse.
For this reason, when carrying out troubleshoot- 5. Troubleshooting
ing, it is necessary to carry out thorough prior Use the results of the investigation and inspec-
investigation and to carry out troubleshooting in tion in Items 2 – 4 to narrow down the causes of
accordance with the fixed procedure. failure, then use the troubleshooting flowchart to
2. Points to ask user or operator locate the position of the failure exactly.
1) Have any other problems occurred apart from fl The basic procedure for troubleshooting is
the problem that has been reported? as follows.
2) Was there anything strange about the ma- 1) Start from the simple points.
chine before the failure occurred? 2) Start from the most likely points.
3) Did the failure occur suddenly, or were there 3) Investigate other related parts or infor-
problems with the machine condition before mation.
this? 6. Measures to remove root cause of failure
4) Under what conditions did the failure occur? Even if the failure is repaired, if the root cause of
5) Had any repairs been carried out before the the failure is not repaired, the same failure will
failure? occur again.
When were these repairs carried out? To prevent this, always investigate why the prob-
6) Has the same kind of failure occurred be- lem occurred. Then, remove the root cause.
fore?
3. Check before troubleshooting
1) Check for symptoms of any abnormality in
the machine.
2) Check the CHECKS BEFORE STARTING items.
20-202
2
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
Office, shop Jobsite
Step 1
Examination, confirmation of symptoms
1) When a request for repairs is received, first

ask the following points.
• Name of customer
• Type, serial number of machine
• Details of jobsite, etc.
2) Ask questions to gain an outline of the prob-
lem.
• Condition of failure
• Work being carried out at the time of the
failure
• Operating environment
• Past history, details of maintenance, etc.
Step 2
Determining probable location of cause
1) Look at the troubleshooting section of the

shop manual to find locations of possible
causes.
012406
Step 3
Preparation of troubleshooting tools
1) Look at the table of troubleshooting tools in

the shop manual and prepare the necessary Step 7
tools. • Pinpoint locations of failure (carry out
• T-adapter troubleshooting)
• Hydraulic pressure gauge kit, etc. • Decide action to take
2) Look in the parts book and prepare the nec-
essary replacement parts. 1) Before starting troubleshooting, locate and
repair simple failures.
• Check before starting items
• Other check items
2) See the Troubleshooting Section of the shop
manual, select a troubleshooting flowchart
that matches the symptoms, and carry out
troubleshooting.
Step 6
Re-enacting failure
• Drive and operate the machine to confirm

the condition and judge if there is really a
failure.
Step 4 Step 5
Go to jobsite Ask operator questions to confirm details of
failure.
• Was there anything strange about the ma-

chine before the failure occurred?
2 • Did the failure occur suddenly?
• Had any repairs been carried out before the
failure?
20-203
2
(9)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

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 re-
pairs 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 hydraulic equipment” (particularly gear oil and hydraulic oil).
1. 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, during
inspection and repair operations, they are fre-
quently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely care-
012406
ful when handling wiring harnesses.
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.
[2] Defective crimping or soldering of connec-

tors
The pins of the male and female connectors
are in contact at the crimped terminal or
soldered portion, but if there is excessive
force brought to bear on the wiring, the plat-
ing at the joint will peel and cause improper
connection or breakage.
20-204
2
(9)
[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 con-
nector, depending on the direction of the
water jet.
As already said, the connector is designed
to prevent water from entering, but at the
same time, if water does enter, it is difficult
012406
for it to be drained. Therefore, if water should

get into the connector, the pins will be short-
circuited by the water, so if any water gets
in, immediately dry the connector or take
other appropriate action before passing elec-
tricity 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 connec-
tor, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a con-
tact restorer.
fl When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
fl If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before clean-
ing with compressed air.
20-205
2
(9)
2) Removing, installing, and drying connectors and

wiring harnesses
‡ Disconnecting connectors
[1] Hold the connectors when disconnecting.
When disconnecting the connectors, hold the
connectors and not the wires. For connec-
tors held by a screw, loosen the screw fully,
then hold the male and female connectors
in each hand and pull apart. For connectors
which have a lock stopper, press down the
stopper with your thumb and pull the con-
nectors apart.
fl Never pull with one hand.
[2] When removing from clips

When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
fl If the connector is twisted up and down
or to the left or right, the housing may
break.
012406
[3] Action to take after removing connectors

After removing any connector, cover it with
a vinyl bag to prevent any dust, dirt, oil, or
water from getting in the connector portion.
fl If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always cover
the connector.
20-206
2
(9)
‡ Connecting connectors
[1] Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation, de-
fective contact, corrosion, or damage to
the connector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
fl 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 connec-
tor, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
fl If there is any damage or breakage, re-
place the connector.
[2] Fix the connector securely.

Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in
the connector until the stopper clicks into
012406
position.
[3] Correct any protrusion of the boot and any

misalignment of the wiring harness
For connectors fitted with boots, correct any
protrusion of the boot. In addition, if the
wiring harness is misaligned, or the clamp
is out of position, adjust it to its correct po-
sition.
fl If the connector cannot be corrected eas-
ily, remove the clamp and adjust the
position.
[4] If the connector clamp has been removed,

be sure to return it to its original position.
Check also that there are no loose clamps.
20-207
2
(9)
‡ Drying wiring harness

If there is any oil or dirt on the wiring harness,
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 wa-
ter 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.
fl If the connector is blown dry with com-
pressed air, there is the risk that oil in
the air may cause defective contact, so
remove all oil and water from the com-
pressed air before blowing with air.
012406
[2] Dry the inside of the connector with a dryer.
If water gets inside the connector, use a dryer
to dry the connector.
fl 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 connec-
tor.
[3] Carry out a continuity test on the connector.

After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
fl After completely drying the connector,
blow it with contact restorer and reas-
semble.
20-208
2
(9)
3) Handling control box

[1] The control box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
[2] Do not open the cover of the control box
unless necessary.
[3] Do not place objects on top of the control

box.
[4] Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with your
hand.
[5] During rainy weather, do not leave the con-
trol box in a place where it is exposed to
rain.
012406
[6] Do not place the control box on oil, water,

or soil, or in any hot place, even for a short
time.
(Place it on a suitable dry stand).
[7] Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors con-
nected to the control box. Fit an arc welding
ground close to the welding point.
2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
fl If the power is turned ON with the connectors still disconnected, unnecessary abnormality
displays will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or
current), move the related wiring and connectors several times and check that there is no
change in the reading of the tester.
fl If there is any change, there is probably defective contact in that circuit.
20-209
2
(9)
3. POINTS TO REMEMBER WHEN HANDLING

HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hy-

draulic equipment, the most common cause of fail-
ure 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 confirm the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and main-tenance of hydraulic equip-
ment should be carried out in a specially pre-
pared dustproof workshop, and the performance
012406
should be confirmed 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 en-
tering. 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 leak-
ing oil so never do this.
Do not simply drain oil out on to the ground,
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4) Do not let any dirt or dust get in during refilling

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.
20-210
2
(9)
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 pos-
sible of the old hydraulic oil must be drained
out. (Do not 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 contaminants and sludge in it will mix with
the new oil and will shorten the life of the hy-
draulic 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 sec-
ondary flushing is carried out with the specified
hydraulic oil.
012406
7) Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the ma-
chine, carry out oil cleaning to remove the sludge
or contaminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3µ) particles that the filter
built into the hydraulic equipment cannot re-
move, so it is an extremely effective device.
20-211
2
(9)
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
Item Judgement
Action
value
1. Check fuel level, type of fuel — Add fuel
2. Check for impurities in fuel — Clean, drain
3. Check hydraulic oil level — Add oil
Lubricating oil, coolant
4. Check steering case oil level — Clean, drain

5. Check power train oil level — Add oil
6. Check engine oil level — Add oil
7. Check coolant level — Add water
8. Check dust indicator for clogging — Clean or replace
9. Check power train oil filter — Replace
10. Check hydraulic filter — Replace
11. Check final drive oil level — Add oil
12. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace
equipment
Electrical
13. Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace
012406
14. Check for looseness, corrosion of starting motor terminal, —
wiring Tighten or replace
15. Check operation of gauges — Repair or replace
Hydraulic, mechani-
16. Check for abnormal noise, smell — Repair

cal equipment
17. Check for oil leakage — Repair

18. Carry out air bleeding — Bleed air
19. Check battery voltage (engine stopped) 24 – 30 V Replace

Electrics, electrical equipment
20. Check battery electrolyte level — Add or replace

21. Check for discolored, burnt, exposed wiring — Replace
22. Check for missing wiring clamps, hanging wiring — Repair
23. Check for water leaking on wiring (pay particularly careful — Disconnect connec-
attention to water leaking on connectors or terminals) tor and dry
24. Check for blown, corroded fuses — Replace

25. Check alternator voltage (engine running at 1/2 throttle After running for
several minutes: Replace
or above) 27.5 – 29.5 V
26. Check operating sound of battery relay (starting switch
ON, OFF) — —
20-212
2
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

1. Category of troubleshooting code number
Troubleshooting
Component
Code No.
S–fifi Troubleshooting of engine system
E–fifi Troubleshooting of electrical system
H–fifi Troubleshooting of hydraulic, mechanical system
M–fifi Troubleshooting of machine monitor system
2. Method of using troubleshooting table for each troubleshooting mode

[1] Troubleshooting code number and problem
The title of the troubleshooting chart gives the troubleshooting code and failure mode (prob-
lem with the machine).
[2] General precautions
When carrying out troubleshooting for the failure mode (problem), precautions that apply to all
items are given at the top of the page and marked with fl.
The precautions marked fl are not given in the , but must always be followed when
carrying out the check inside the .
[3] Distinguishing conditions
Even with the same failure mode (problem), the method of troubleshooting may differ accord-
ing to the model, component, or problem. In such cases, the failure mode (problem) is further
divided into sections marked with small letters (for example, a), b)), so go to the appropriate
012406
section to carry out troubleshooting.

If the troubleshooting table is not divided into sections, start troubleshooting from the first
check item in the failure mode.
[4] Method of following troubleshooting chart
YES
• Check or measure the item inside , and according to the answer follow either
NO
the YES line or the NO line to go to the next . (Note: The number written at the top
right corner of the is an index number; it does not indicate the order to follow.)
• Following the YES or NO lines according to the results of the check or measurement will
lead finally to the Cause column.
Check the cause and take the action given in the Remedy column on the right.
• Below the there are the methods for inspection or measurement, and the judge-
ment values. If the judgement values below the are correct or the answer to the
question inside the is YES, follow the YES line; if the judgement value is not
correct, or the answer to the question is NO, follow the NO line.
• Below the is given the preparatory work needed for inspection and measurement,
and the judgement values. If this preparatory work is neglected, or the method of opera-
tion or handling is mistaken, there is danger that it may cause mistaken judgement, or the
equipment may be damaged. Therefore, before starting inspection or measurement,
always read the instructions carefully, and carry out the work in the correct order.
[5] Troubleshooting tools
When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For
details, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.
[6] Installation position, pin number
A diagram or chart is given for the connector type, installation position, and connector pin
number connection. When carrying out troubleshooting, see this chart for details of the
connector pin number and location for inspection and measurement of the wiring connector
number appearing in the troubleshooting flow chart for each failure mode (problem).
20-213
2
(9)
<Example>
[1] M-4. CAUTION items light up or flash
[2] a) (charge) lights up or flashes

SAP00522
Cause Remedy
[1] When it lights up
[3]
YES
Defective monitor panel Replace
ªA 2
Defective contact, or
Is voltage disconnection in wiring harness
YES between CN49 between CN49 (4) - CN31 (4) -
(4) and chassis 3 YES CN17 (5) - alternator terminal R, Repair or
ground normal? or same wiring harness - CN16 replace
Is voltage between
(2) - starting motor terminal R -
• 10 - 30V alternator terminal
1 battery relay short circuiting with
• Start engine. NO R and chassis chassis ground
Does engine oil ground normal?
Defective alternator or
pressure caution Repair
• 10 - 30V NO defective regulator
lamp also light
up? • Remove wiring
harness connected to alternator terminal R.
• Start engine. ªB 4 YES • Start engine.
Defective monitor panel Repair
When cranking, is
voltage between
NO CN49 (5) and chassis disconnection in wiring
ground normal? Repair or
harness between CN49 (5)
NO replace
• 10 - 30V - CN31 (5) - CN32 (8) -
• Turn starting starting switch terminal C
switch ON.
012406
[4] fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.
20-214
2
(9)
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTOR TYPES AND MOUNTING LOCATIONS

Serial No. B20001 – B30000, 50001 – 50200
Connector Connector No. of Add- Connector Connector No. of Add-

Place of use Place of use
No. type pins ress No. type pins ress
M4 — 1 Battery relay K5 CN15 X 2 Engine water temperature sensor D5
Front lamp switch
M5 — 1 Alternator C5 CN15 — 2 (cab specification) L2
M5 — 1 Heater relay H2 CN16 X 2 Starting motor G2
M6 Heater relay Rear lamp switch
— 1 H2 CN16 — 2 (cab specification) K2
M8 — 1 Alternator C5 CN17 SWP 6 Intermediate connector H2
Right wiper motor
M8 — 1 Battery relay K4 CN17 — 4 (cab specification) G9
CN1 — 1 Rear lamp K7 CN18 L 1 Intermediate connector G2
Additional lamp power source G9 Left wiper motor
CN1 — 1 (cab specification) I9 CN18 — 4 (cab specification) K7
CN2 Additional rear lamp Intermediate connector
— 1 (cab specification) J8 CN19 — 4 (cab specification) J3
CN2 Right rear speaker
— 1 (cab specification) H9 CN20 SWP 8 Intermediate connector G2
CN3 X 2 Fuel level sensor K7 CN20 — 1 Intermediate connector J4
CN3 1 Right rear speaker 6
— (cab specification) H9 CN21 SWP Intermediate connector H3
CN4 4 1 Intermediate connector
X Intermediate connector K5 CN21 — (cab specification) J4
CN4 4 Rear wiper motor 1 Cigar lighter
— I9 CN22 — L2
012406
(cab specification) (cab specification)
CN5 — 1 Front right lamp D6 CN23 X 3 Neutral limit switch K6
CN5 1 Left rear speaker I9 CN24 — 1 J8
— (cab specification) Horn switch
CN6 — 1 Front left lamp E6 CN24 — 1 Service power source J4
CN6 — 1 Left rear speaker J8 CN26 KES 4 J3
(cab specification) Intermediate connector
CN7 — 1 Horn D6 CN27 X 3 Intermediate connector J3
Additional lamp power source H9
CN7 — 1 (cab specification) J8 CN28 X 2 Power train oil temperature sensor I3
CN8 X 2 Intermediate connector F1 CN30 — 2 Intermediate connector K4
Room lamp I3
CN8 — 1 (cab specification) I9 CN31 SWP 16 Intermediate connector D7
Washer motor I3
CN9 KES 2 (cab specification) E6 CN32 SWP 16 Intermediate connector D7
Front wiper motor I3
CN9 — 4 (cab specification) G9 CN33 X 4 Intermediate connector D6
CN10 KES 2 Washer motor F7 CN35 — 6 Intermediate connector B6
(cab specification)
CN10 9 4 Magnet relay
— Radio (cab specification) H9 CN36 KES (air conditioner specification) A7
CN11 Washer motor Air conditioner relay
KES 2 (cab specification) E6 CN37 KES 4 (air conditioner specification) A7
CN11 Left wiper switch
— 6 (cab specification) K1 CN38 KES 3 Bimetal timer A6
Washer motor Blower resistor
CN12 KES 2 (cab specification) F7 CN39 KES 3 (air conditioner specification) D6
CN12 Front wiper switch
— 2 (cab specification) K2 CN41 M 2 Buzzer A8
CN13 6 Intermediate connector 4 Pressure switch
SWP E1 CN43 KES (air conditioner specification) C6
CN13 Right wiper switch Blower switch
— 6 (cab specification) K2 CN44 KES 4 (air conditioner specification) A8
CN14 1 Air conditioner compressor 3 Air conditioner switch
X (air conditioner specification) G2 CN45 KES (air conditioner specification) A8
CN14 Rear wiper switch
— 6 (cab specification) K2 CN46 KES 4 Glow switch D8
20-215-1
7
Serial No. B30001 – B40000, 50201 and up
Connector Connector No. of Add- Connector Connector No. of Add-

Place of use Place of use
No. type pins ress No. type pins ress
M4 — 1 Battery relay K5 CN15 DT 2 Engine water temperature sensor C5
M5 Alternator Front lamp switch

— 1 C5 CN15 — 2 (cab specification) L2
M5 — 1 Heater relay H2 CN16 DT 2 Starting motor G1
M6 1 Heater relay 2 Rear lamp switch
— H2 CN16 — (cab specification) L2
M8 — 1 Alternator C5 CN17 SWP 6 Intermediate connector H2
M8 Right wiper motor
— 1 Battery relay K4 CN17 — 4 (cab specification) G9
CN1 — 1 Rear lamp K7 CN18 L 1 Intermediate connector H2
CN1 Additional lamp power source G9 Left wiper motor
— 1 (cab specification) I9 CN18 — 4 (cab specification) K8
CN2 Additional rear lamp Intermediate connector
— 1 (cab specification) J8 CN19 — 4 (cab specification) J3
CN2 1 Right rear speaker 12
— (cab specification) H9 CN20 SWP Intermediate connector G2
CN3 DT 2 Fuel level sensor K7 CN20 — 1 Intermediate connector J4
CN3 1 Right rear speaker 1 Intermediate connector
— (cab specification) I9 CN21 — (cab specification) K4
CN4 X 4 Intermediate connector K6 CN22 — 1 Cigar lighter L2
(cab specification)
CN4 4 Rear wiper motor 3
— I9 CN23 DT Neutral limit switch K6
012406
(cab specification)
CN5 DT 2 Front left lamp D6 CN24 — 1 Horn switch K8
CN5 — 1 Left rear speaker J9 CN24 — 1 K4
(cab specification) Service power source
CN6 DT 2 Front right lamp D5 CN25 — 1 Backup power sorce K4
CN6 — 1 Left rear speaker J9 CN26 KES 4 J3
(cab specification) Intermediate connector
CN7 — 1 Horn D6 CN27 DT 3 Backup alarm K6
CN7 Additional lamp power source H9
— 1 (cab specification) J8 CN28 DT 2 Power train oil temperature sensor I3
CN8 J3
X 2 Intermediate connector B5 CN30 — 2 Intermediate connector D7
CN8 Room lamp I3
— 1 (cab specification) I9 CN31 SWP 12 Intermediate connector D7
CN9 Washer motor I3
KES 2 (cab specification) E6 CN32 SWP 12 Intermediate connector D7
CN9 Front wiper motor I3
— 4 (cab specification) G9 CN33 DT 4 Intermediate connector D6
CN10 2 Washer motor F7 CN36 KES 4 Magnet relay A7
KES (cab specification) (air conditioner specification)
CN10 Air conditioner relay
— 9 Radio (cab specification) H9 CN37 KES 4 (air conditioner specification) A7
CN11 Washer motor
KES 2 (cab specification) E6 CN38 DT 3 Bimetal timer A6
CN11 Left wiper switch Blower resistor
— 6 (cab specification) K1 CN39 KES 3 (air conditioner specification) D6
CN12 Washer motor
KES 2 (cab specification) F7 CN40 SWP 6 Gear speed pilot lamp B9
CN12 Front wiper switch
— 2 (cab specification) K1 CN41 M 2 Buzzer A8
CN13 SWP 6 Intermediate connector E6 CN43 KES 4 Pressure switch C6
(air conditioner specification)
CN13 Left wiper switch Blower switch
— 6 (cab specification) K2 CN44 KES 4 (air conditioner specification) A9
CN14 2 Air conditioner compressor 3 Air conditioner switch
DT-T (air conditioner specification) G2 CN45 KES (air conditioner specification) A8
CN14 Rear wiper switch
— 6 (cab specification) K2 CN46 KES 4 Glow switch D8
20-215-3
(9)
Connector Connector No. of Add-

Place of use
No. type pins ress
CN47 KES 4 Front lamp switch D8
CN48 KES 4 Rear lamp switch D8
CN49 AMP 16 Monitor panel D9
CN50 AMP 12 Monitor panel D9
CN54 — 2 Backup alarm K7
CN57 Blower motor C6

KES 2 (air conditioner specification)
CN58 — 1 Intermediate connector J4
Starting switch D9
CN72 — 6 (canopy specification)
CN96 Condenser K8
— 1 (air conditioner specification)
CN98 Condenser relay K8
KES 4 (air conditioner specification)
CN100 DT 2 Intermediate connector G9
CN101 SWP 8 Intermediate connector K5
CNLM1 DT 3 Intermediate connector K5
CNLM3 DT 3 Intermediate connector K5

012406
FB1 — — Fuse box 1 K6
FB2 — — Fuse box 2 K5
20-215-4
(9)
TROUBLESHOOTING CONNECTOR ARRENGEMENT DIAGRAM
CONNECTOR ARRENGEMENT DIAGRAM

Serial No.: B20001 – B30000, 50001 – 50200
012406
20-215-5
(9)
012406
20-215-6
(9)
012406
20-215-7
(9)
012406
20-215-8
(9)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

★ The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.
X type connector
No. of
pins T-adapter
Male (female housing) Female (male housing) Part No.
1 Part number: 08055-00181 Part number: 08055-00191 799-601-7010
2 799-601-7020
Part number: 08055-00282 Part number: 08055-00292
3 799-601-7030
4 799-601-7040
Terminal part number: 79A-222-3370 Terminal part number: 79A-222-3390
— • Electric wire size: 0.85 • Electric wire size: 0.85 —

• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty: 20

• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
20-216 D41E, P-6

Å (9) Å
SWP type connector

No. of
pins T-adapter
6 799-601-7050

012406
8 799-601-7060
12 799-601-7310
14 799-601-7070
20-217
(9)Å Å
X type connector
No. of
pins T-adapter
16 799-601-7320
Terminal part number: Terminal part number:

• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty: 20
Terminal part number: Terminal part number:

• Electric wire size: 1.25 • Electric wire size: 1.25
012406
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
20-218
Å (9) Å
M type connector
No. of
pins T-adapter
1 Part number: 08056-00171 Part number: 08056-00181 799-601-7080
2 799-601-7090
3 799-601-7110
012406
4 799-601-7120
6 799-601-7130
8 799-601-7390
20-219
(9)Å Å
S type connector
No. of
pins T-adapter
8 799-601-7140
10
799-601-7150
(White)
012406
12
799-601-7350
(White)
16
799-601-7330
(White)
20-220
Å (9) Å
20 Tro
ublesh
ooting
S type connector
No. of
pins T-adapter
10
—
(Blue)
— —
12
799-601-7160
(Blue)
012406
16
799-601-7170
(Blue)
20-221
(9) Å Å
MIC type connector

No. of
pins T-adapter
Body part number: 79A-222-2640 Body part number: 79A-222-2630

7 —
(Q’ty: 5) (Q’ty: 5)

11 —
(Q’ty: 5) (Q’ty: 5)
5 799-601-2710
012406
(Q’ty: 5) (Q’ty: 5)
9 799-601-2950

(Q’ty: 5) (Q’ty: 5)
13 799-601-2720

(Q’ty: 2) (Q’ty: 2)
20-222
Å (9) Å
MIC type connector

No. of
pins T-adapter
17 799-601-2730

(Q’ty: 2) (Q’ty: 2)
012406
21 799-601-2740

(Q’ty: 2) (Q’ty: 2)

—
(Q’ty: 50) (Q’ty: 50)
20-223
(9) Å Å
MIC type connector

No. of
pins T-adapter
8 799-601-7180
Housing part number: 79A-222-3430

—
(Q’ty: 5)
12 799-601-7190
012406
—
(Q’ty: 5)
16 799-601-7210

—
(Q’ty: 5)
20 799-601-7220

—
(Q’ty: 5)
★ Terminal part number: 79A-222-3470 (No relation with number of pins)
20-224
Å (9) Å
AMP070 type connector

No. of
pins T-adapter
10 799-601-7510
— Part number: 08195-10210
12 799-601-7520
— Part number: 08195-12210

012406
14 799-601-7530
— Part number: 08195-14210
18 799-601-7540
— Part number: 08195-18210
20 799-601-7550
— Part number: 08195-20210
20-225
(9) Å Å
L type connector
No. of
pins T-adapter
2 —
— —
Connector for PA
No. of
pins T-adapter
012406
9 —
— —
Bendix MS connector
No. of
pins T-adapter
10 799-601-3460
— —
20-226
Å (9) Å
KES 1 (Automobile) connector

No. of
pins T-adapter
2 —
Part number: 08027-10210 (Natural color) Part number: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
012406
4 —
08027-10420 (Black) 08027-10470 (Black)
6 —
08027-10620 (Black) 08027-10670 (Black)
20-227
(9) Å Å
KES 1 (Automobile) connector

No. of
pins T-adapter
8 —
08027-10820 (Black) 08027-10870 (Black)
Connector for relay (Socket type)

No. of
pins T-adapter
012406
5 799-601-7360
— —
6 799-601-7370
— —
20-228
Å (9) Å
20 Tr
oubl TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
esho
oting
F type connector
No. of
pins T-adapter
4 —
— —
012406
20-229
(9) Å Å
[The pin No. is also marked on the connector (electric wire insertion end)]
Type HD30 Series connector

(shell size T-adapter
code) Body (plug) Body (receptacle)
Part No.
Pin (male terminal) Pin (female terminal)
799-601-9210
Part number: 08191-11201, 08191-11202, Part number: 08191-14101, 08191-14102,

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male terminal)
799-601-9210
012406
08191-11205, 08191-12206 08191-13105, 08191-13106
799-601-9220

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220

08191-22205, 08191-22206 08191-23105, 08191-23106
20-230
Å (9) Å

Part No.
799-601-9230
18-20 Part number: 08191-31201, 08191-31202 Part number: 08191-34101, 08191-34102

799-601-9230
012406
Part number: 08191-32201, 08191-32202 Part number: 08191-33101, 08191-33102

799-601-9240

799-601-9240
20-231
(9) Å Å

Part No.
799-601-9250

799-601-9250
012406
799-601-9260

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260

08191-62205, 08191-62206 08191-63105, 08191-63106
20-232
Å (9) Å

Part No.
799-601-9270

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270
012406

08191-72205, 08191-72206 08191-73105, 08191-73106
799-601-9280

08191-81203, 08191-81204, 08191-84103, 08191-84104,
24-22 08191-81205, 08191-80206 08191-84105, 08191-84106
799-601-9280

08191-82203, 08191-82204, 08191-83103, 08191-83104,
08191-82205, 08191-82206 08191-83105, 08191-83106
20-233
(9) Å Å

Part No.
799-601-9290

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290
012406
08191-92205, 08191-92206 08191-93105, 08191-93106
20-234
Å (9) Å
DT Series connector
No. of
pins T-adapter
Body (plug) Body (receptacle) Part No.
2 799-601-9020
Part number: 08192-12200 (normal type) Part number: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
012406
4 799-601-9040
6 799-601-9050
20-235
(9) Å Å
DT Series connector
No. of
pins T-adapter
8GR : 799-601-9060
8B : 799-601-9070
8
8G : 799-601-9080
8BR : 799-601-9080
012406
12GR : 799-601-9110
12B : 799-601-9120
10
12G : 799-601-9130
12BR : 799-601-9140
20-236
Å (9) Å
DTM Series connector

No. of
pins T-adapter
2 799-601-9010
DTHD Series connector

No. of
pins T-adapter
012406
1 —
Part number: 08192-31200 (Contact size #12) Part number: 08192-31100 (Contact size #12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
20-237
(9) Å Å
DT Series connector
No. of
pins T-adapter
24 799-601-9360
— Part number: 7821-93-3110
40
799-601-9350
(A)
012406
— Part number: 7821-93-3120
40
799-601-9350
(B)
— Part number: 7821-93-3130
20-238
Å (9) Å
TESTING AND ADJUSTING T-ADAPTER TABLE
T-ADAPTER TABLE
fl The part Nos. of the T-adapter boxes and T-adapters are shown in the columns and those of the
wiring harness checker assemblies are shown in the lines.
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
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
—
Port No. Connector type Pin No.
799-601-2600 For measuring box Econo-21P fi fi fi fi fi fi

799-601-3100 For measuring box MS-37P fi
799-601-3200 For measuring box MS-37P fi
799-601-3300 For measuring box Econo-24P fi
799-601-3360 Plate For MS box
799-601-3410 BENDIX (MS) 24P fi fi
799-601-3420 BENDIX (MS) 24P fi fi
799-601-3430 BENDIX (MS) 17P fi fi
799-601-3440 BENDIX (MS) 17P fi fi
799-601-3450 BENDIX (MS) 5P fi fi
012406
799-601-3460 BENDIX (MS) 10P fi fi
799-601-3510 BENDIX (MS) 5P fi fi
799-601-3520 BENDIX (MS) 14P fi fi
799-601-3530 BENDIX (MS) 19P fi fi
799-601-2910 BENDIX (MS) 14P fi fi
799-601-3470 CASE fi
799-601-2710 MIC 5P fi fi fi fi
799-601-2720 MIC 13P fi fi fi fi
799-601-2730 MIC 17P fi fi fi fi fi fi fi
799-601-2740 MIC 21P fi fi fi fi fi fi fi
799-601-2950 MIC 9P fi fi fi fi
799-601-2750 ECONO 2P fi fi
799-601-2760 ECONO 3P fi fi
799-601-2770 ECONO 4P fi fi
799-601-2780 ECONO 8P fi fi
799-601-2790 ECONO 12P fi fi
799-601-2810 DLI 8P fi fi
799-601-2820 DLI 12P fi fi
799-601-2830 DLI 16P fi fi
799-601-2840 Extension cable fi fi fi
799-601-2850 CASE fi
799-601-7010 X 1P fi fi
799-601-7020 X 2P fi fi fi fi
799-601-7030 X 3P fi fi fi fi
799-601-7040 X 4P fi fi fi fi
20-240
(9)
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
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
—
799-601-7050 SWP 6P fi fi fi
799-601-7060 SWP 8P fi fi fi
799-601-7310 SWP 12P fi
799-601-7070 SWP 14P fi fi
799-601-7320 SWP 16P fi
799-601-7080 M 1P fi fi
799-601-7090 M 2P fi fi fi fi
799-601-7110 M 3P fi fi fi fi
799-601-7120 M 4P fi fi fi fi
799-601-7130 M 6P fi fi fi fi
799-601-7340 M 8P fi
799-601-7140 S 8P fi fi fi fi
799-601-7150 S 10P-White fi fi fi fi
799-601-7160 S 12P-Blue fi fi fi
799-601-7170 S 16P-Blue fi fi fi fi
799-601-7330 S 16P-White fi
799-601-7350 S 12P-White fi
012406
799-601-7180 AMP040 8P fi
799-601-7190 AMP040 12P fi fi
799-601-7210 AMP040 16P fi fi fi fi
799-601-7220 AMP040 20P fi fi fi fi
799-601-7230 Short connector X-2 fi fi fi fi
799-601-7240 Case fi fi
799-601-7270 Case fi
799-601-7510 070 10P fi
799-601-7520 070 12P fi
799-601-7530 070 14P fi
799-601-7540 070 18P fi
799-601-7550 070 20P fi
799-601-7360 Relay connector 5P fi
799-601-7370 Relay connector 6P fi
799-601-7380 JFC connector 2P fi
799-601-9010 DTM 2P fi fi
799-601-9020 DT 2P fi fi
799-601-9030 DT 3P fi fi
799-601-9040 DT 4P fi fi
799-601-9050 DT 6P fi fi
799-601-9060 DT 8P-Gray fi fi
799-601-9070 DT 8P-Black fi fi
799-601-9080 DT 8P-Green fi fi
799-601-9090 DT 8P-Blown fi fi
799-601-9110 DT 12P-Gray fi fi
20-241
(9)
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
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
—
799-601-9120 DT 12P-Black fi fi
799-601-9130 DT 12P-Green fi fi
799-601-9140 DT 12P-Blown fi fi
799-601-9210 HD30 18-8 fi fi
799-601-9220 HD30 18-14 fi fi
799-601-9230 HD30 18-20 fi fi
799-601-9240 HD30 18-21 fi fi
799-601-9250 HD30 24-9 fi fi
799-601-9260 HD30 2-16 fi fi
799-601-9270 HD30 24-21 fi fi
799-601-9280 HD30 24-23 fi fi
799-601-9290 HD30 24-31 fi fi
012406
799-601-9310 Plate For HD30 fi fi fi
799-601-9320 For measuring box For DT, HD fi fi fi
799-601-9330 Case fi
799-601-9340 Case fi
799-601-9350 DRC26 40P fi
799-601-9360 DRC26 24P fi
799-601-9410 For NE, G sensor 2P fi
799-601-9420 For boost pressure,
3P
fuel fi
799-601-9430 PVC socket 2P fi
AMP 2-963215-1
799-601-9710 AMP 2-963217-1 16P fi
for HST controller
AMP 1-963215-1
799-601-9720 AMP 1-963217-1 16P fi
for HST controller
AMP 2-1437285-2
799-601-9730 AMP 2-1437285-8 26P fi
for HST controller
20-242
(9)
TROUBLESHOOTING OF ENGINE SYSTEM
(S MODE)
Method of using troubleshooting charts ............................................................................................. 20-252

S- 1 Starting performance is poor (Starting always takes time) .................................................. 20-256
S- 2 Engine does not start ............................................................................................................... 20-258
1) Engine turns but no exhaust smoke comes out (Fuel is not being injected) ............. 20-258
2) Exhaust smoke comes out but engine does not start (Fuel is being injected) ........... 20-259
S- 3 Engine does not pick-up smoothly (Follow-up is poor) ........................................................ 20-260
S- 4 Engine stops during operations .............................................................................................. 20-261
S- 5 Engine does not rotate smoothly (Hunting) ........................................................................... 20-262
S- 6 Engine lacks output (or lacks power) ...................................................................................... 20-263
S- 7 Exhaust smoke is black ............................................................................................................ 20-264
S- 8 Oil consumption is excessive (or exhaust gas is blue) ......................................................... 20-265
S- 9 Oil becomes contaminated quickly ......................................................................................... 20-266
S-10 Fuel consumption is excessive ................................................................................................ 20-267
S-11 Oil is in cooling water, or water spurts back, or water level goes down .......................... 20-268
S-12 Oil pressure caution lamp lights up (Drop in oil pressure) .................................................. 20-269
012406
S-13 Oil level rises (Water, fuel in oil) ............................................................................................. 20-270

S-14 Water temprautre becomes too high (Overheating) ............................................................. 20-271
S-15 Abnormal noise is made .......................................................................................................... 20-272
S-16 Vibration is excessive ............................................................................................................... 20-273
20-251
2
(9)
METHOD OF USING TROUBLESHOOTING CHARTS
This troubleshooting chart is divided into three

sections: 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 with-
out 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-
spond to the items where answers can be ob-
tained from the user. The items in [B] are items
that can be obtained from the user, depending
on the user’s level.
[Check items] Causes
The serviceman carries out simple inspection to
narrow down the causes. The items under [C] in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information [A] that he has obtained from the
user and the results of [C] that he has obtained
012406
from his own inspection.
[Troubleshooting] (1) (2) (3)
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
(a)
Question
A
[A] (b)
(c)
(d)
(e)
B
[B]
C
[C]
Check item
i
ii
shooting
Trouble-
iii
20-252
2
(9)
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 !, and of these, causes that have a high prob-
ability are marked with T.
Check each of the [Questions] and [Check items] in
turn, taking note of the ! or T marks in the chart for
the horizontal lines of symptoms applicable to the
machine. The vertical column (Causes) that has the
highest number of applicable ! or T marks is the
most probable cause, so start troubleshooting for
that item to make final confirmation of the cause.
Causes
*1. For (Confirm recent repair history) in the
[Questions] Section, ask the user, and mark
the Cause column with # to use as reference
n)
ctio
for locating the cause of the failure. How-
inje
ever, do not use this when making calcula-
sive
tions to narrow down the causes.
e
renc
*2. Use the # in the Cause column as reference
xces
zle
noz
ent
for [Degree of use (Operated for long pe-
erfe
p (e
r
g
inde
lem
tion
riod)] in the [Questions] section as reference.
imin
, int
pum
er e
c
, cyl
As a rule, do not use it when calculating the
rger
inje
on t
ion
lean
012406
ring
points for locating the cause, but it can be
cha
ecti
zed
ject
air c
included if necessary to determine the order
urbo
, sei
ston
r inj
e in
for troubleshooting.
rope
ged
ged
ctiv
n pi
ed t
Clog
Clog
Defe
Wor
Seiz
Imp
*1
ª1 Confirm recent repair history
*2
ª2 Degree of use Operated for long period
20-253
2
(9)
• 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 a causal relationship with this problem: [Exhaust gas gradually became black],
[Powergradually 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.
Causes
• Insufficient intake of air.
• Improper condition of fuel injection.
ead
d)
ion)
eize
• Excessive injection of fuel.
yl. h
ject
er s
nd c
e in
lung
ck, p t
a
er a
e se
essiv
elem rence
harg
zle
valv
(exc
noz
p (ra
cylin nt
terfe
rboc
lve,
e
der
r
ed m ce
ion
ump
le
timin
pum
r, in
aran
u
f
f va
f
t
en t
u
c
p
rope ized inje
n pis cleaner
arge
ct o
e cle
ion
rope jection
ion
e
,
ring
betw
Legend
onta
ject
ject
logg
Clog urboch
valv
: Possible causes (judging from Questions and check items)
ton
, se
in
e in
e in
air
age
c
d, c
: Most probable causes (judging from Questions and Check items)
e
ged
ged
ctiv
ctiv
ctiv
ed t
leak
she
: Possible causes due to length of use (used for a long period)
Clog
Defe
Defe
Defe
Wor
Seiz
Imp
Imp
Cru
Air
: 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
Question
012406
Blue under light load
Engine oil must be added more frequently
Suddenly
Power was lost
Gradually
Non-specified fuel has been used
Dust indicator is red
Interference sound heard around turbocharger
Blow-by gas is excessive
Engine pickup is poor and combustion is irregular
When exhaust manifold is touched immediately after
Check items
starting engine, temperature of some cylinders is low

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
Air leakage / loose clamp between turbocharger and cyl. head
Turbocharger cannot be hand-rotated smoothly

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
Adjust
Adjust
Adjust
Repair
Clean
Remedy
20-254
2
(9)
5 causes
Step 1
Clarify the relationship between the three
symptoms in the [Questions] and [Check items]
section and the 5 Cause items in the vertical
column.
Three symptoms
012406
Step 2
Add up the total of and marked 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 cyl. head:
(3) Clogged, seized injection nozzle:
(4) Defective contact of valve, valve seat:
(5) Worn piston ring, cylinder:
Step 3
The calculations in Step 2 show 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.
20-255
2
(9)
TROUBLESHOOTING S-1
S-1 Starting performance is poor

(Starting always takes time)
General causes why exhaust smoke comes out but en-
gine takes time to start
• Defective electrical system
• Insufficient supply of fuel Causes
• Insufficient intake of air
• Improper selection of fuel
(At ambient temperature of 10°C or
below, use ASTM D975 No. 1)
fl Battery charging rate.
t
elem alve sea
Charging rate
Ambient 100% 90% 80% 75% 70%
r
filte
temperature
,v
ent
er
20°C 1.28 1.26 1.24 1.23 1.22
uze
r
r
alve
inde
eate
rain
p ga
0°C 1.29 1.27 1.25 1.24 1.23
v
, cyl
air h
r, st
f
aner
act o
pum
–10°C 1.30 1.28 1.26 1.25 1.24
filte
ring
ake
ir cle
cont
• The specific gravity should exceed the value for the
d
fuel
l int
ston
e e
charging rate of 70% in the above table.
f
ctive
trica
ged
ged
ged
n pi
• In cold areas the specific gravity must exceed the value
Defe
Clog
Clog
Clog
Elec
Wor
for the charging rate 75% in the avobe table.
Degree of use of machine Operated for long period
Gradually became worse
Ease of starting
Starts when warm
Questions
Preheating indicator lamp does not light up
012406
Replacement of filters has not been carried out according to operation Manual
Dust indicator lamp is red
Non-specified fuel has being used
Battery charge lamp 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 injection pump sleeve nut is losened
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
Troubleshooting
When feed pump strainer is inspected directly, it is found to be clogged

Heater mount does not become warm
Is voltage 26–30V 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 pump)
When fuel cap is inspected directly, it is found to be clogged
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
20-256 *ª Use a test stand

2
(9)
012406
Replace Defe
ctive
Replace regu
Legend
Defe lato
ctive r
Replace Defe a ltern
ctive ator
Replace Defe or d
eter
ctive iora
ªAdjust Defe injec ted
batt
tive tion ery
nozz
Replace Defe
injec
tion le
tive t i m
Correct Leak injec
tion
ing
age, pum
Clean c l o
TROUBLESHOOTING
Clog ggin p (ra

ged g, ai ck, p : Items to confirm the cause.
Replace a i r bre r i n fu lung
Defe athe e l pip
er s t
uck)
ctive
feed r h ole i ing Causes
pum n fu
p el t a
nk
2
(9)
S-1
20-257
TROUBLESHOOTING S-2
S-2 Engine does not start

1) Engine turns but no exhaust smoke comes
out
(Fuel is not being injected)
General causes why engine turns but no exhaust smoke

comes out
• Supply of fuel impossible

• Supply of fuel is extremely small
• Improper selection of fuel (particularly in winter)
Causes
fl Standards for use of fuel
AMBIENT TEMPERATURE
ed)
KIND OF
seiz
FLUID -22 -4 14 32 50 68 86 104˚F
-30 -20 -10 0 10 20 30 40˚C
ger
key
nk
ASTM D975 No.2
el ta
u
Diesel fuel
aft,
l
ck, p
ston
ASTM D975 No.1
e sh
in fu
p pi
p (ra
ng
iner
driv
oid
e
ole
pipi
m
fl In winter, if ASTM D975 No.1 diesel oil is
n
stra
pum
olen
i
stra
u
nk
mp
h
p
not available, a 50-50 mixture of ASTM D975
fuel
her
in ta
ump
eed
n pu
ut s
ed
ion
No. 2 diesel oil and kerosene can be used. lter,
reat
king
l us
en f
c
fuel
ject
p
ctio
el fi
Legend
l
air b
feed
e
r fue
, lea
brok
u
e in
inje
: Possible causes (judging from Questions and check items) ent

u
f
f
e
ged
rope
ged
ged
ged
ctiv
ctiv
ffici
ed,
ken
: Possible causes due to length of use (used for a long period) Clog
Defe
Clog
Defe
Clog
Clog
Insu
Seiz
Imp
012406
Bro

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 starting switch is turned ON, linkage is not actuated
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 injection pump 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 return
Troubleshooting
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
Cannot be moved by hand even when linkage of fuel cut
solenoid is disconnected
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
20-258
2
(9)
TROUBLESHOOTING S-2
2) Exhaust smoke comes out but Causes

engine does not start (Fuel is
.)
being injected)
r, etc
)
tuck
leve
cap
General causes why exhaust smoke comes out but
er s
pray
cker
engine does not start
lung
tank
stem
ve s
ater
e, ro
k, p
ttery
fuel
i
ir he
(valv
el sy
t
r
c
• Lack of rotating force due to defective electri-
line
defe
(rac
ent
iner
le in
d ba
ke a
in fu
cal system
tem
er
der
ump
zle,
elem
rain
stra
r ho
rate
e sys
• Insufficient supply of fuel
inta
n
r
noz
i
i
, cyl
a
on p
s
ump
terio
e
ner
valv
ed
ical
ing,
h
lter,
tion
reat
ring
l us
a
ecti
ectr
ed p
e
ken
ogg
e
el fi
Legend
d
l
njec
air b
air c
r fue
j
ston
e or
, bro
e in
e el
e, cl
u
f e
f
rope
ged
ged
ged
ged
ged
ctiv
ctiv
ctiv
ctive
n pi
kag
Defe
Defe
Defe
Clog
Clog
Clog
Clog
Clog
Wor
Defe
Imp
Lea
Questions
Suddenly failed to start

When engine is cranked, abnormal noise is heard from
around head
Non-specified fuel is being used
Operation Manual
012406
Preheating indicator lamp does not light up

Starting motor cranks engine slowly
Check items
When fuel lever is placed at FULL position, it does not contact stopper
1) Little fuel comes out even when injection pump sleeve nut
is loosened
2) No fuel comes out even when fuel filter air bleed plug is
loosened
When exhaust manifold is touched immediately after starting
engine, temperature of some cylinders is low
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
When fuel filter, strainer are inspected directly, they are
Troubleshooting
found to be clogged
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
Correct
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
20-259
2
(9)
TROUBLESHOOTING S-3
S-3 Engine does not pick up smoothly Causes

(follow-up is poor)
General causes why engine does not pick up smoothly
ap
y
seat
spra
nk c
lve
el ta
ive
nce
• Improper condition of fuel injection
d va
fect
er
er
in fu
fere
• Improper fuel used
r lin
ung
e an
ent
ng
, de
er
er
nter
rain
pipi
e
hole
e
lem
p pl
rain
valv
zzle
ranc
d
cylin
er, i
p st
er e
fuel
pum
r, st
n no
her
clea
t of
pum
harg
lean
reat
filte
king
ring
ntac
ctio
tion
lve
Legend
air b
feed
air c
urbo
uel
, lea
inje
r va
ston
e co
njec
rope
ged
ged
ged
ged
ged
ged
ctiv
ed t
ed i
n pi
Clog
Clog
Clog
Defe
Clog
Clog
Clog
Seiz
Seiz
Wor
Imp
Questions

Operation Manual
Noise of interference is heard from around turbocharger
Engine pick-up suddenly became poor
012406
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
found to be clogged
When feed pump strainer is inspected directly, it is found to be
Troubleshooting
clogged
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
When turbocharger is rotated by hand, it is found to be heavy
When valve clearance is checked directly, it is found to be
When fuel tank cap is inspected directly, it is found to be clogged
When feed pump is operated, operation is too light or too heavy
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
20-260
2
(9)
TROUBLESHOOTING S-4
S-4 Engine stops during operations

General causes why engine stops during operations
• Seized parts inside engine

Causes
c.)
• Overheating
r, et
)
tuck
leve
fl If there is overheating and the engine stops,
er s
cker
carry out troubleshooting for overheating.
rod
lung
tank
e, ro
ent
key
ring
ting
k, p
ston
fuel
(valv
• Failure in power train
ipm
aft,
a
nec
c
p pi
f t be
p (ra
g
le in
er
equ
n
tem
er
e sh
rain
con
p ipi
p um
train
in
fl If the engine stops because of a failure in
ksha
r ho
pum
s
nk
r tra
liary
driv
y
p st
in
on,
fuel
the power train, carry out troubleshooting
in ta
er, s
r tra
athe
e
feed
cran
v
gea
ion
pist
pu m
i
p
x
l
for the chassis.
king
pum
p au
v
owe
e
fuel
ject
l
zed
i
c
zed
zed
r
zed
Legend
f
i
air b
feed
ynam
fuel
, lea
pum
e in
in p
fuel
, sei
ent
, sei
, sei
, sei
ged
ged
ged
ged
ctiv
en d
ffici
ken
ure
ken
ken
ken
ken
ken
Clog
Clog
Defe
Clog
Clog
Insu
Brok
Fail
Bro
Bro
Bro
Bro
Bro
Bro

Abnormal noise was heard and
engine stopped suddenly
Condition when engine
Questions
Engine overheated and stopped

stopped
Engine stopped slowly
012406
There was hunting and engine stopped

Fuel gauge indicated below E level
Replacement of filters has not been carried out according
to Operation Manual
Engine rotates, but stops when power train is operated
Check items
Does not turn at all

When it is attempted to Turns in opposite direction
turn by hand using
barring tool Moves amount of backlash
Shaft does not turn
Troubleshooting of CHASSIS

Metal particles are found when oil is drained
Remove oil pan and inspect directly

Remove head cover and inspect directly
Troubleshooting
When gear train is inspected, it does not turn

Rotates when pump auxiliary equipment is removed
found to be clogged
When feed pump strainer is inspected directly, it is found to
be clogged
Inspect feed pump directly
does not return
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
Add
20-261
2
(9)
TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly

(Hunting)
General causes why engine does not rotate smoothly Causes
p
le
pum
nozz
• Air in fuel system
eed
• Defective governor mechanism
and
nd f
• Defective electric governor mechanism
mp
nk a
nk
(engine with electric governor)
d pu
el ta
k
el ta
r
l rac
erno
rn o r
n fee
in fu
n fu
o
fl If hunting stops when electric governor rod is
er
gov
ontr
ove
in ta low
wee
iner
wee
rain
hole
disconnected, carry out troubleshooting for the
of g
t of
of c
t bet
o
stra
nk
t bet
p st
is to
chassis.
her
men
ion
i on
i
p um
ircui
,
circu
ilter
reat
eed
erat
erat
just
fuel
c
Legend
air in
air b
feed
g sp
air in
fuel
e ad
e op
e op
ent
idlin
ged
ged
ged
ged,
ctiv
ged,
ctiv
ctiv
ffici
Clog
Clog
Clog
Defe
Defe
Defe
Clog
Insu
Clog
Low

Occurs at a certain speed range
Occurs at low idling
Condition of hunting
Questions
Occurs even when speed is raised

Occurs on slopes
012406
to Operation Manual
Rust, water are found when fuel tank is drained
When feed pump is operated,
1) No response, light, return is quick
Check items
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
Troubleshooting
improperly adjusted
does not return
When feed pump strainer is inspected directly, it is
found to be clogged
found to be clogged
Correct
Correct
Adjust
Adjust
Adjust
Adjust
Clean
Clean
Clean
Remedy
Add
20-262
2
(9)
TROUBLESHOOTING S-6
S-6 Engine lacks output

(or lacks power)
General causes why engine lacks output Causes
ent
stm
ray
seat
e sp
adju
nk
lve
• Improper fuel used
el ta
ctiv
e
d va
tive
(if non-specified fuel is used, output drops)
renc
in fu
r
defe
c
e an
• Lack of output due to overheating
ung
ng
ent
defe
iner
erfe
iner
r
hole
pipi
e
inde
zle,
lem
p pl
valv
ranc
stra
, int
ge,
stra
noz
fl If there is overheating and lack of output,
fuel
er e
pum
, c yl
her
rger
nka
t of
a
mp
e
ter,
carry out troubleshooting for overheating.
tion
reat
lean
king
ring
ntac
d pu
er li
cha
tion
lve
l
Legend
f i
air b
air c
inje
l lev
fuel
urbo
, lea
e co
r va
ston
njec
f e
t fue
rope
ged
ged
ged
ged
ged
ged
ctiv
ed t
n pi
ed i
Clog
Clog
Clog
Defe
Clog
Clog
Clog
Seiz
Seiz
Wor
Ben
Imp

Suddenly
Power was lost
Gradually
Questions

to Operation Manual
012406

Black
Check items
High idling speed under no load is normal, but speed

suddenly drops when load is applied
High idling speed of engine is low
When air cleaner element is inspected directly, it is found to be

clogged
found to be clogged
Troubleshooting
When feed pump strainer is inspected directly, it is found

to be clogged
is stopped
does not return
When valve clearance is checked directly, it is found to be
When lever is placed at FULL position, it does not contact stopper
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
20-263
2
(9)
TROUBLESHOOTING S-7
S-7 Exhaust smoke is black

(incomplete combustion) Causes
General causes why exhaust smoke is black
d)
ad
)
tion
eize
d he
njec
er s
at
ray
r an
e se
lung
e sp
ve i
arge
valv
essi
• Excessive injection of fuel
ctiv
ck, p
renc
och
and
( exc
defe
p (ra
ent
turb
erfe
lve
g
r
ce
inde
mp
lem
zle,
uffle
imin
, int
pum
een
aran
f va
u
z
er e
, cyl
n no
ed m
rger
on t
w
ct o
e cle
ion
ion
t
lean
ir be
ring
ctio
c ha
ecti
onta
ject
ject
logg
Legend
valv
air c
a
inje
urbo
r inj
ston
e in
e in
c
e of
d, c
e
r
rope
rope
ged
ctiv
ctiv
ged
ctiv
n pi
ed t
she
kag
Defe
Defe
Defe
Clog
Clog
Wor
Seiz
Imp
Imp
Cru
Lea

Suddenly became black
Color of exhaust gas Gradually became black
Questions

Suddenly
Power was lost
Gradually
012406
When exhaust manifold is touched immediately after
starting engine, temperature of some cylinders is low
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

When air cleaner is inspected directly, it is found to be clogged
Troubleshooting

is 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
When muffler is removed, exhaust color returns to normal
does not return
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Adjust
Clean
Remedy
20-264
2
(9)
TROUBLESHOOTING S-8
S-8 Oil consumption is excessive

(or exhaust smoke is blue)
fl Do not run the engine at idling for more than 20
minutes continuously. (Both low and high idling) Causes
r
arge
General causes why oil consumption is excessive
och
• Abnormal combustion of oil
Turb
al
d
hea
• External leakage of oil
n se
ace
stem
e
ping l cooler
hos
• Wear of lubrication system
surf
der
oke
er
e sy
r lin
cylin
her
), br
seal
plug
i
or o
reat
k
inde
end
nd
ui de
inta
n or
eal,
ain
er e
or b
ilter
, cyl
bine
m, g
om
ar s
il pa
il dr
il pi
ing
blow
oil f
ther
r
ring
in fr
n re
oole
t tur
(ste
mo
mo
mo
on r
Legend
m
brea
l at
roke
ston
cked
al a
oil c
e fro
e fro
e fro
e fro
lve
pist
a
n va
n se
n se
ged
n, b
n pi
t su
kag
ken
kag
kag
kag
ken
Clog
Wor
Wor
Wor
Wor
Wor
Dus
Lea
Bro
Lea
Lea
Lea
Bro

Oil consumption suddenly increased
Questions
Engine oil becomes contaminated quickly

Exhaust smoke is blue under light load
Excessive
012406
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 clutch or TORQFLOW transmission damper
chamber rises
Clamps for intake system are loose

When breather element is inspected, it is found to be
Troubleshooting
clogged with dirty oil

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
20-265
2
(9)
TROUBLESHOOTING S-9
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated quickly
• Entry of exhaust gas due to internal wear

• Clogging of lubrication passage
• Improper fuel
• Improper oil used
• Operation under excessive load
Causes
end
ine
turb
pe
ose
er
n pi
e r
r lin
er h
harg
drai
inde
eath
ide
boc
lack
rger
e gu
, cyl
r, br
t tur
is b
r
cha
oole
ring
valv
ilter
al a
h
oke
Legend
urbo
t
brea
oil c
oil f
ston
e se
lve,
t sm
t
ged
n va
ged
ged
ged
ctiv
n pi
aus
: Possible causes due to length of use (used for a long period) Clog
Defe
Clog
Clog
Clog
Wor
Wor
Exh
012406
Questions

Non-specified oil is being used
Black
Carry out troubleshooting for 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 found to be clogged with dirty oil
Troubleshooting
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 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
—
20-266
2
(9)
TROUBLESHOOTING S-10
S-10 Fuel consumption is excessive

General causes why fuel consumption is ex-
cessive
• Leakage of fuel
Causes
• Excessive injection of fuel
)
tion
ge
ter
on)
njec
linka
el fil
(pist
ive i
g, fu
trol
mp
er
er
cess
l con
pipin
d pu
v
lung
o
ng
y
c
p (ex
spra
f fue
ead
timi
e fee
p
fuel
mp
pum
h
lder
nt o
tion
nsid
from
side
n pu
le ho
stme
injec
tion
i
el in
o
l
Legend
age
a
t i
e
injec
injec
nozz
adju
oil s
fuel
of fu
leak
ctive
ctive
ctive
ctive
ctive
ctive
age
rnal
: Possible causes due to length of use (used for a long period) Defe
Defe
Leak
Defe
Defe
Defe
Defe
Exte

Questions

More than for other machines of same
Condition of fuel model
consumption Gradually increased
012406
Suddenly increased
Black
Exhaust smoke color
White
There is irregular combustion
Check items
When exhaust manifold is touched immediately after starting engine,

temperature of some cylinders is low
Match mark on 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 control rack is pushed, it is found to be heavy, or does not return

When check is made using delivery method, 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
20-267
2
(9)
S-11 Oil is in cooling water, or water

spurts back, or water level
goes down
General causes why oil is in cooling water
• Internal leakage in lubrication system

• Internal leakage in cooling system
Causes
et
gask
k
bloc
ing
ler
head
l coo
, O-r
der
g
cylin
ittin
core
ead,
in oi
by p
er h
r tra
oler
s in
Legend
ylind
rack
used
owe
il co

nal c
en o
en p
en c
s ca

Brok
Brok
Hole
Brok
Inter

Questions
012406
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
20-268
2
(9)
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
• Improper oil used (improper viscosity)
• Deterioration of oil due to overheating
fl Standard for engine oil selection
AMBIENT TEMPERATURE
KIND OF
FLUID -22 -4 14 32 50 68 86 104˚F Causes
-30 -20 -10 0 10 20 30 40˚C
SAE 30
SAE 10W
Engine oil
SAE 10W-30
g
ipin
SAE 15W-40
n
n
l pa
sor
l pa
lic p
ing
sen
e oi
e oi
alve
drau
braz
l
d
sure
nsid
urna
e
tor v
insi
d hy
an
pipe
valv
mp
oil p
pres
pe i
g, jo
il
ilter
iner
gula
she
l pu
in o
lief
Legend ion
il pi
il in
stra
oil f
l
arin
, cru
e re
e re
e oi
e oi
suct
uel
o
012406
of o
n be
ctiv
ctiv
ged
ged
ged
ctiv
ctiv
king
er, f
ken
Defe
Defe
Defe
Defe
Lack
Clog
Clog
Clog
Wor
Wat
Lea
Bro

Questions

Operation Manual
Caution lamp 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 sensor lamp 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
Carry out troubleshooting
for “OIL LEVEL RISES”.
When oil filter is inspected, it is found to be clogged

Troubleshooting

Oil pump rotation is heavy, there is play
There is catching of relief valve or regulator valve, spring or
valve guide is broken
When oil pressure is measured, it is found to be within
standard value
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
—
Add
20-269
2
(9)
S-13 Oil level rises (Water, fuel in oil)

fl If there is oil in the cooling water, carry out
troubleshooting for “Oil is in cooling water”.
General causes why oil level rises
• Water in oil
• Fuel in oil (diluted, and smells of diesel fuel)
• Entry of oil from other component
Causes
ber)
r
ham
ove
ion c
ad c
seal
bust
e he
ent
mp
com
ipm
nsid
ace
n pu
t (pre
e
surf
-ring
equ
leev
ng i
k
i
aske
bloc
njec
seal
pipi
ary
er s
re, O
ad g
g
i
de i
der
hold
l
from
ittin
t
rear
osta
aux
d, he
r co
cylin
insi
by p
zzle
oole
ged
r hea
erm
mp
fuel
Legend
part
side
e no
e pu
ama
ade
linde
e th
oil c
: Possible causes (judging from Questions and check items) e of

e
ks in
sm
ctiv
ctiv
ctiv
ctiv
en cy
n, d
kag
ken

Defe
Hole
Defe
Defe
Defe
Crac
Wor
Lea
Brok
Bro
012406
Questions

There is oil in radiator cooling water
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 transmission, or damper case

Oil level goes down in hydraulic tank
Engine oil smells of diesel fuel
Fuel must be added more frequently
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 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
20-270
2
(9)
S-14 Water temperature becomes too

high (Overheating)
Causes
General causes why water temperature becomes too
high
• Lack of cooling air (deformation, damage of fan)
en)
• Drop in heat dissipation efficiency
ure
e
k et
t op
aug
lley
• Defective cooling circulation system
erat
gas
g
ns
s no
n pu
emp
ture
or fi
ead
r
fl Carry out troubleshooting for chassis.
doe
oole
rn fa
oil t
e
pera
diat
d, h
valv
tat (
g
core
oil c
, wo
ittin
e
sion
d ra
h ea
ump
tem
a t
e
mos
ng w
r
ator
by p
essu
ping
k en
she
mis
der
ater
er p
Legend
ther
, bro
radi
, cru
ooli
cylin
ans
p
e pr
ade
ew
wat
s li
e
in tr
of c
ged
ged
ged
sm
ctiv
ctiv
ctiv
belt
ken
ken
Clog
Defe
Hole
Clog
Defe
Lack
Clog
Defe
Rise
Bro
Bro
Fan

Questions
Suddenly overheated
Condition of overheating
Always tends to overheat
Water temperature Rises quickly
gauge Does not go down from red range
Fan belt whines under sudden load
Cloudy white oil is floating on cooling water
012406
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
Carry out troubleshooting for CHASSIS.
Temperature difference between top and bottom radiator tanks

is excessive
Temperature difference between top and bottom radiator tanks
is slight
Troubleshooting
When water filler port is inspected, core is found to be clogged

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
20-271
2
(9)
S-15 Abnormal noise is made

fl Judge if the noise is an internal noise or an external
noise. Causes
etc.)
General causes why abnormal noise is made
)
ition
d
d)
ion)
hea
ver,
eize
r
f pos
line
ject
er le
and
er s
• Abnormality due to defective parts
ce
n
out o
der
rock
aran
lung
rger
• Abnormal combustion
ive
e
ylin
c
e
,
• Air sucked in from intake system
oard
e cle
cess
alve
eren
a
ck, p
renc
och
pum ozzle
g, c
m (v
ing b
ash
x
valv
f
p (ra
turb
erfe
n rin
r
p (e
e
n
ackl
yste
lt in
ion
divid
, int
t of
pum
een
isto
n
ject
b
lve s
i
n be
ush
men
rger
fler (
train
etw
of p
ion
ion
n
ic va
ed b
n, fa
i
cha
just
air b
muf
ized
ject
ject
ear
r
Legend
a
ynam
z
urbo
r ge
d fa
e ad
ve w
e in
side
, sei
e in
e
e of
, s
rme
rope
ctiv
ged
ctiv
ct in
en d
ctiv
ed t
sing
essi
kag
Defe
Defo
Defe
Defe
Clog
Defe
Brok
Seiz
Imp
Lea
Mis
: Items to confirm the cause. Exc
Questions
Condition of abnormal Gradually occurred

noise Suddenly occurred
012406
Black
Metal particles are found in oil filter
Engine pickup is poor and combustion is abnormal
Check items

Abnormal noise is loud when accelerating engine
Leakage of air between turbocharger and head, loose clamp
Vibrating noise is heard from around muffler

Remove gear cover and inspect directly
Speed does not change when operation of certain cylinders is
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
20-272
2
(9)
S-16 Vibration is excessive

fl If there is abnormal noise together with the vi- Causes
bration, carry out troubleshooting also for “Ab-
)
stuck
normal noise is made”.
ion
n)
, etc.
d
ctio
gne
ush
lever
per)
General causes why vibration is excessive
inje
isali
en c
cker
dam
sive
ring
nm
brok
e, ro
• Defective parts (abnormal wear, breakage)
aft (
xces
bea
a i
(valv
r
• Improper alignment
lts,
t
h
t sh
wer
klas
ain
p (e
g bo
• Abnormal combustion
tem
utpu
d, m
o
bac
pum
p
s
ntin
y
d
s
de o
g ro
n
n
alve
ing
u
ion
a
a i
o
gine
ar tr
mic v
m
ctin
insi
ject
s
Legend
u
e
r ge
nne
ngin
b
f en
dyna
e in
part
m
n co
rope
ter o
n ca
ctiv
se e
ctive
ken
Defe
Wor
Wor
Imp
Cen
Loo
Defe
Bro
Questions
Suddenly increased
Condition of vibration
Gradually increased
Metal particles are found in oil filter
Oil pressure is low at low idling
012406
Check items
Vibration occurs at mid-range speed

Vibration follows engine speed
Exhaust smoke is black

Remove side cover and inspect directly
Troubleshooting
Inspect directly for loose engine mounting bolts, broken cushion

Inspect inside of output shaft (damper) directly
When face runout and radial runout are inspected, they are
found to be incorrect
Remove front cover and inspect directly
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
20-273
2
(9)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM
ENGINE AND CHASSIS RELATED SYSTEM DIAGRAM

Serial No. B20001 – B30000, 50001 – 50200
012406
20-304
2
7
012406
20-305-1
(9)
012406 TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM
20-305-2
7
TROUBLESHOOTING E-1
E-1. Starting motor is not cranked when starting switch is turned to START
Serial No. B20001 – B30000, 50001 – 50200
fl Before carrying out troubleshooting, check that fuse FB2, No. 5 is normal.
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
YES
3 YES 6 YES
Does starting Is voltage between
YES motor pinion starting motor
YES 5 terminal R and
make a sound of
chassis normal?
moving in? Is voltage between
starting motor • Turn starting NO
• Turn starting
terminal S and switch ON.
switch to 4 chassis normal? • Max. 1 V
START. Is voltage between
starting switch • Turn starting
terminal C and switch to START. NO
NO chassis normal? • 18 - 28V
ª Check operation of limit switch before starting
• Turn starting troubleshooting.
ª Note 1) 2 switch to START.
NO
Does battery relay • 18 - 28V
YES make a noise when
starting switch is
turned OFF?
• Turn starting
YES
switch ON → 9
Is resistance of wiring
OFF.
012406
harness between
YES starting switch
terminal BR and
ª Note 1) 8 battery relay (+)
ª Note 1) 1 normal?
Is there continuity
Are specific YES between starting • Between starting
gravity and switch BR and NO
switch terminals B
voltage of ª Note 1) 7 and BR? battery relay: Max. 1 Ω
battery normal? • Between wiring harness and chassis: Min. 1 MΩ
Is voltage of • Disconnect both starting switch and battery relay ends.
• Turn starting
• Min. 24V starting switch
switch ON. NO
• Specific gravity: terminal B
NO • Remove terminal
Min. 1.26 normal?
B.
• Connect (-) pole
of tester to (-)
terminal of NO
battery.
• 20 - 29V
NO
E-1. Related electrical circuit diagram
20-306
7
2
TROUBLESHOOTING E-1
fl Before carrying out troubleshooting, check that fuse FB2, No. 5, is normal.
ª Note. 1) 4 YES
Is voltage between
YES terminal B of start-
ing motor and chas-
3 sis ground normal?
• 20 - 30 V NO
YES Is rushing sound • Turn starting
of starting motor
pinion heard? switch ON.
5 YES
Is voltage between
terminal C of start-
NO ing switch and chas-
sis ground normal?
• 20 - 30 V NO
• Turn starting
ª Note. 1) 2 switch to START
position.
When starting
YES switch is oper-
ated, does battery YES
relay make noise? 8
• Turn starting Is resistance of wir-
switch ON and YES ing harness between
BR of starting switch
OFF. ª Note. 1) and (+) of battery re-
7 lay normal?
Is there continuity
ª Note. 1) 1 YES between termi- • Between BR of
starting switch NO
nals B and BR of and battery relay: Max. 1 Ω
012406
Are voltage and ª Note. 1) 6 starting switch? • Between wiring harness and chassis ground: Min. 1 MΩ
specific gravity of • Disconnect both starting switch and battery relay sides.
battery normal? Is voltage between • Turn starting
terminal B of start- switch ON. NO
• 20 - 30 V NO ing switch and chas- • Disconnect
sis ground normal? terminal B.
• Specific
gravity: Min. • 20 - 30 V
1.26 • Connect (–) pin
NO
of tester to (–)
terminal of
battery.
NO
20-307-1
(9)
TROUBLESHOOTING E-1
Cause Remedy
Defective starting motor Replace
Defective contact in wir-

ing harness between (+) Repair or
terminal of battery - ter- replace
minal B of starting motor
Disconnection or defec-
tive contact in wiring har-
ness between terminal C Repair or
of starting switch - termi- replace
nal S of starting motor
or defective limit switch
Defective starting switch
(Between terminals B - C) Replace
9 YES
Defective battery relay Replace
Is there continuity
between (–) termi-
nal of battery and Defective contact in wir-
frame ground? ing harness between (–) Repair or
NO terminal of battery - replace
frame ground
tive contact in wiring har- Repair or
ness between terminal replace
BR of starting switch - (+)
012406
terminal of battery relay

Defective starting switch
(Between terminals B - Replace
BR)
tive contact in wiring har- Repair or
ness between (+) termi- replace
nal of battery - terminal
BR of starting switch
Defective battery Charge or

replace
Note 1) If the lamp (headlamp or rear lamp) cir-

cuit or the horn circuit is normal, this
check may be substituted by checking that
the light or horn is turned on normally.
20-307-2
7
TROUBLESHOOTING E-2
E-2. Engine does not start (defective operation of engine stop solenoid)
Serial No. B20001 – B30000, 50001 – 50200
fl When the starting motor rotates normally.

Cause Remedy
1 YES Defective adjustment of

Adjust
Does condition linkage
become normal
when linkage is
adjusted? YES Defective engine stop
Replace
2 solenoid
ª See TESTING
AND Is voltage
ADJUSTING. between
disconnection in wiring
NO solenoid (+) and 3 YES harness between starting Replace wiring
GND normal? Is voltage between switch terminal ACC - harness
starting switch CN32 (9) - CN20 (3) -
• Turn starting
terminal ACC and solenoid (+)
switch ON. NO GND normal?
• 20 - 30V Defective starting switch
Replace
NO (between B and ACC)
• Turn starting
switch ON.
• 20 - 30V
012406
20-308
2
7
TROUBLESHOOTING E-2
fl When the starting motor rotates normally.

Cause Remedy
1 YES Defective adjustment of

Adjust
Does condition linkage
become normal
when linkage is
adjusted? YES Defective engine stop
Replace
2 solenoid
ª See TESTING
AND Is voltage
ADJUSTING. between
NO solenoid (+) and 3 YES harness between starting Replace wiring
GND normal? Is voltage between switch terminal ACC - harness
starting switch CN32 (9) - CN20 (3) -
• Turn starting
terminal ACC and solenoid (+)
switch ON. NO GND normal?
• 20 - 30V Defective starting switch
Replace
NO (between B and ACC)
• Turn starting
switch ON.
012406
• 20 - 30V
20-309
2
(9)
TROUBLESHOOTING E-3
E-3. Lamps do not light up

Serial No. B20001 – B30000, 50001 – 50200
fl When the battery is normal.

a) Front lamps
Cause Remedy
Lamp which does not

4 YES light up is defective, or Repair or
Is voltage there is defective contact replace
YES between CN5 or in wiring
3 CN6 and chassis Defective contact, or
Is continuity normal? disconnection in wiring Repair or
YES between front lamp • 20 - 30V NO harness between CN5 or replace
switch (L) and (M) as • Turn starting switch ON. CN6 and CN48
2 shown in Table 1? • Turn front lamp
Is voltage • Disconnect CN48. switch ON.
YES between CN48 Defective front lamp
• Turn starting switch Replace
NO switch
(2) and chassis OFF.
1 normal? ª If the rear lamp is normal, it is also possible
to interchange the front and rear lamp Defective contact, or
Does battery relay • 20 - 30V switches and check again. disconnection in wiring
make a noise when Repair or
• Turn starting harness between CN48
012406
starting switch is NO replace
switch ON. and fuse FB1, No. 6
turned OFF?
• Turn starting Start troubleshooting

switch ON → from E-1 Item 7
OFF. NO
Table 1
E L M Continuity
OFF No
ON Yes
E-3. a) Related electrical circuit diagram
20-309-1
7
TROUBLESHOOTING E-3
b) Rear lamps
Cause Remedy
Lamp which does not

YES between CN1 in wiring
3 and chassis Defective contact, or
YES between rear lamp • 20 - 30V NO harness between CN1 and replace
switch (L) and (M) • Turn starting switch ON. CN47
2 as shown in Table 2? • Turn rear lamp switch
Is voltage • Disconnect CN47. ON. Defective rear lamp
YES between CN47 Replace
• Turn starting switch switch
NO
1 normal? ª If the front lamp is normal, it is also possible to
Does battery relay interchange the front and rear lamp switches and Defective contact, or
• 20 - 30V check again. disconnection in wiring
turned OFF?

OFF. NO
012406
Table 2
E L M Continuity
OFF No
ON Yes
E-3. b) Related electrical circuit diagram
20-309-2
7
TROUBLESHOOTING E-3

a) Front lamps
Cause Remedy
Lamp which does not

YES between CN5 or in wiring
3 CN6 and chassis Defective contact, or
YES between front lamp • 20 - 30V NO harness between CN5 or replace
switch (L) and (M) as • Turn starting switch ON. CN6 and CN48
2 shown in Table 1? • Turn front lamp
Is voltage • Disconnect CN48. switch ON.
YES between CN48 Defective front lamp
• Turn starting switch Replace
NO switch
1 normal? ª If the rear lamp is normal, it is also possible
to interchange the front and rear lamp Defective contact, or
Does battery relay • 20 - 30V switches and check again. disconnection in wiring
012406
turned OFF?

OFF. NO
Table 1
E L M Continuity
OFF No
ON Yes
E-3. a) Related electrical circuit diagram
20-310
2
(9)
TROUBLESHOOTING E-3
b) Rear lamps
Cause Remedy
Lamp which does not

YES between CN1 in wiring
3 and chassis Defective contact, or
YES between rear lamp • 20 - 30V NO harness between CN1 and replace
switch (L) and (M) • Turn starting switch ON. CN47
2 as shown in Table 2? • Turn rear lamp switch
Is voltage • Disconnect CN47. ON. Defective rear lamp
YES between CN47 Replace
• Turn starting switch switch
NO
1 normal? ª If the front lamp is normal, it is also possible to
Does battery relay interchange the front and rear lamp switches and Defective contact, or
• 20 - 30V check again. disconnection in wiring
turned OFF?

OFF. NO
012406
Table 2
E L M Continuity
OFF No
ON Yes
E-3. b) Related electrical circuit diagram
20-311
2
7
TROUBLESHOOTING E-4
E-4. Automatic preheating is not carried out when glow switch is turned
to AUTO
Serial No. B20001 – B30000, 50001 – 50200

5
Is there continuity
YES between CN46 (2)
and (3) when glow
4 switch is placed at
Is voltage between AUTO?
YES CN46 (3) and
chassis normal in • Check glow
temperature switch as an
3 conditions below? individual part.
Is there continuity • 20 - 30V • Turn starting
YES between CN38 switch OFF.
• Turn starting
(male) (1) and switch ON. NO
2 (2)? • When ambient
Is voltage temperature is
YES • Check bimetal
between CN38 less than –5°C
timer as an
(2) and chassis individual part. NO
Note 1) 1 normal? • Turn starting
Does battery relay • 20 - 30V switch OFF.
make a noise when • Turn starting
starting switch is switch ON. NO
turned OFF?
012406
• Turn starting
switch ON →
OFF. NO
Note 1) If the lamps (front lamps, rear lamps) or horn circuit are normal, it is possible to check instead
if the lamps light up normally or if the horn sounds normally.
20-312
2
7
TROUBLESHOOTING E-4

5
Is there continuity
YES between CN46 (2)
and (3) when glow
4 switch is placed at
Is voltage between AUTO?
YES CN46 (3) and
chassis normal in • Check glow
temperature switch as an
3 conditions below? individual part.
Is there continuity • 20 - 30V • Turn starting
YES between CN38 switch OFF.
• Turn starting
(male) (A) and switch ON. NO
2 (B)? • When ambient
Is voltage temperature is
YES • Check bimetal
between CN38 less than –5°C
timer as an
(B) and chassis individual part. NO
Note 1) 1 normal? • Turn starting
Does battery relay • 20 - 30V switch OFF.
make a noise when • Turn starting
starting switch is switch ON. NO
turned OFF?
012406
• Turn starting
switch ON →
OFF. NO
20-313-1
(9)
TROUBLESHOOTING E-4
Cause Remedy
6 YES
Defective heater relay Replace
Is voltage between
YES heater relay
terminal (+) and Defective contact, or
chassis normal? disconnection in wiring Repair or
• 20 - 30V NO harness between CN46 (2) replace
• Turn starting and heater relay (+)
switch ON.
Defective glow switch Replace
NO
disconnection in wiring Repair or
harness between CN46 (3) replace
and CN38 (A)
Defective bimetal timer Replace
Repair or
harness between starting
replace
switch terminal BR and
CN38 (B)
012406
Start troubleshooting
from E-1 Item 7
20-313-2
7
TROUBLESHOOTING E-5
E-5. Cab wiper does not work

Serial No. B20001 – B30000, 50001 – 50200
fl Before carrying out troubleshooting, check that the fuse for each wiper is normal.
Note 2) 5 YES
Check connector
directly in front of
wiper motor. Is
YES continuity between
connector terminal
4 (male) (2) and (3)
(for front wiper: (5)
Does it work if it and (2)) normal?
YES is interchanged
with another • Max. 10 Ω NO
3 wiper switch? • Turn starting
Do washers work switch OFF.
YES normally in places • Turn starting
where wiper does switch ON.
• Turn wiper
NO
not work?
2 switch ON.
• Turn starting ª When other wipers are normal.
YES Do other wipers switch ON.
work? • Turn washer NO
Note 1) 1 switch ON.
Does battery relay ª When washers
• Turn starting
make a noise when are normal.
switch ON.
starting switch is • Turn wiper NO
turned OFF? switch ON.
• Turn starting ª When other wipers are normal.
012406
switch ON→
OFF. NO
Note 2) This troubleshooting flowchart uses the left wiper as an example. For the other wipers, the
connectors corresponding to CN11 are as shown in the table below.
Note 3) The connector numbers in this troubleshooting flowchart are the connector numbers in the
operator’s cab, not the connector numbers on the chassis (in some cases, the same connector
numbers are used on the chassis and in the operator’s cab).
Wiper Left wiper Front wiper Right wiper

Connector No. CN11 CN12 CN13
20-314
2
7
TROUBLESHOOTING E-5

YES
5
When wiper switch
YES is replaced with an-
other one, does
4 wiper operate?
Does washer of • Turn starting
YES wiper which does
switch ON.
not operate spout NO
washer normally? • Turn wiper
3 switch ON.
• Turn starting ª When other wiper switches are normal.
YES Do other wipers switch ON.
operate? • Turn washer NO
2 switch ON.
ª When washer
Is there continuity • Turn starting is normal.
YES between termi- switch ON.
nals B and BR of • Turn wiper NO
Note 1) 1 starting switch? switch ON.
When starting • Turn starting ª When other wipers
switch is oper- switch ON. are normal.
ated, does battery • Disconnect NO
012406
relay make noise? terminal B.
• Turn starting
switch ON and
OFF. NO
Note 2) This troubleshooting flowchart uses the left wiper as an example. For the other wipers, the
connectors corresponding to CN11 are as shown in the table below.
Wiper Left wiper Front wiper Right wiper Rear wiper

Connector No. CN11 CN12 CN13 CN14
20-315-1
(9)
TROUBLESHOOTING E-5
Cause Cause
7 YES
Defective wiper motor Replace
YES
6 • Is wiper arm
Is there continuity be- normal?
tween connector ter-
minals (male) (2) and Defective wiper motor Replace
(3) just before wiper NO
motor (between (5)
and (2) for front wiper Note 2)
and between (1) and Disconnection or defec-
(2) for rear wiper)? tive contact in wiring har- Repair or
ness between CN11 (4) -
• Max. 10 Ω NO connect (2) ((5) for front replace
• Turn starting wiper) just before wiper
switch OFF. motor
Defective wiper switch Replace

Note 2)
• Disconnection or defec-
tive contact in wiring
harness between CN11 Repair or
(3) on cab side - fuse on replace
cap side
• Breakage of fusible link
on cab side or discon-
nection or defective con- Repair or
tact in wiring harness
between battery relay - replace
terminal B of fuse box
on cab side
Defective starting switch Replace

012406
• Circuit diagrams of right, left, and rear wipers • Circuit diagrams of front wiper
20-315-2
7
TROUBLESHOOTING E-6
E-6. No washer fluid is sprayed out

Serial No. B20001 – B30000, 50001 – 50200
YES
5 YES
2 YES Is washer motor

properly
Does washer grounded?
YES motor rotate?
(Can a rotating 4
• Turn starting NO
sound be heard?) Is voltage between
YES washer motor switch OFF.
• Turn starting
connector (2) and 6 YES
switch ON. GND normal?
• Turn washer 3 Does it work if it is
1 switch (wiper • Turn starting interchanged with
switch) ON. Do other another washer
switch ON. NO
Does wiper work washers work switch (wiper switch)?
• Wiper switch:
normally? NO normally? Set to WASHER
• 20 - 30V
switch ON.
• Turn starting • Turn washer
• Turn starting
switch ON. switch ON.
switch ON.
• Turn washer
• Turn wiper NO
switch ON.
switch ON.
012406
NO
20-316
2
7
TROUBLESHOOTING E-6

YES
1 YES
Does washer mo-
tor rotating (Does 5
rotating sound of
motor come out)? Does wiper of
YES washer which does
• Turn starting not spout water
4 operate normally?
switch ON.
• Turn washer • Turn starting
switch ON. YES Do other wash- switch ON.
ers operate nor-
(Wiper switch) mally? • Turn wiper NO
Is there continuity • Turn starting ª When wiper is
012406
YES between termi- switch ON. normal.
nals B and BR of • Turn washer NO
When starting • Turn starting ª When other washers
NO ated, does battery • Disconnect NO
• Turn starting
switch ON and
OFF. NO
20-317-1
(9)
TROUBLESHOOTING E-6
Serial No. B30001 and up, 50201 and up

YES
1 YES
Does washer mo-
tor rotating (Does 5
rotating sound of
motor come out)? Does wiper of
YES washer which does
• Turn starting not spout water
4 operate normally?
switch ON.
• Turn washer • Turn starting
switch ON. YES Do other wash- switch ON.
ers operate nor-
(Wiper switch) mally? • Turn wiper NO
Is there continuity • Turn starting ª When wiper is
012406
YES between termi- switch ON. normal.
nals B and BR of • Turn washer NO
When starting • Turn starting ª When other washers
NO ated, does battery • Disconnect NO
• Turn starting
switch ON and
OFF. NO
20-317-1
7
TROUBLESHOOTING E-6
Cause Cause
Insufficient water, clogged Repair or

nozzle, or defective water replace
piping
8 YES
Defective washer motor Replace
YES Is ground wire of
washer motor
7 connected?
Is voltage between Repair or
YES CN26 on cab side Defective ground wire replace
NO
and chassis
6 ground normal? Note 2)
When washer
(wiper) switch is re- • 20 - 30 V Disconnection or defective
placed with an- contact in wiring harness Repair or
• Turn starting NO between CN26 on cab side replace
other one, does
washer operate? switch ON. - CN11 on cab side
• Turn washer
• Turn starting switch ON.
switch ON. Defective washer (wiper) Replace
• Turn washer NO switch
switch ON.
ª When other Note 2)
washer Disconnection or defective
contact in wiring harness Repair or
between CN11 (2), (3) on cab replace
side - fuse on cab side
Breakage of fusible link on
012406
cab side or disconnection or Repair or

defective contact in wiring
harness between battery re- replace
lay - terminal B of fuse box
on cab side
Defective starting switch Replace
Note 2) This troubleshooting flowchart uses the left washer as an example. For the other washers,
the connectors corresponding to CN11 in the cab are as shown in the table below.
Left wiper Front wiper Right wiper Rear wiper

Connector No. CN11 CN12 CN13 CN14
20-317-2
7
TROUBLESHOOTING
TROUBLESHOOTING OF MACHINE
MONITOR SYSTEM
(M MODE)
Table of failure modes and causes (machine monitor system) ....................................................... 20-502
Electrical circuit diagrams for each system ........................................................................................ 20-504
M-1 No display is given on monitor panel when starting switch is turned to ON ..................... 20-506
M-2 When starting switch is turned to ON, all monitor panel lamps light up
and do not go out ........................................................................................................................ 20-506
M-3 Preheating display ( ) is abnormal ................................................................................... 20-507
SAP00526
a) Preheating monitor does not light up ................................................................................. 20-507

b) Preheating monitor stays lighted up ................................................................................... 20-507
M-4 CAUTION items light up or flash ............................................................................................... 20-509
a) ( SAP00522
) (charge) lights up or flashes .................................................................................. 20-509
b) When starting switch is turned to ON and engine is started,
( ) (engine oil pressure) lights up or flashes ........................................................... 20-510
012406
c) ( ) (coolant temperature) flashes ................................................................................ 20-511

SAP00527
d) ( ) (power train oil temperature) flashes ................................................................... 20-512

M-5 Buzzer is abnormal ...................................................................................................................... 20-513
a) Caution item flashes but buzzer does not sound .............................................................. 20-513
b) Monitor display is normal, but buzzer sounds .................................................................. 20-513
M-6 Warning lamp is abnormal ......................................................................................................... 20-514
a) Caution item is flashing but lamp does not flash ............................................................. 20-514
b) Monitor display is normal but lamp flashes ...................................................................... 20-514
M-7 Gauge is abnormal ...................................................................................................................... 20-515
a) Abnormality in engine coolant temperature gauge .......................................................... 20-515
b) Abnormality in power train oil temperature gauge .......................................................... 20-516
c) Abnormality in fuel level gauge .......................................................................................... 20-517
M-8 Service meter does not move after engine is started ............................................................. 20-518
M-9 Monitor panel lighting does not light up (front lamps are normal) ...................................... 20-519
20-501
(9)
2
ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM

MACHINE MONITOR RELATED SYSTEM DIAGRAM
Serial No. B20001 – B30000, 50001 – 50200
012406
20-504
7
2
012406
20-505-1
(9)
012406 TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM
20-505-2
7
TROUBLESHOOTING M-3
M-3. Preheating display is abnormal

SAP00526
Serial No. B20001 – B30000, 50001 – 50200
fl When the battery and battery relay are normal.
(If it is blown, check for a short circuit with ground in the wiring harness between grid heater
relay – CN20(8) – CN32(7) – starting switch terminal R1, terminal B – CN32(5) – fuse, or between
battery relay – CN32(6),(12),(14) – CN38(2), CN46(4).)
Cause Remedy
1 YES
Go to M-3. a), b)
Does problem in
M-3 a), b) appear
again? Carry out troubleshooting
of bimetal timer, glow
• Disconnect CN38 NO switch.
and CN46. (Go to E-4)
a) Preheating monitor does not light up

Cause Remedy
012406
YES
1
Disconnection in wiring
Is voltage 3 YES harness between CN49 (6) Repair
between CN49 – CN31 (6) – CN20 (7) – or replace
(female) (6) and Is voltage between
YES heater relay output heater relay
chassis normal?
2 terminal and
• 4 – 30V chassis normal?
Is voltage between Defective heater relay Replace
heater relay • 4 – 30V
switch to terminal R1 and
NO • Turn starting switch
PREHEAT. chassis normal? Defective contact, or
• Disconnect CN49 to PREHEAT. disconnection in wiring
Repair
(female) and • 16 – 30V harness between starting
NO or replace
connect T-adapter. • Turn starting switch terminal R1 –
switch to PREHEAT. heater relay – chassis
b) Preheating monitor stays lighted up

Cause Remedy
Contact of +24V with
wiring harness between
CN49 (6) – CN31 (6) –
1 YES Repair
CN20 (7) – heater relay, or
or replace
Is voltage between starting switch
between CN49 R1 – CN32 (7) – CN20 (8) –
(6) and chassis heater relay
normal?
• 4 – 30V NO
20-507
7
2
TROUBLESHOOTING M-3

fl When the battery and battery relay are normal.
(If it is blown, check for a short circuit with ground in the wiring harness between grid heater
relay – CN20(8) – CN32(7) – starting switch terminal R1, terminal B – CN32(5) – fuse, or between
battery relay – CN32(6),(12),(14) – CN38(2), CN46(4).)
Cause Remedy
1 YES
Go to M-3. a), b)
Does problem in
M-3 a), b) appear
again? Carry out troubleshooting
of bimetal timer, glow
• Disconnect CN38 NO switch.
and CN46. (Go to E-4)
a) Preheating monitor does not light up

Cause Remedy
012406
YES
1
Is voltage Disconnection in wiring
3 YES Repair
between CN49 harness between CN49 (6)
Is voltage between or replace
(female) (6) and – heater relay
YES heater relay output
chassis normal?
2 terminal and
• 4 – 30V chassis normal?
Is voltage between Defective heater relay Replace
heater relay • 4 – 30V
switch to terminal R1 and
NO • Turn starting switch
PREHEAT. chassis normal? Defective contact, or
• Disconnect CN49 to PREHEAT. disconnection in wiring
Repair
(female) and • 16 – 30V harness between starting
NO or replace
connect T-adapter. • Turn starting switch terminal R1 –
switch to PREHEAT. heater relay – chassis
b) Preheating monitor stays lighted up

Cause Remedy
Contact of +24V with

wiring harness between
1 YES CN49 (6) – heater relay, or Repair
between starting switch or replace
Is voltage
between CN49 R1 – CN32 (7) – CN20 (8) –
(6) and chassis heater relay (+)
normal?
• 4 – 30V NO
20-508-1
(9)
TROUBLESHOOTING M-3
M-3. a), b) Related electrical circuit diagram
012406
20-508-2
7
TROUBLESHOOTING M-4
M-4. CAUTION items light up or flash

Serial No. B20001 – B30000, 50001 – 50200
a) (charge) lights up or flashes

SAP00522
1 When it lights up Cause Remedy
YES Defective monitor panel Replace

ªA 2
Is voltage disconnection in wiring
YES between CN49 harness between CN49 (4) –
(4) and chassis 3 YES CN31 (4) – CN17 (5) – alter-
nator terminal R, or same Repair
ground normal? Is voltage between wiring harness – CN16 (2) – or replace
alternator terminal starting motor terminal R –
1 • 10 – 30V battery relay short cicuiting
• Start engine. NO R and chassis with chassis ground
pressure caution Defective alternator or Replace
• 10 – 30V NO defective regulator
lamp also light • Remove wiring
up? harness connected to alternator terminal R.
• Start engine.
• Start engine. ªB 4 YES
When cranking, is
voltage between
NO CN49 (5) and chassis Defective contact, or
012406
ground normal? disconnection in wiring Repair

harness between CN49 (5) or replace
• 10 – 30V NO – CN31 (5) – CN32 (8) –
• Turn starting starting switcn terminal C
switch ON.
2 When it flashes
Start troubleshooting from the items marked ª in a).
M-4. a) Related electrical circuit diagram
If the result of the continuity check on

the sensor is as shown in the table
below, the sensor is normal.
Engine oil pressure: No
0.05 MPa (0.5 kg/cm2)
and above Continuity
Engine oil pressure:
Less than 0.05 MPa Continuity
(0.5 kg/cm2)
20-509
7
2
TROUBLESHOOTING M-4
b) When starting switch is turned to ON and engine is started
(engine oil pressure) lights up or flashes
fl Check that the engine oil pressure is the specified value before starting troubleshooting.
1 YES Start troubleshooting

from ªA in M-4. a)
Does charge
lamp also light
up?
NO from ªB in M-4. a)
• Start engine.
2 When it flashes Cause Remedy

Check that contact
and insertion of ter-
minal are correct,
carry out sensor
YES Defective engine oil check according to
1 pressure sensor system STANDARD
Remove wiring VALUE TABLE,
012406
harness terminal of replace
Contact of chassis ground
engine oil pressure with wiring harness
sensor. Does 2 YES Repair
display go out? between CN49 (8) – CN20
Is there continuity (1) – engine oil pressure or replace
• Remove terminal between CN49 sensor
of engine oil NO (female) (8) and
pressure sensor. chassis ground?
• Start engine. • Turn starting NO
switch OFF.
• Remove terminal of
engine oil pressure
sensor.
M-4. b) Related electrical circuit diagram

0.05 MPa (0.5 kg/cm2)
(0.5 kg/cm2)
20-510
7
2
TROUBLESHOOTING M-4
c) (coolant temperature) flashes

SAP00527
Cause Remedy
Carry out
sensor check
YES Defective coolant according to
2 temperature sensor STANDARD
VALUE TABLE,
YES Does flashing go replace
out when CN15
3 YES
is disconnected? Defective monitor panel Replace
1 Is voltage
• Disconnect between CN50 Wiring harness between
Is indicator of
coolant tempera- CN15. NO (1) and CN50 (4) CN50 (1) – CN31 (11) –
• Run engine at normal? CN17 (3), (2) – CN15 (1) – Repair
ture gauge above
border of red zone? half throttle or • Min. 2.5V NO coolant temperature or replace
above. • Start engine. sensor short circuiting
• Start engine. • Run engine at half throttle or above. with ground
• Run engine at • Disconnect CN15.
half throttle or Defective monitor panel Replace
NO
above.
012406
M-4. c) Related electrical circuit diagram
20-511
2
(9)
TROUBLESHOOTING M-4
d) (power train oil temperature) flashes
Cause Remedy
Carry out
sensor check
YES Defective power train oil according to
VALUE TABLE,
out when CN28
3 YES
1 Is voltage
• Disconnect CN28. between CN50
Is indicator of power Wiring harness between
train oil temperature • Start engine. NO (2) and CN50 (4)
• Run engine at normal? CN50 (2) – CN31 (12) –
gauge below border Repair
half throttle or CN28 (1) – power train oil
of red zone? • Min. 2.5V NO or replace
above. temperature sensor short
• Start engine.
• Start engine. circuiting with ground
• Run engine at half throttle or above.
above. NO
012406
M-4. d) Related electrical circuit diagram
20-512
(9)
2
TROUBLESHOOTING M-4
Serial No. B30001 – B40000, 50201 and up
a) (charge) lights up or flashes

SAP00522
[1] When it lights up Cause Remedy
YES Defective monitor panel Replace

ªA 2
Is voltage Defective contact, or
YES between CN49 harness between CN49 (4) –
(4) and chassis 3 YES alternator terminal R, or Repair
ground normal? same wiring harness –
Is voltage between starting motor terminal R – or replace
• 10 – 30V alternator terminal battery relay short cicuiting
1 with chassis ground
• Start engine. NO R and chassis
pressure caution Defective alternator or Replace
• 10 – 30V NO defective regulator
lamp also light • Remove wiring
up? harness connected to alternator terminal R.
• Start engine.
• Start engine. ªB 4 YES
When cranking, is
voltage between
012406
NO CN49 (5) and chassis Defective contact, or

harness between CN49 (5) or replace
• 10 – 30V NO
– starting switcn terminal
• Turn starting C
switch ON.
[2] When it flashes

Start troubleshooting from the items marked ª in a).

0.05 MPa (0.5 kg/cm2)
(0.5 kg/cm2)
20-512-1
(9)
TROUBLESHOOTING M-4
b) When starting switch is turned to ON and engine is started
(engine oil pressure) lights up or flashes
fl Check that the engine oil pressure is the specified value before starting troubleshooting.
1 YES Start troubleshooting

from (ªA) in M-4. a)
Does charge
lamp also light
up?
NO from (ªB) in M-4. a)
• Start engine.
2 When it flashes Cause Remedy

Check that contact
and insertion of ter-
minal are correct,
carry out sensor
YES Defective engine oil check according to
1 pressure sensor system STANDARD
Remove wiring VALUE TABLE,
012406
harness terminal of replace
Contact of chassis ground
engine oil pressure with wiring harness
sensor. Does 2 YES Repair
display go out? between CN49 (8) – CN20
Is there continuity (1) – engine oil pressure or replace
• Remove terminal between CN49 sensor
of engine oil NO (female) (8) and
pressure sensor. chassis ground?
• Start engine. • Turn starting NO
switch OFF.
• Remove terminal of
engine oil pressure
sensor.

0.05 MPa (0.5 kg/cm2)
(0.5 kg/cm2)
20-512-2
7
TROUBLESHOOTING M-4
c) (coolant temperature) flashes

SAP00527
Cause Remedy
Carry out
sensor check
YES Defective coolant according to
VALUE TABLE,
out when CN15
3 YES
1 Is voltage
• Disconnect between CN50
Is indicator of Wiring harness between
coolant tempera- CN15. NO (1) and CN50 (4)
CN50 (1) – CN15 (1) –
• Run engine at normal? Repair
ture gauge above coolant temperature
border of red zone? half throttle or • Min. 2.5V NO sensor short circuiting or replace
above. • Start engine. with ground
• Start engine. • Run engine at half throttle or above.
NO
above.
012406
20-512-3
7
TROUBLESHOOTING M-4
d) (power train oil temperature) flashes
Cause Remedy
Carry out
sensor check
YES Defective power train oil according to
VALUE TABLE,
out when CN28
3 YES
1 Is voltage
• Disconnect CN28. between CN50
Is indicator of power Wiring harness between
train oil temperature • Start engine. NO (2) and CN50 (4)
• Run engine at normal? CN50 (2) – CN28 (1) –
gauge below border Repair
half throttle or power train oil
of red zone? • Min. 2.5V NO or replace
above. temperature sensor short
• Start engine.
• Start engine. circuiting with ground
• Run engine at half throttle or above.
above. NO
012406
M-4. d) Related electrical circuit diagram
20-512-4
7
TROUBLESHOOTING M-5
M-5. Buzzer is abnormal

fl Of the caution items, only CHARGE does not have the alarm buzzer sound when there is an
abnormality.
a) Caution item flashes but buzzer does not sound
Cause Remedy
1 YES
When circuit bet-
ween CN50 (female)
(7) and chassis
ground is connected, disconnection in wiring
does buzzer sound? harness between fuse FB1 Repair
NO No. 1 - CN32 (4) - CN41 or replace
• Ground CN50
(1),(2) - buzzer - CN50 (7),
(female) (7) to chassis?
or defective buzzer
b) Monitor display is normal, but buzzer sounds

Cause Remedy
012406
1 YES
When CN50 is
removed, does Wiring harness between
buzzer stop? CN50 (7) and CN41 (2) Repair
short circuiting with or replace
• Remove CN50. NO ground, or defective
• Turn starting buzzer
switch ON.
M-5. Related electrical circuit diagram
20-513
7
2
TROUBLESHOOTING M-6
M-6. Warning lamp is abnormal

a) Caution item is flashing but lamp does not flash

fl When a visual check shows that the bulb is not blown.
(If it is blown, replace the lamp bulb.)
Cause Remedy
b) Monitor display is normal but lamp flashes
Cause Remedy
012406
20-514
2
TROUBLESHOOTING M-7
M-7. Gauge is abnormal

a) Abnormality in engine coolant temperature gauge

• The engine coolant temperature gauge shows an abnormally low temperature.
Serial No. B20001 – B30000, 50001 – 50200
Cause Remedy
Carry out sensor

1 check according
Connect short con- YES Defective coolant to STANDARD
nector to CN15. Does temperature sensor system VALUE TABLE,
indicator go com- replace
pletely to high tempe- Defective contact, or
rature side, does cau-
tion lamp flash, and disconnection in wiring
does buzzer sound? harness between CN15 (1) Repair
NO – CN17 (3) – CN31 (11) – or replace
• Connect short CN50 (1), or between CN15
connector to (2) – CN17 (2) – CN31 (14) –
CN15 (female). CN50 (4) – chassis ground
• Turn starting
switch ON.
012406
When the sensor is checked as an

individual part, if the condition is as shown
in the table below, the sensor is normal
Ambient When normal
temperature
l l
l l
20-515
7
2
TROUBLESHOOTING M-7
Cause Remedy
Carry out sensor

1 check according
Connect short con- YES Defective coolant to STANDARD
nector to CN15. Does temperature sensor system VALUE TABLE,
indicator go com- replace
pletely to high tempe- Defective contact, or
rature side, does cau- disconnection in wiring
tion lamp flash, and harness between CN15
does buzzer sound? (female) (1) – CN50 Repair
NO (female) (1), or between or replace
• Connect short CN15 (female) (2) – CN17
connector to (2) – CN31 (14) – CN50 (4) –
CN15 (female). chassis ground
• Turn starting
switch ON.
012406

Ambient When normal
temperature
l l
l l
20-515-1
(9)
TROUBLESHOOTING M-7
b) Abnormality in power train oil temperature gauge

• The power train oil temperature gauge shows an abnormally low temperature.
Cause Remedy
Carry out sensor

1 check according
Connect short con- YES Defective power train oil
to STANDARD
nector to CN28. Does temperature sensor system
VALUE TABLE,
indicator go com-
pletely to high tempe- replace
rature side, does cau-
tion lamp flash, and disconnection in wiring Repair
does buzzer sound? harness between CN28 (1) or replace
NO – CN31 (12) – CN50 (2), or
• Connect short between CN28 (2) and
connector to chassis ground
CN28.
• Turn starting
switch ON.

Serial No.: B20001 – B40000, 50001 – 50200
012406

Ambient When normal
temperature
l l
l l
20-516
(9)
2
TROUBLESHOOTING M-7
c) Abnormality in fuel level gauge
[1] Fuel level is always shown as FULL Cause Remedy
Carry out sensor

check according
2 YES Defective fuel level sensor to STANDARD
When CN3 is system VALUE TABLE,
YES disconnected, replace
1 does fuel level go Wiring harness between
below E mark? CN3 (1) – CN4 (2) – CN31 Repair
Does fuel level (13) – CN50 (3) short or replace
• Disconnect CN3. NO
go below E circuiting with ground
mark? • Wait for approx. 1 minute.
• Remove CN50. Defective monitor panel Replace

NO
• Turn starting
switch ON.
• Wait for approx. 1 minute.
[2] Fuel level is always shown as EMPTY Cause Remedy
Carry out sensor

check according
2 YES Defective fuel level sensor to STANDARD
When short con- system VALUE TABLE,
YES nector is connected replace
012406
to CN3, does fuel Defective contact, or

1 level go above F disconnection in wiring
mark? harness between CN3 (1) Repair
Does fuel level • Connect short NO – CN4 (2) – CN31 (13) – or replace
go above F connector to CN3. CN50 (3), or between CN3
mark? • Turn starting switch ON. (2) and chassis ground
• Short circuit Defective monitor panel Replace
CN50 pins (3) (4). NO

Serial No.: B20001 – B30000, 50001 – 50200
20-517
(9)
2
TROUBLESHOOTING M-8
When checking sensor as individual

part, if condition is as in table below,
sensor is normal.
Upper stopper Max.
(FULL) position approx. 12 Ω
Lower stopper Approx.
(EMPTY) position 85 – 110 Ω
M-8. Service meter does not move after engine is started

012406
Cause Remedy
1 YES
Go to M-4. a).
Does charge
abnormality
display flash?
• Start engine. NO
20-518
7
2
TROUBLESHOOTING M-9
M-9. Monitor panel lighting does not light up (front lamps are normal)
fl When a visual check shows that the bulb is not blown.
(If it is blown, replace the lamp bulb.)
(If it is blown, check for a short circuit between fuse – CN32(3),(4) – CN48(3),(2) – CN5(1) – CN6(1)
lamp)
Cause Remedy
1 YES
Is voltage
between CN49
(7) and chassis Defective contact, or
NO harness between CN49 (7) or replace
• 20 – 30V
– CN32 (3) – CN48 (3)
• Turn front lamp switch ON.
M-9. Related electrical circuit diagram

Serial No.: B20001 – B30000, 50001 – 50200
012406
20-519
(9)
2
DISASSEMBLY AND ASSEMBLY RADIATEUR
TRANSMISSION PRESSURE VALVE MAIN CONTROL VALVE

Removal .................................................. 30-108 Removal .................................................. 30-174
Installation .............................................. 30-108 Installation .............................................. 30-175
Disassembly ........................................... 30-110 Disassembly ........................................... 30-176
Assembly ................................................ 30-111 Assembly ................................................ 30-182
MAIN RELIEF VALVE
Removal .................................................. 30-188
STEERING PISTON Installation .............................................. 30-188
Removal .................................................. 30-112
Installation .............................................. 30-112 STEERING PPC VALVE
Disassembly ........................................... 30-113 Removal .................................................. 30-189
Assembly ................................................ 30-113 Installation .............................................. 30-189
Disassembly ........................................... 30-190
PARKING BRAKE CYLINDER Assembly ................................................ 30-191
Removal .................................................. 30-114
BLADE ANGLE CYLINDER
Installation .............................................. 30-115
Removal .................................................. 30-193
Disassembly ........................................... 30-116
Installation .............................................. 30-193
Assembly ................................................ 30-117
BLADE LIFT CYLINDER
FINAL DRIVE Removal .................................................. 30-194
Removal .................................................. 30-118 Installation .............................................. 30-194
Installation .............................................. 30-118
Disassembly ........................................... 30-119 BLADE TILT CYLINDER
Assembly ................................................ 30-123 Removal .................................................. 30-195
Installation .............................................. 30-195
IDLER, RECOIL SPRING
Removal .................................................. 30-128 HYDRAULIC CYLINDER
Disassembly ........................................... 30-196
Installation .............................................. 30-128
Assembly ................................................ 30-198
012406
RECOIL SPRING
WORK EQUIPMENT
IDLER Disassembly ........................................... 30-202
Disassembly ........................................... 30-131 Assembly ................................................ 30-205
Assembly ................................................ 30-132 HYDRAULIC TANK
TRACK ROLLER Removal .................................................. 30-208
Removal .................................................. 30-134 Installation .............................................. 30-208
Installation .............................................. 30-134 ROPS ROOF, GUARD
CARRIER ROLLER CANOPY
Removal .................................................. 30-138 Removal .................................................. 30-210
Disassembly ........................................... 30-139 OPERATOR'S CAB
Assembly ................................................ 30-140 Removal .................................................. 30-211
TRACK SHOE Installation .......................................... 30-212-1
Removal .................................................. 30-142 OPERATOR'S CAB GLASS (STUCK GLASS)
Installation .............................................. 30-143 Removal ...............................................30-212-5
Overall disassembly .............................. 30-144 Installation .......................................... 30-212-6
Overall assembly ................................... 30-149
FLOOR FRAME
Press-fitting jig dimension table Removal .................................................. 30-213
for link press .......................................... 30-163 Installation .............................................. 30-217
ONE LINK AIR CONDITIONER COMPRESSOR
Field disassembly .................................. 30-164 Removal .................................................. 30-218
Field assembly ....................................... 30-166 Installation .............................................. 30-219
HYDRAULIC PUMP AIR CONDITIONER CONDENSER
Removal .................................................. 30-172 Removal .................................................. 30-220
30-2
(8)
DISASSEMBLY AND ASSEMBLY RADIATEUR
MONITOR
Removal .................................................. 30-222
Installation .............................................. 30-222
Removal, installation of
DT connector pins ............................... 30-223
Removal, installation of
HD connector pins ............................... 30-225
Repair procedure for wiring harness ....... 30-226
012406
30-2-1
(8)
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) or units, be sure to follow the
general precautions 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 blind 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 neces-
sary 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
disconnecting 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 entering after removal.
fl Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Hoses and tubes using sleeve nuts
Nominal number Plug Sleeve nut (elbow end) Use the two items below as a set
012406
02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
03 07376-50315 07221-20315 (Nut), 07222-00312 (Plug)
04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)
10 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)
2) Split flange type hoses and tubes
Nominal number Flange (hose end) Sleeve head (tube end) Split flange
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.
Dimensions (mm)
Nominal number Part 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 Taper 1/8
øD
ød
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
L
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
DED01250
27 07049-02734 27 22.5 34
30-4
(9)
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
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.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pin or lock plate 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 not 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.
fl When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and
other hydraulic equipment removed for repair, always bleed the air as follows:
1. Start the engine and run at low idling.
2. Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times,
012406
stopping 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.
fl When using the machine for the first time after repair or long storage, follow the same
procedure.
3. Precautions when completing the operation

• If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run
the engine to circulate the water through the system. Then check the water level again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified
level. Run the engine to circulate the oil through the system. Then check the oil level again.
• If the hydraulic equipment has been removed for repair, 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.
30-5
(9)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

fl Tools with part number 79fiT-fififi-fifififi cannot be supplied (they are items to be locally
manufactured).
fl 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 other models
Blank .. Tools already available for other models, used without any modification
fl Tools marked fi in the Sketch column are tools introduced in special sketches (See SKETCHES OF
SPECIAL TOOLS).
remodel
Sketch
Qty
New/
Component Symbol Part No. Part Name Nature of work, remarks
1 795-799-1130 Barring tool 1 Adjusting valve clearance
Engine A 2 795-799-1210 Puller 1 Removal of fuel injection pump
Removal, installation
3 790-331-1110 Wrench 1 Tightening of cylinder head
Removal, installation of round
Transmission 1 09003-06270 Wrench 1 nut
D
assemby Checking operation of clutch
2 799-301-1600 Oil leak tester 1 piston
1 790-337-1032 Lifting tool 1 Removal, installation of
final drive assembly
2 791T-427-1150 Bracket 1 N fi
1
Commercialy
3 available Shackle 1 SD type nominal diameter 14
4 01010-51640 Bolt 1
2 792-520-2121 Installer 1 N Installation of floating seal
012406
790-101-2310 Block 1
790-101-2800 Puller 1
790-101-2390 Leg 2
790-101-2360 Plate 4 Removal of taper roller

3 (large) bearing
791-112-1180 Nut 2
790-434-1050 Screw 1
790-101-2102 Puller (294kN {30ton}) 1

Disassembly, assembly
Final drive 790-101-1102 Pump 1

assembly Press fitting of taper roller
J 4 791T-427-1160 Push tool 1 N fi (large) bearing
790-434-1050 Screw 1
01643-32460 Washer 1
5 01580-12419 Nut 1 Press fitting of shaft
790-101-2102 Puller (294kN {30ton}) 1
790-101-1102 Pump 1
790-101-2310 Block 1
790-101-2350 Leg 2
790-101-2360 Washer 4
6 Removal of shaft
02215-11622 Nut 2
790-101-2420 Adapter 2
790-201-2650 Plate 1
790-201-2750 Spacer 1
30-6
(9)
remodel
Sketch
Qty
New/
790-101-2102 Puller 1
6 Removal of shaft
Final drive 790-101-1102 Pump 1
J
assembly 796-730-2140 Wrench 1
7 Measuring No. 1 pinion torque
01300-20616 Screw 2
1 791T-430-3210 Push tool 1 N fi Press fitting of idler bushing

1
2 791-675-1510 Installer 1 Installation of idler floating seal
Press fitting of track roller
Roller 1 791T-430-3220 Push tool 1 N fi bushing
L 2
assembly, Installation of track roller
2 791-651-1510 Installer 1 floating seal
idler assembly
Installation of carrier roller
3 791-430-3230 Installer 1 floating seal
4 790-601-3000 Oil pump 1 Charging oil, checking air leakage
791-685-8005 Compressor(B) 1
790-201-2870 Spacer 1
Recoil spring Removal, installation of
M 791-635-3160 Extension 1
assembly recoil spring assembly
790-101-1600 Cylinder (686kN {70ton}) 1
790-101-1102 Pump 1 Disassembly, assembly

012406
791-635-3110 Frame 1 Remover & installer assembly

791-630-3200
791-635-3160 Extension 1
791-635-3170 Nut 4
Disassembly, assembly of
791-635-3180 Screw 1
track (removal of link pin)
791-635-3190 Screw 1
791-630-3310 Adapter 1
791-630-3260 Pusher 1 Parts marked ª are used with
the track shoe assembly still
1 791-630-3530 Pusher 1
installed to the chassis when
791-635-3120 Support ª 1 removing or press fitting the
Track shoe
R link pin
assembly 791-635-3130 Nut ª 1
791-635-3140 Screw ª 1
791-635-3150 Hook ª 1
790-101-1102 Pump 1
790-101-1300 Cylinder (980kN {100ton}) 1
790-105-2300 Jack (196kN {20ton}) 1

Removal of pin plug of oil
2 791-646-7531 Remover 1 sealed track link
3 791-660-7460 Brush 1 Cleaning of oil sealed track link
790-646-7550 Bar 1 Push tool kit: 791-432-1110

4
791-646-7560 Guide 1 For large plug
30-7
7
remodel
Sketch
Qty
New/
791-646-7523 Bar 1
5 For small plug
791-646-7590 Guide 1
Checking air tightness of oil
6 790-701-3000 Checker 1 sealed track link
7 791-646-8002 Lubricator Filling oil sealed track link
1 with oil
790-105-2300 Jack (196kN {20ton}) 1
8 Disconnection of link
790-101-1102 Pump 1
791-635-3160 Extension 1 791-630-3200
791-635-3170 Nut 4
791-635-3180 Screw 2
791-635-3190 Screw 1 Removal of bushing

791-635-3250 Adapter 1
791-635-3230 Adapter 4
9
791-630-3230 Extension 2
791-630-3280 Spacer 1
012406
Disassembly, assembly
04530-11018 Eyebolt 1
01580-01210 Nut 1
Track shoe
R
assembly 790-101-1102 Pump 1
790-101-1300 Cylinder (980kN {100ton}) 1
790-105-2300 Jack (196kN {20ton}) 1
10 791-630-3310 Adapter 1 Press fitting of bushing
791-630-3220 Adapter 1
11
791-630-3250 Adapter 1
12 791-630-3290 Guide 1 Guide when press fitting link

791-635-3160 Extension 1 791-630-3200
791-635-3170 Nut 4
Press fitting of link pin
791-635-3180 Screw 2
791-635-3190 Screw 1
13 791-630-3310 Adapter 1
791-630-3210 Pin guide 1
791-630-3270 Guide 1
791-630-3280 Spacer 1
04530-11018 Eyebolt 1
01580-01210 Nut 1
30-8
3
remodel
Sketch
Qty
New/
790-101-1102 Pump 1 Remover & installer assembly

13
790-101-1300 Cylinder (980kN {100ton}) 1
791-630-3200
790-635-3110 Frame 1
Press fitting of link pin
791-635-3160 Extension 1
790-635-3170 Nut 1
791-635-3180 Screw 1
Track shoe 791-635-3190 Screw
R 1
assembly
14 791-630-3310 Adapter 1
791-630-3270 Guide 1
791-630-3210 Pin guide 1
791-630-3250 Adapter 1
790-101-1102 Pump 1
790-101-1300 Cylinder (980kN {100ton}) 1
15 791-630-3270 Guide 1 Installation of pin
790-502-1003 Repair stand 1 Disassembly, assembly

012406
Disassembly, assembly of
1
790-101-1102 Pump 1 hydraulic cylinder
2 790-102-3802 Wrench 1 Removal, installation of cylinder

head
790-302-1280 Socket 1 Lift, tilt cylinder Removal,
3 installation
790-302-1290 Socket 1 Angle cylinder of piston nut
1 790-720-1000 Expander 1
796-720-1660 Rubber band 1

Lift, tilt cylinder
4 07281-01159 Clamp 1 Installation of
2
Rubber band piston ring
796-720-1670 1
Angle cylinder
Hydraulic 07281-01279 Clamp 1
cylinder U
assembly 790-201-1761 Push tool 1 Lift cylinder
Press fitting
790-201-1771 Push tool 1 Tilt cylinder of coil
bushing
5 790-201-1791 Push tool 1 Angle cylinder
790-101-5021 Grip 1
Assembly Part No. 790-201-1702
01010-50816 Bolt 1
790-201-1570 Plate 1 Lift cylinder

Press fitting
790-201-1580 Plate 1 Tilt cylinder
of dust seal
6 790-201-1610 Plate 1 Angle cylinder
790-101-5021 Grip 1
Assembly Part No. 790-201-1500
01010-50816 Bolt 1
30-9
7
remodel
Sketch
Qty
New/
Contact size #20
799-601-7820 Remover 1
Removal, installation, repair

(Tool color: White)
Contact size #16 (Thin)
799-601-7830 Remover 1
Removal of pin
(Tool color: Light blue)
Contact size #16 (Normal)
DT connector pin 799-601-7840 Remover 1 (Tool color: Blue)
1 Connector
HD connector pin Contact size #12 tool kit
X 799-601-7850 Remover 1 (Tool color: Yellow)
799-601-7800
Contact size #8
Wiring harness 799-601-7860 Remover 1 (Tool color Green)
Contact size #4
799-601-7870 Remover 1 (Tool color: White)
2 799-601-7810 Hand clip 1 Crimping of wiring harness
Operator's cab Lifter

X1 793-498-1210 2 Installation of window glass
glass (Stuck glass) (Suction cup)
799-703-1200 Service tool kit 1
installation
799-703-1100 Vacuum pump (100V) 1
Removal,
Air conditioner Charging air conditioner
Y 799-703-1111 Vacuum pump (220V) 1
unit with gas
799-703-1121 Vacuum pump (240V) 1
799-703-1401 Gas leak detector 1
012406
30-10
(9)
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.
J1-2
012406
J4
5
C0.5
P
10
R1
30
R0
.8
ø134+0.5
ø152.4
ø150-0.5
0
P(1:1)
(ø132.4)
220 CDD00505
HEAT TRETMENT MATERIAL

1123001900 STKM13A
PART NAME QTY

PUSH TOOL 1
791T-427-1160
30-12
(9)
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
L1-1
012406
L2-1
30-13
(9)
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
REMOVAL OF FUEL INJECTION

PUMP ASSEMBLY
D41E-6 Serial No.: B20001 - B20980
D41P-6 Serial No.: B20001 - B20983
1
¤ Disconnect the cable from the negative (–) ter-
minal of the battery.
¤ Bleed refrigerant gas from air conditioner.
1. Open engine left side cover (top) and remove
cover (bottom).
CED00009
2. Close valve of fuel supply piping.
3. Remove air conditioner compressor assembly.

For details, see REMOVAL OF AIR CONDITIONER
7
COMPRESSOR ASSEMBLY.
5
4. Remove bracket (1) of air conditioner compres-
sor.
2
5. Remove engine stop solenoid (2).
4
6. Remove fuel control linkage (3). 3
012406
7. Disconnect lubrication hose (4). 6 CED00010
8. Disconnect fuel hoses (5) and (6).
9. Disconnect 6 delivery tubes (7).
10. Remove bracket (8).
8
CED00011
11. Using tool A1, rotate engine in normal direc-

tion, and push pin (9) (for positioning No. 1 9
cylinder compression top dead center) into gear.
fl Push the pin lightly into the gear and rotate
slowly.
A1
CED00012
30-17
(9)
12. Remove cover, then remove nut (10).
10
CED00013
13. Remove 4 mounting nuts (11) of injection pump

assembly (12).
12
11
012406
CED00014
14. Using tool A2, push out injection pump assem-

bly and remove. 5
A2
CED00015
30-18
REMOVAL OF FUEL INJECTION

PUMP ASSEMBLY
fl Although the engine stop solenoids on D41E-6
and D41P-6, Serial No. 50201 and up, are in-
1
stalled to positions different from this illustra-
tion, they can be removed and installed basi-
cally by the procedure explained here.
D41E-6 Serial No.: B20981 – B40000
D41P-6 Serial No.: B20984 – B40000

minal of the battery. CED00009

1. Open engine left side cover (top) and remove
cover (bottom).
2. Close valve of fuel supply piping.
3. Remove air conditioner compressor assembly.

For details, see REMOVAL OF AIR CONDITIONER
COMPRESSOR ASSEMBLY.
4. Remove bracket (1) of air conditioner compres-

012406
sor.
5. Remove engine stop solenoid control linkage

(2A).
6. Remove fuel control linkage (3).
7. Disconnect lubrication hose (4).
8. Disconnect fuel hoses (5) and (6).
9. Disconnect 6 delivery tubes (7).
10. Remove bracket (8).
11. Using tool A1, rotate engine in normal direc- 9

tion, and push pin (9) (for positioning No. 1
cylinder compression top dead center) into gear.
fl Push the pin lightly into the gear and rotate
slowly.
A1
CED00012
30-18-1
(9)
12. Remove cover, then remove nut (10).
10
CED00013
13. Remove 4 mounting nuts (11) of injection pump

assembly (12).
12
11
012406
CED00014
14. Using tool A2, push out injection pump assem-

bly and remove. 5
A2
CED00015
30-18-2
7
INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY
• Carry out installation in the reverse order to
removal.
fl Install the hoses without twisting or inter-

ference.
fl Be careful not to let any dirt, dust, or water
get inside the hose of the air conditioner
circuit when installing the hose.
fl Check that there is an O-ring at the piping
connection portion of the air conditioner
hose when installing.
Coat the O-ring thoroughly with compressor
oil (DENSO: ND-OIL8, ZEXEL: ZXL100PG).
The tightening torques for the air condi-
tioner gas piping are as follows.
Tightening torque
Thread size Nm (kgm)
11.8 – 14.7
16 x 1.5 (1.2 – 1.5)
19.6 – 24.5
22 x 1.5 (2.0 – 2.5)
29.4 – 34.3
24 x 1.5
012406
(3.0 – 3.5)
• Charging air conditioner with gas

Using tool Y, charge the air conditioner circuit
with air conditioner gas (R134a).
fl Adjust the linkage.

Adjusting of engine stop solenoid linkage.
fl Adjust the linkage.

Adjusting fuel control linkage.
Delivery tube sleeve nut:

29.4 Nm (3.0 kgm)
30-19
(9)
DISASSEMBLY AND ASSEMBLY ENGINE HOOD
REMOVAL OF ENGINE HOOD

ASSEMBLY
1
fl Although the hinges and gas springs of the en-
gine hoods on D41E-6 and D41P-6, Serial No.
50201 and up, are installed to positions differ-
ent from this illustration, they can be removed
and installed basically by the procedure ex-
plained here.
1. Open both sides of hood side cover (1).
2. Loosen clamp 1, and disconnect engine hood

assembly (2) and air duct (3). CED00501
3. Remove 4 hood mounting bolts, fit rope to han-

dle 2 of engine hood, then lift off engine hood
assembly (2). w
fl Be careful not to lose the spacer when re- 1
moving the mounting bolts.
fl When removing with the exhaust pipe still
installed, be careful to maintain the weight
balance when lifting. q
3
012406
CDD00502
INSTALLATION OF ENGINE
HOOD ASSEMBLY
2
removal.
CED00503
30-25
7
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
REMOVAL OF CYLINDER HEAD

ASSEMBLY
1. Drain coolant.
2. Close fuel supply valve.
3. Remove hood assembly.

For details, see REMOVAL OF HOOD ASSEM-
BLY.
4. Remove engine side covers (left and right).
5. Remove turbocharger adiabatic cover (1). 1

5
6. Remove heater hose clamp (2), then remove
cover (3).
7. Disconnect evaporator (4) from frame. 4

fl There is a clamp at the evaporator inlet hose.
8. Disconnect turbocharger intake connector (5).

1
012406
2 3 CED00024
9. Remove 2 clamps (6), then put down fuel filter

(7) and bracket as one unit.
fl Although the engine stop solenoids on D41E-
installed to positions different from this il-
lustration, they can be removed and installed
basically by the procedure explained here.
10. Remove 3 air conditioner hose clamps (8).

fl The clamps at the dashboard end are tight-
ened together with the wiring harness.
11. Disconnect sub-tank hose (9) at radiator end,

and pull out towards dashboard. 9
fl There are 2 clamps.
CED00026
30-26
7
DISASSEMBLY AND ASSEMBLY FUEL TANK
7. Disconnect backup buzzer wiring harness (7),

and remove from clamp.
fl Although the connectors on D41E-6 and
D41P-6, Serial No. 50201 and up, are in-
stalled to positions different from this illus-
tration, they can be removed and installed
CED00053
8. Remove 4 mounting bolts.
9. Lift off fuel tank assembly (8). 8
4 Fuel tank assembly: 110 kg (dry weight)

012406
CED00054
INSTALLATION OF FUEL TANK

ASSEMBLY
removal.
30-33
7
DISASSEMBLY AND ASSEMBLY RADIATOR, OIL COOLER
REMOVAL OF RADIATOR, OIL

COOLER ASSEMBLY
minal of the battery. 1
1. Drain coolant.

BLY.
3. Remove engine left, right, and bottom side cov-

ers. CED00064
4. Remove radiator top cover (1).
5. Disconnect window washer tank assembly (2), 2

and move it towards engine.
fl Although the shapes of the covers on D41E-
removed and installed basically by the pro-
cedure explained here.
012406
CED00065
6. Remove fan guard (3). 5

6
7. Remove shroud (4). 4
8. Disconnect clamps (5), and remove grommet

(6). 7
9. Disconnect sub-tank hose (7). 8
10. Disconnect radiator inlet hose (8).

3
11. Remove grills (top, middle, bottom). CED00066
12. Disconnect 2 transmission oil cooler hoses (9).

9
13. Disconnect radiator outlet hose (10). 1
10
CED00067
30-34
7
DISASSEMBLY AND ASSEMBLY RADIATOR, OIL COOLER
14. Remove 4 bolts (11), and leave hydraulic cooler

on guard.
11
CED00068
15. Sling radiator and oil cooler assembly.

12
16. Remove 2 top mount bolts (12) and 2 bottom
mount bolts (13), then lift off radiator and oil
cooler assembly.
fl Be extremely careful not to damage the wir-
ing and hoses when removing.
4 Radiator, oil cooler assembly: 75 kg

012406
INSTALLATION OF RADIATOR,
OIL COOLER ASSEMBLY
removal.
1
3 Radiator outlet hose clamp:
5.9 ± 0.49 Nm (0.6 ± 0.05 kgm)
13
• Refilling with water
CDD00069
Add water through water filler to the specified
level.
fl Run the engine to circulate the water
through the system. Then check the water
level again.
• Refilling with oil (hydraulic tank, transmission

case)
Add oil through oil filler to the specified level.
fl Run the engine to circulate the oil through
the system. Then check the oil level again.
30-35
DISASSEMBLY AND ASSEMBLY HYDRAULIC COOLER
REMOVAL OF HYDRAULIC
COOLER
1. Remove grills (top, middle, bottom).
2. Disconnect 2 hoses (1).
3. Remove 4 bolts (2). 2
4. Remove hydraulic cooler (3).
1
CED00099
INSTALLATION OF HYDRAULIC
COOLER
removal.
012406
30-36
7
DISASSEMBLY AND ASSEMBLY ENGINE
REMOVAL OF ENGINE
ASSEMBLY
fl Although the engine stop solenoids on D41E-6
and D41P-6, Serial No. 50201 and up, are in- 1
stalled to positions different from this illustra-
2
tion, they can be removed and installed basi-
cally by the procedure explained here.
D41E-6 Serial No.: B20001 – B20980
D41P-6 Serial No.: B20001 – B20983

minal of the battery. CED00070
fl Close the fuel supply valve on the fuel tank.
3 4 5 6
1. Remove left and right side steps (1) and left
and right side covers (2).

BLY.
3. Remove radiator guard and radiator assembly.

7
For details, see REMOVAL OF RADIATOR,
012406
GUARD ASSEMBLY.
CED00071
4. Disconnect 2 air conditioner hoses (3).

fl Loosen the sleeve nuts slightly and release
the air conditioner gas (R134a) completely
before removing the hoses.
fl Fit blind plugs to prevent dirt or water from
getting inside the hoses.
5. Remove 3 air conditioner hose clamps (4), then 11

move towards dashboard or evaporator.
6. Disconnect sub-tank hose (5) and remove sub-

8 9
tank (6).
10
7. Disconnect 2 heater hoses (7). CED00072
8. Disconnect fuel control rod (8).
9. Remove bracket (9) and move it towards left

side of chassis.
10. Disconnect spill hose (10). 12

11. Disconnect fuel supply hose (11).
12. Disconnect fuel return hose (12).
13. Remove 2 fuel return hose clamps (13). 13

CED00073
30-37
(9)
14. Remove 2 mounting bolts (14) of evaporator,

and move towards rear.
14
CED00074
15. Disconnect connectors (15) (CN-17), (16) (CN-

18), and (17) (CN-20). 20
16
18
16. Disconnect connector (18) (CN-99) from holder. 15 17
17. Remove 3 hose clamps (19).
18. Disconnect 3 starting motor wires (20).
19
012406
CED00075
19. Remove valve (21) of heater hose.

fl This will contact the lifting hook, so remove
it.
20. Disconnect drive shaft (22) at damper end.2
21. Remove rear mount bolt (23).
22. Remove front mount bolt (24).

fl Although the front mount bolts on D41E-6
and D41P-6, Serial No. 50201 and up, are
removed and installed basically by the pro-
cedure explained here.
23. Move engine assembly (25) towards front and

gradually lift off.
fl When removing the engine assembly, be
carefull not to damage the wiring and hoses.
4 Engine assembly: 550 kg
30-38
7
No.: B20981 – B40000
No.: B20984 – B40000
INSTALLATION OF ENGINE
ASSEMBLY
removal.

ference.
circuit when installing the hose. O-ring
CED00016
Tightening torque
11.8 – 14.7
16 x 1.5 (1.2 – 1.5)
19.6 – 24.5
22 x 1.5 (2.0 – 2.5)
29.4 – 34.3
24 x 1.5
012406
(3.0 – 3.5)

Drive shaft mounting bolt:

66.2 ± 7.4 Nm (6.75 ± 0.75 kgm)
30-39
(9)
DISASSEMBLY AND ASSEMBLY RADIATOR, GUARD
REMOVAL OF RADIATOR,
GUARD ASSEMBLY
¤ Disconnect the cable from the negative (–) ter- 1
1. Drain coolant.

For details, see REMOVAL OF HOOD ASSEM- 2
BLY.
3. Remove engine side covers (left, right, bottom).

CED00055
4. Remove fan guard.
5. Open radiator top cover.
6. Disconnect sub-tank hose (1).
7. Disconnect radiator inlet hose (2) at engine end.
8. Remove grills (top, middle, bottom).
9. Disconnect 2 hydraulic cooler hoses (3).
012406
CED00056
10. Disconnect 2 transmission oil cooler hoses (4).
11. Disconnect radiator outlet hose (5). 1
5 4
CED00057
12. Disconnect 2 window washer hoses (6) from
right side of radiator guard.
13. Disconnect connectors (7) and (8)(CN-8), (CN-

21).
14. Sling radiator guard assembly temporarily, and 7

8
remove 4 mounting bolts (9) and 4 front mount-
ing bolts of radiator.
15. Pull out hydraulic cooler hose from hole in ra-

diator guard, and lift off radiator guard and ra-
diator assembly (10). 6
9
CED00058
4 Radiator guard, guard assembly: 210 kg
30-40
7
DISASSEMBLY AND ASSEMBLY TRANSMISSION
6) Remove snap ring (43), then remove bear-

ing (44).
Press
44 43
CDD00282
13. No. 1 (R) clutch springs, disc, plates

1) Remove plate (45).
2) Remove springs (46) and (47), and guide 45
(48).
3) Remove disc (49) and plate (50).
50 47
48
49 46
012406
CED00283
14. No. 1 ring gear

Remove ring gear (51) of No. 1 clutch. 51 52
15. No. 2 housing

Remove No. 2 housing (52).
CED00284
16. No. 2 (F) clutch springs, disc, plates

D41E-6 Serial No.: B20001 – B35176 49
D41E-6 Serial No.: B35178 – B35179 53
D41E-6 Serial No.: B35185 – B35186
D41E-6 Serial No.: B35189
D41E-6 Serial No.: B35213 – B35215 50
D41E-6 Serial No.: B35224 – B35225 54
D41E-6 Serial No.: 50001 – 50312
D41P-6 Serial No.: B20001 – B35176 48
D41P-6 Serial No.: 50001 – 50305 55
1) Remove washer (53), springs (54) and (55), 45
and guide (48).
CED00285
2) Remove disc (49) and plates (45) and (50).
30-56
(9)

D41E-6 Serial No.: B35180 – B35184
D41E-6 Serial No.: B35187 – B35188
D41E-6 Serial No.: B35190 – B35191
D41E-6 Serial No.: B35193 – B35212
D41E-6 Serial No.: B35216 – B35221
D41E-6 Serial No.: B35226 – B35231
D41E-6 Serial No.: 50313 and up
D41P-6 Serial No.: 50306 and up
1) Remove springs (54) and guide (48) and
springs (55).
2) Remove disc (49) and plates (45) and (50).
17. No. 1 carrier ring gear

1) Remove snap ring (56). 56
2) Remove No. 1 carrier ring gear (57). 57
18. No. 2 clutch ring gear

Remove No. 2 clutch ring gear (58).
58
012406
CED00286
19. Relief valve

Remove valve (59) and spring (60). 61
59 60
20. Torque pin
Remove torque pin (61).
CED00287 CED00288
21. No. 3 housing assembly

Remove No. 3 housing assembly (62) together 62
with piston.
CED00289
30-57
(9)
22. No. 3 (3rd) clutch spring, disc, plates

2) Remove spring (64), disc (49), and plate (50). 45
49
64 50 CED00290
23. No. 2, 3 carrier assembly

1) Remove snap ring (65). 65 r
2) Using puller [4], remove No. 2, 3 carrier as-
sembly (66).
fl The inner race of bearing (123) will come
out.
66
012406
123
CED00291 CED00292
3) Disassembly of No. 2, 3 carrier assembly

i) Remove seal ring (67). 69
ii) Knock pin (68) into shaft (69).
68
67
CED00293
iii) Pull out shaft (69), then remove thrust

70
washers (70), gears (71), and bearings
(72). 71
72
70 69
70
72 71
70
CDD00294
30-58
(9)
iv) Remove snap ring (73), then remove

bearing (123).
74 75
24. No. 3 clutch ring gear 123
1) Remove snap ring (74). 73
2) Remove No. 3 clutch ring gear (75).
CED00295 CED00296
25. No. 4 housing

Remove No. 4 housing (76). 76
012406
CED00297
26. No. 4 (2nd) clutch spring, disc, plates

2) Remove spring (77), disc (49), and plate (50). 45
77
49
50 CED00298

Remove No. 4 clutch ring gear (78).
117
28. Housing
Remove housing (117).
78
CED00299
30-59
(9)
29. No. 3 carrier sun gear

1) Remove snap ring (79).
2) Remove No. 3 carrier sun gear (80). 80
30. Collar
Remove collar (81).
31. No. 4 carrier sun gear 79

Remove No. 4 carrier sun gear (82).
82 81
CED00300 CED00301
32. Output shaft assembly

1) Turn over transmission. 88
92
2) Remove 4 bolts, then remove output shaft
assembly (83) from rear housing (96).
fl Check the number and thickness of
shims (118), and keep in a safe place.
fl When doing this, install bolt (121) (di- 118
ameter: 12 mm, length: 15 mm) in the 121
tap hole to prevent cover (92) and cage
(88) from separating.
96
012406
83
CED00302
3) Disassembly of output shaft assembly

i) Remove seal rings (84).
ii) Using tool D1, remove nut (85).
D1
fl Hold the output shaft with a press. 84
85
CED00303
iii) Measure and note dimensions [b] and

[c] in diagram accurately, and use meas-
urements when assembling to check that
taper roller bearing is press fitted to 124
specified dimension.
fl Dimension [b]:Distance from tip of c
shaft to tip of cover
fl Dimension [c]: Distance from tip of
Shim
inner race to stepped
portion of shaft
iv) Remove collar (124) and spacer (86). 86A b
CDD00495
30-60
(9)
v) Using press, remove output shaft (87) Press

from cage (88).
vi) Remove spacer (86A) and inner race (90) 87
from output shaft (87).
90
86 88
87
86A
CDD00304 CDD00305
vii) Remove bolt (121) (installed above), then

remove cover (92) and shim (91) from 88 92
cage (88).
fl Shim (118) and shim (91) are the
same shape, so check the number 92
and thickness of the shims, mark
121
with tags, and keep in a safe place.
viii)Remove oil seal (93) from cover (92). 93
91
012406
CED00306 CDD00307
ix) Using push tool, push out outer race Press

(63), and remove bearing (94) and spacer
(120) from cage (88). 88
63 120
94
CDD00308
33. No. 5 (1st) clutch assembly 122 96

Remove 5 bolts (122), then remove No. 5 clutch
assembly (95) from rear housing (96).
95
CDD00309
30-61
(9)
• Disassembly of No. 5 clutch assembly

1) Remove No. 5 clutch housing (97). 97
CED00310
2) Remove plate (98), disc (49), spring (64), and

pins (99). 49
98
3) Remove hub (100).
100
99
012406
64 CED00311
4) Remove piston (105). Press

5) Remove snap ring (102), then remove collar 105 97 103
(101), bearing (103), and cage (104) from
housing (97).
fl Be careful not to lose ball (115).
115 101 104 102
CDD00312
6) Remove snap rings (106) and (107), then

remove bearings (103) and (108) from cage 103 104 108 107 106
(104).
7) Remove seal rings (109).
109
CDD00313
30-62
(9)
8) No. 4 clutch carrier assembly 111

i) Knock pin (110) into shaft (111).
ii) Pull out shaft (111), and remove thrust 112
washers (112), gear (113), and bearing 114
(114).
113
112
110
CDD00314
012406
30-62-1
(9)
ASSEMBLY OF
TRANSMISSION ASSEMBLY
fl Clean all parts, and check for dirt or damage.
Coat the sliding surfaces of all parts with en-
gine oil before installing.
fl Clean all the oil holes in the housing before
assembling.
fl The seal ring must be installed facing in the
correct direction, so install with the side receiv-
ing the pressure facing the housing as shown
in the diagram.
1. No. 5 (1st) clutch assembly 111

• Assembly of No. 5 clutch assembly
1) No. 4 clutch carrier assembly 112
i) Assemble bearing (114) to gear (113), 114
put thrust washers (112) in contact on
both sides, and assemble to carrier. 113
fl One side of the thrust washer has 112
an R. Install with that side facing the
110
carrier.
ii) Align pin holes and install shaft (111),

012406
then knock in pin (110). CDD00314

fl If there are burrs in the pin holes,
remove them with sandpaper.
fl Check that the planetary gear rotates
smoothly.
fl After inserting pin (110), caulk 2
points on the periphery to prevent
the pin from coming out. Caulk
points "a" in the figure to prevent
deformation of the thrust washer
sliding surface.
2) Using push tool, press fit bearings (108) and

(103) to cage (104), then install snap rings 103 104 108 107 106
(107) and (106).
3) Install seal rings (109).
109
CDD00313
30-63
(8)
4) Set collar (101) to cage (104), and assemble

104
ball (115) to collar (101).
5) Using push tool, align groove of ball (115), 97 115
then install bearing (103) and collar (101) to
rear housing (97).
101
103
CDD00316
6) Install snap ring (102).

7) Set hub (100) to No. 4 clutch carrier assem-
bly (116). 100 116
012406
102
CED00317 CED00318
8) Assemble discs (49), plates (98), pins (99),

and spring (64).
98
fl Discs: 3, plates: 4 49
fl Free length of spring: 29 mm
99
64
CED00319
9) Assemble No. 5 clutch piston to No. 5 hous-

ing. 97
10) Install No. 5 clutch housing (97).
2 Mounting bolt:
Mounting bolt:
31.9 ± 2.5 Nm {3.25 ± 0.25 kgm}
CED00310
30-64
(8)
11) Install No. 5 clutch assembly (95) to rear 122 96

housing (96) with bolt (122).
2 Mounting bolt:
Mounting bolt:
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
95
CDD00309
2. Output shaft assembly

1) Assembly of output shaft assembly
i) Using push tool, press fit outer race (63)
to cage (88).
ii) Set spacer (120) and bearing (94) in po-
sition, and press fit outer race (63).
012406
iii) Using push tool, press fit oil seal (93) to

cover (92).
2 Oil seal mounting surface:
Gasket sealant (LG-5)
fl Coat the mounting surface thinly,
and wipe off any gasket sealant that
is pushed out.
2 Lip of oil seal: Grease (G2-LI)
92 93
CDD00322
iv) Assemble shim (91), spacer (86) and

tighten cover (92) temporarily to cage
(88) with mounting bolts (121).
v) Adjust shim thickness as follows.
Set cover to cage without installing any
shim, measure clearance at portion a,
then adjust shim thickness so that clear-
ance is 0.05 – 0.15 mm.
fl There are two types of shim thick-
ness: 0.2, 0.3 mm
30-65
(8)
vi) Using push tool, press fit inner race (90)

to output shaft (87), then assemble
spacer (86A).
vii) Push spacer (86) with press, and install
cage (88) to output shaft (87).
fl Check that dimensions b and c in

the diagram are press fitted to the
same dimensions as those measured
during disassembly.
012406
viii) Hold output shaft with press, then using
tool D1, tighten nut (85) and install col-
lar (124).
D1
2 Nut: Thread tightener (LT-2) 84
Nut: 269.7 ± 24.5 Nm
{27.5 ± 2.5 kgm}
ix) Install seal rings (84).
85
CED00325
x) Assemble removed shim (118), then in-

stall output shaft assembly (83) to rear 88
92
housing (96).
fl After installing, remove bolt (121)
used for temporarily holding cage
(88) and cover (92).
fl Always assemble the original thick- 118
ness of shim. 121
fl Measure the dimension between the end
face of the rear housing and the end
face of the bevel gear. 96
For details, see the notes marked fl for 83
CED00302
Steps in DISASSEMBLY.
30-66
(8)
3. No. 4 carrier sun gear

1) Turn over rear housing assembly.
2) Install No. 4 carrier sun gear (82). 80
4. Collar
Install collar (81).
5. No. 3 carrier sun gear 79

1) Install No. 3 carrier sun gear (80).
2) Install snap ring (79). 82 81
CED00301 CED00300
6. Housing
Install housing (117).
117
7. Install No. 4 clutch ring gear (78).
fl Set with the face with the large cut on the
outside circumference facing up.
78
012406
CED00299
8. Torque pin, guide pin

61 119
Install torque pin (61) and guide pin (119).
fl Use the guide pin as a guide for the spring,
and remove when installing the tie bolt.
9. No. 4 (2nd) clutch, plates, discs, springs 45

1) Assemble plates (50), discs (49), and springs 50
(77).
2) Assemble plate (45).
fl Disc (49): 2, plates (50): 2, plate (45): 1
fl Free length of spring: 23.7 mm 77 49
CED00326
10. No. 4 housing

Install No. 4 housing (76) together with No. 4
clutch piston.
76
CED00327
30-67
(8)

Set No. 3 clutch ring gear (75) in position, and 74
75
install snap ring (74).
123 73
12. No. 2, 3 carrier assembly
1) Assembly of No. 2, 3 ring gear assembly
i) Using push tool, press fit bearing (123)
to carrier, then install snap ring (73).
CED00328 CED00295
ii) Assemble bearings (72) to gears (71),

70
put thrust washers (70) in contact on
71
both sides, and assemble to carrier. 72
iii) Align pin holes, and install shaft (69).
fl One side of the thrust washer has 70 69
an R. Install with that side facing the
carrier.
fl Check that the gear rotates smoothly. 70
72 71
012406
70
CDD00294
iv) Install pin (68) to shaft (69).

fl If there are burrs in the pin holes, 69
fl After inserting pin (68), caulk 2 points 68
on the periphery to prevent the pin
from coming out. Caulk points "a" 67
in the figure to prevent deformation
of the thrust washer sliding surface.
v) Install seal ring (67).
CED00293
30-68
(8)
2) Using push tool, install No. 2, 3 carrier as-

sembly (66) to output shaft. 65
fl Press fit the inner race of bearing (123)
(installed in Step 12-1)-i)) to the output 66
shaft.
3) Install snap ring (65).
CED00329
123 CED00330
13. No. 3 (3rd) clutch plates, discs, springs

1) Install plates (50), discs (49), and springs
(64). 45
fl Free length of spring: 29 mm
2) Install plate (45).
fl Discs (49): 3, plates (50): 3, plate (45): 1
64
49
012406
50
CED00331
14. No. 3 housing assembly

1) Assemble No. 3 clutch and No. 4 clutch pis-
ton to No. 3 housing.
2) Install No. 3 housing assembly (62).
62
CED00332
15. Relief valve

Assemble spring (60) and install valve (59).
58
59
16. No. 2 clutch ring gear 60
Install No. 2 clutch ring gear (58).
outside circumference facing down.
CED00333 CED00334
30-69
(8)
17. No. 1 carrier ring gear

1) Install No. 1 carrier ring gear (57) to No. 3 56
carrier.
2) Install snap ring (56). 57
CED00335
18. No. 2 (F) clutch plates, discs, springs
D41E-6 Serial No.: B20001 – B35176
D41E-6 Serial No.: B35178 – B35179
D41E-6 Serial No.: B35185 – B35186
D41E-6 Serial No.: B35213 – B35215 49
D41E-6 Serial No.: B35224 – B35225
D41E-6 Serial No.: 50001 – 50312 54
D41P-6 Serial No.: B20001 – B35176 53
D41P-6 Serial No.: 50001 – 50305
1) Install plate (45), discs (49), and plates (50). 48
fl Discs: 5, plates (50): 5, plate (45): 1 50
2) Install springs (55) and (54), guide (48), and 55 45
washer (53).
012406
fl Free length of spring (large): 22.93 mm CED00336
(small): 18.65 mm

D41E-6 Serial No.: B35180 – B35184
D41E-6 Serial No.: B35187 – B35188
D41E-6 Serial No.: B35190 – B35191
D41E-6 Serial No.: B35193 – B35212
D41E-6 Serial No.: B35216 – B35221
D41E-6 Serial No.: B35226 – B35231
D41E-6 Serial No.: 50313 and up
D41P-6 Serial No.: 50306 and up
1) Install plate (45), discs (49), and plates (50).
fl Discs: 5, plates (50): 5, plate (45): 1
2) Install springs (55), guide (48), and springs
(54).
fl Free length of spring (55): 22.93 mm
(White mark is made on periphery for distinction.)
19. No. 2 housing 52 51

Install No. 2 housing (52).

Install No. 1 clutch ring gear (51).
outside circumference facing up.
CED00337
30-70
(8)
(9)
21. No. 1 (R) clutch plates, discs, springs

1) Install plates (50), discs (49), springs (47) 45
and (46), and guide (48).
fl Free length of spring (large): 25 mm
fl Free length of spring (small): 17.55 mm
2) Install plate (45). 50 47
fl Discs: 5, plates (50): 5, plate (45): 1
49
48 46
CED00338
22. No. 1 housing, No. 1 carrier assembly

• Assembly of No. 1 housing, No. 1 carrier as-
sembly
1) Using push tool, press fit bearing (44) to 43 44
housing, then install snap ring (43).
012406
CDD00339
2) Assembly of No. 1 carrier assembly

i) Assemble bearing (41) to gear (40), put 42
thrust washers (39) in contact on both
38
sides, and assemble to carrier (42).
fl One side of the thrust washer has 39
an R. Install with that side facing
the carrier.
40
ii) Align pin holes, and assemble shaft (38), 41
then install pin (37).
fl If there are burrs in the pin holes, 39
remove them with sandpaper. 37
fl Check that the gear rotates smoothly. CDD00281
fl After inserting pin (37), caulk 2 points
on the periphery to prevent the pin
from coming out. Caulk points "a"
30-71
(8)
(9)
3) No. 1 carrier assembly

i) Assemble collar (36) to carrier assembly 33 35
(34) end.
ii) Install No. 1 carrier assembly (34) to
housing (35).
iii) Install snap ring (33).
36 34
CDD00340
4) Input shaft
i) Using push tool, press fit bearing (32) to 32
input shaft (29), then install snap ring
(31). 30
ii) Install snap ring (30).
29
012406
31
CED00279
iii) Install input shaft (29) to No. 1 carrier

assembly (34). 29
iv) Install snap ring (28).
34 28
CDD00341
5) No. 1 carrier sun gear

i) Install No. 1 carrier sun gear (27).
ii) Install snap ring (26). 24
23
6) No. 2 carrier sun gear
i) Install snap ring (25). 27
ii) Install No. 2 carrier sun gear (24). 25
26
CED00277 CED00276
30-72
(8)
(9)
7) Installation of No. 1 housing, No. 1 carrier

i) Install No. 1 housing and No. 1 carrier
22
assembly (22).
fl When the meshing of the gear
matches, it will fall, so be careful
not to get your fingers caught. 119
ii) Remove guide pin (119).
CED00342
23. Tie bolt

Tighten tie bolt (21).
Tie bolt: 63.7 ± 4.9 Nm {6.5 ± 0.5 kgm} 21
012406
CED00343
24. Checking actuation of piston

Using tool D2, check stroke of each piston.
D2
fl Air pressure: 0.49 – 0.59 MPa {5 – 6 kg/cm2}
Piston Standard stroke (mm)

R 5
F 6
1st 3
2nd 2.7
3rd 3.6
CED00344
25. PTO, transmission case assembly

1) Using eyebolts [2] and shackle [3], raise PTO
and transmission case assembly horizon-
w e
tally.
2) Align sleeve hole and housing lock bolt hole
of transmission case assembly (20) and
lower slowly into position.
20
CED00274
30-73
(8)
(9)
3) Using eyebolts [1], install 5 sleeves (10).
10
CED00269
4) Tighten housing lock bolts (18) (left and

right: 2 each).
Housing lock bolt:
277 ± 32 Nm {28.25 ± 3.25 kgm}
5) Tighten transmission case mounting bolts
(19).
18
19
012406
CED00273
26. Coupling
1) Assemble spacer (17). 14 16
2) Install coupling (16).
17
2 Coupling bolt: Adhesive (LT-2)
Coupling bolt:
176.5 ± 19.6 Nm {18 ± 2 kgm}
3) Fit holder (15) and tighten bolt (14).
15
CED00272 CED00271
27. Strainer
1) Install strainer case (12). 11 12
2) Assemble strainer assembly (13) and spring
to strainer case (12), then install cover (11). 13
fl Clean the strainer assembly before as-
sembling it again.
CED00270
30-74
(8)
(9)
28. Shift valve assembly

Install shift valve assembly (9).
Mounting bolt:
30.9±3.4Nm {3.15±0.35kgm}
9
CED00268
29. Pressure control valve

Install pressure control valve assembly (8). 5
Mounting bolt:
30.9±3.4Nm {3.15±0.35kgm}
6
30. Oil temperature sensor
Install oil temperature sensor (6).
31. Transmission inlet hose 7

Install hose (5).
012406
8 CED00267
32. Inching valve bracket assembly

Install bracket assembly (4).
fl Install the bracket assembly horizontally,
mesh the pin and yoke securely, and check
that the pin does not come out even when
the yoke is rotated.
fl Check that the clearance between the yoke
and lever is approx. 1 mm.
4
CED00266
33. Tandem pump assembly

2
1) Install tubes (2) and (1).
2) Install tandem pump assembly (3).
3
1
CED00265
30-74-1
(9)
DISASSEMBLY AND ASSEMBLY STEERING CASE
3) Remove clutch disc (20) and brake disc (21).

fl Remove on the opposite side in the same 21
way.
20 CED00393
4) Disassembly of shaft assembly

i) Remove snap ring (23), then remove 27
shaft (24) from cover (27). Press
24
fl The shape of the cover is different
depending on Serial Numbers.
23
012406
CED00394
ii) Remove snap ring (25), then remove Press

bearing (26) from shaft (24).
25 26
24
CED00395
12. Clutch, brake lining

28
Remove clutch lining (28) and brake lining (29).
fl Remove on the opposite side in the same
way.
29
CED00396
30-78
(9)
ASSEMBLY OF STEERING
CASE ASSEMBLY
1. Using push tool, press fit bearing (56) to steer-

ing case (55).
2. Carrier, bevel gear assembly

1) Assembly of carrier assembly
i) Assemble bearing (50) to gear (49), put 47
46 48
thrust washers (48) in contact on both
sides, and assemble to carrier.
ii) Install shaft (47) and knock in pin (46).
fl If there are burrs in the pin holes,
fl Check that the planetary gear rotates 50
smoothly. 49
48
012406
fl After inserting pin (46), caulk 2 points

on the periphery to prevent the pin CED00407
from coming out. Caulk points "a"

2) Assembly of carrier, bevel gear assembly

i) Install outer race (53) to plate (43). 43
43 45
ii) Install bevel gear (45) and plate (43) to
ring gear (54).
Mounting bolt:
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
53
54
CED00409 CED00406
30-81
(8)
iii) Set with bevel gear end at bottom and

assemble carrier assembly (44). 44
44
fl Be careful not to get your fingers
caught.
fl Be careful to install facing in the cor-
rect direction.
iv) Install carrier assembly (44) on opposite
side.
v) Install plate (43).
Mounting bolt:
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm} 43
CED00405 CED00410
3) Assembly of cage, sun gear assembly

i) Using push tool, press fit bearing (41),
37 38
and install snap ring (40).
ii) Using push tool, press fit bearing (37),
40
41
012406
CED00411
iii) Using push tool, install bearing (42) to

cage (35).
35 42
CED00412
iv) Using push tool, press fit bearing (37) to

sun gear (34), and install snap ring (36).
v) Press fit bearing (39) of cage (35) to sun
34
gear (34), and install snap ring (33). 39 35
36 33
37
34
CED00413 CED00414
30-82
(8)
4) Installation of carrier, bevel gear assembly 30

i) Raise carrier and bevel gear assembly
(30), and assemble to steering case. 31
ii) Assemble cage and sun gear assembly
(31) to both sides.
CED00415
iii) Pass pipe through center, sling again,

then assemble removed shim (32), and
install cage and sun gear assembly (31).
Mounting bolt:
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
32
31
31
012406
CED00416
3. Adjusting preload
1) Adjust shim (32) so that starting torque at
32
tip of bevel gear is 13.7 – 22.6 N {1.4 – 2.3
kg}.
fl Do not mesh the bevel pinion when ad-
justing.
2) Adjust so that thickness of shim is more or 32
less equal on left and right.
fl There are three types of shim thickness:
0.2, 0.3. 1.0 mm
CED00417 CED00418
4. Adjusting tooth contact, backlash

1) Adjusting backlash
Put the probe of dial gauge 2 at right an- w
gles in contact with the tip of the bevel gear
teeth. Hold the bevel pinion in position,
and read the measurement when the bevel
gear is moved forward and backward.
fl Standard value for backlash: 0.18 – 0.25
mm
fl Measure at a minimum of three points
on opposite sides.
• If the result of the inspection shows that CED00419
the correct backlash is not being ob-
tained, adjust as follows.
30-83
(8)
• Adjust by changing the shim thickness

at the cage. However, do not change
the preload of the bearing. Adjust by
moving shims between one side and the
other. Always keep the same total thick-
ness of shims.
2) Adjusting tooth contact

Testing
i) Coat the tooth face of the bevel pinion
lightly with red lead (minium). Rotate
the bevel gear forward and backward
and inspect the pattern left on the teeth.
ii) The center of the tooth contact "b"
should be in the center of the tooth
height and at a position 20 – 40% of the
tooth length with "a" width of contact 30
– 50% of the tooth length.
012406
In addition, there should be no strong
contact at the addendum or dedendum
(tip or root of the gear teeth) or at the
big and small ends.
fl If the gears are adjusted to this pat-
tern, the tooth contact will be cor-
rect when load is applied.
Adjustment
If the result of the inspection shows that the
correct tooth contact is not being obtained,
adjust again as follows.
i) If bevel pinion is too far from center line
of bevel gear.
Contact is at the small end of the con-
vex tooth face of the bevel gear and at
the big end of the concave tooth face.
• Correct the tooth contact as follows.
Adjust the thickness of the shims at the
bevel pinion to move the bevel pinion
in direction A.
In addition, adjust the thickness of the
shims to move the bevel gear in direc- B
tion B, then check the tooth contact pat-
tern and backlash again.
ii) If bevel pinion is too close to center line A

of bevel gear.
Contact is at the big end of the convex CED00424
tooth face of the bevel gear and the

small end of the concave tooth face.
30-84
(8)
• Correct the tooth contact as follows.

Adjust the thickness of the shims at the
bevel pinion to move the bevel pinion
in direction A (the opposite direction
from B above).
fl When adjusting the movement in or out B
of the bevel gear, do not change the
preload of the bearing. Adjust by mov-
ing shims between one side and the
other. Always keep the same total thick- A
ness of shims.
CED00425
5. Clutch, brake lining assembly

1) Install lining (58) to housing.
2 Screw: Thread tightener (LT-2)
Screw: 25.4 ± 2.1 Nm {2.6 ± 0.21 kgm}
012406
58
CED00426
2) Install clutch lining (28) and brake lining (29). 28

fl Install on the opposite side in the same
way.
29
CED00396
6. Clutch, brake disc

1) Assembly of shaft 25
i) Using push tool, press fit bearing (26) to 26
shaft (24), and install snap ring (25).
24
CED00427
30-85
(8)
ii) Using push tool, install shaft (24) to

cover (27).
fl The shape of the cover is different
depending on Serial Numbers.
2) Assemble clutch disc (20) and brake disc

(21) to inside case.
21
fl Assemble the clutch disc to the spline
of the sun gear.
012406
20 CED00393
3) Support clutch disc (20) and brake disc (21),

then align spline and install shaft assembly
(19).
21
19
20 19
CED00392 CED00391
7. Shaft, cam case assembly

1) Using push tool, press fit bearings (22) to
cam case (17). 22 59 22
2) Install lining (59).
2 Screw: Thread tightener (LT-2)
Screw: 25.4 ± 2.1 Nm {2.6 ± 0.21 kgm}
17
CED00430
30-86
(8)
3) Install washers (14) to steering case end.
14 14
CED00389
4) Align with washer installed above, and set

clutch cam case assembly (17) and brake 15 15
cam case assembly (18) in position.
14 14
5) Align with bearing, and install shafts (16)
and (15). 17
fl If anything catches on the bearing, do 17
not push in by force. Lift up slightly
16 16
and rotate the shaft to the left and right
to install. 14 14
fl Set with the punch mark on the end face
of the shaft facing the front of the ma-
012406
18 18
chine. CED00388
6) Install washers (14).
8. Cover assembly
1) Using push tool, install bearings (13) to
cover.
2) Install steering piston assembly (11) to cover

assembly (10). 10
11 11
CED00386
30-87
(8)
3) Using eyebolts 1, raise cover assembly (10)

horizontally and install. 10
2 Both steering case end and cover
end: Gasket sealant (LG-4)
Mounting bolt:
274.6 ± 29.4 Nm {28 ± 3 kgm} q
fl Check that the shaft moves smoothly.
CED00385
4) Using push tool, install oil seal (12) to case.

2 Oil seal press-fitting surface (hous-
ing end): Gasket sealant (LG-5)
fl Wipe off the gasket sealant that is
pushed out.
012406
9. Brake, clutch lever
Align match mark of shaft and install brake le- 9 9
vers (8) and clutch levers (9).
fl For details of the method for adjusting the
clearance between the lever and piston, see
TESTING AND ADJUSTING.
8
8
CED00384
10. Breather hose, suction tube

1) Install hydraulic suction tube (7).
2) Install breather hose (6).
7 6
CED00383
30-88
(8)
11. Piping, spring

1) Install springs (5).
2) Install piping (4), (3), (2), and (1). 5
5 2 3
CED00382
12. Transmission assembly

Install transmission assembly.
For details, see INSTALLATION OF TRANSMIS-
SION ASSEMBLY.
13. Fuel tank assembly

Install fuel tank assembly.
For details, see INSTALLATION OF FUEL TANK
ASSEMBLY.
14. Floor frame assembly

012406
Install floor frame assembly.

For details, see INSTALLATION OF FLOOR
FRAME ASSEMBLY.
15. Final drive assembly (left, right)

Install final drive assembly.
For details, see INSTALLATION OF FINAL DRIVE
ASSEMBLY.
16. Refilling with oil

1) Add oil to the steering case to the specified
level.
Steering case: 80 ¬
2) Add oil to the hydraulic tank to the speci-

fied level.
Hydraulic tank: Approx. 37 ¬
fl Run the engine to circulate the oil

through the system. Then check the oil
level again.
30-89
(8)
DISASSEMBLY AND ASSEMBLY BRAKE CONTROL VALVE
DISASSEMBLY OF BRAKE CONTROL VALVE ASSEMBLY
1 2
4 3
012406
5 8
6
9
7
10
18
11
19 21 20 22 17 16 14 15
CDD00358
30-94
(9)
1. Disassembly of valve plate

Remove unions (1) and (2), then remove balls
(3) and (4). 1 2
4 3
CDD00359 CDD00360
2. Disassembly of parking brake control valve

spool
1) Remove oil seal cap (5), then remove oil 6 5 8 9
seal (6) from cap.
2) Pull out spool (7), and remove spring (8)
from spool.
fl Measure the free length of the spring.
3) Remove plug (9).
7
012406
CDD00361
3. Disassembly of brake control valve spool

1) Remove oil seal cap (10), then remove oil 10 17
seal (11) from cap.
2) Pull out guide assembly (12).
3) Remove plug (13), then remove spring (14)
and shim (15).
fl Check the number and thickness of the
shims, and keep in a safe place.
4) Pull out spool (16), and remove piston (17) 11 16 14 15 13
from spool.
5) Disassembly of guide assembly (12) CDD00362
• Pull out pin (19) from guide (18), and
remove shaft (20), spring (21), and guide
(22).
12
fl Check the number and thickness of the
shims, and keep in a safe place.
18 19 20 21 22
CDD00363
30-95
(9)
ASSEMBLY OF BRAKE CONTROL VALVE ASSEMBLY
1 2
4 3
012406
5 8
6
9
7
10
18
11
19 21 20 22 17 16 14 15
CDD00358
30-96
(9)

Coat the sliding surfaces of all parts with en- 12
1. Assembly of brake control valve spool 18 19 20 21 22

1) Assembly of guide assembly (12)
Assemble guide (22) and spring (21) to shaft
(20), then assemble to guide (18) and install
pin (19).
fl Assemble with cut direction of the cut a
in the pin (19) facing in direction [a].
fl Free length of spring (21): 39.55 mm CDD00363
2) Assemble piston (17) to spool (16), then as-
semble to valve body.
fl When assembling, leave part of spool
(16) extending outside the valve body,
10 17
and set so that spring (14) can be as-
sembled during the next step.
3) Fit plug (13) and O-ring, assemble shim (15)
and spring (14), then align protruding part
of spool (16) with tip of spring (14), and
assemble in valve body.
fl Standard thickness of shim (15): 1.5 mm
fl Free length of spring (14): 52 mm 11 16 14 15 13
4) Assemble guide assembly (12) to valve body.
012406
5) Fit oil seal (11) to oil seal cap (10) and in- CDD00362
stall to valve body.
6) Tighten plug (13) to specified torque.
Plug (13): 68.6 ± 9.8 Nm (7 ± 1 kgm)
2. Assembly of parking brake control valve spool

1) Fit O-ring to plug (9) and assemble to valve
body.
Plug (9): 68.6 ± 9.8 Nm (7 ± 1 kgm)
2) Assemble spring (8) to spool (7) and install
to valve body.
3) Assemble oil seal (6) to oil seal cap (5), and
install to valve body.
2 Lip of oil seal (6): Grease (G2-LI)
6 5 8 9
7
CDD00361
30-97
(9)
3. Assembly of valve plate

Assemble balls (4) and (3), then fit O-rings to
unions (2) and (1) and install to valve plate. 2 1
3 4
3 Union: 49.0 ± 4.9 Nm (5 ± 0.5 kgm)
CDD00360 CDD00359
012406
30-98
DISASSEMBLY AND ASSEMBLY TRANSMISSION SHIFT VALVE
REMOVAL OF TRANSMISSION
SHIFT VALVE ASSEMBLY
1. Remove parking brake cylinder assembly.
For details, see REMOVAL OF PARKING BRAKE
CYLINDER ASSEMBLY.
2. Disconnect 2 rods (1), and move bracket (2) to- 1

wards side. 2
CED00187
3. Pull out pin (3), and remove lever (speed, direc-

tional) (4).
fl Leave the cable installed.
3
4
012406
CED00188
4. Disconnect tube (5).
5. Disconnect pressure detection hose (6).

6
6. Remove transmission shift valve assembly (7).
5
CED00189
INSTALLATION OF TRANS-
MISSION SHIFT VALVE
ASSEMBLY
removal.
30-99
(9)
DISASSEMBLY OF TRANSMISSION SHIFT VALVE ASSEMBLY
012406
30-100
(9)
fl Remove the tubes before disassembling.

1. F-R spool assembly
1) Remove plug (1).
2) Loosen nut (2) and remove yoke (3).
3) Remove spool (4).
4) Remove oil seal (5) from body (6).
5) Remove detent assembly (7).
2. Speed spool assembly

1) Remove two detent assemblies (8).
2) Remove plug (9).
3) Loosen nut (10) and remove yoke (11).
5) Remove oil seal (13) from body (6).
3. Inching spool assembly

1) Remove nut (14), then remove yoke (15).
2) Remove cover (16) and shims (17) together
with the spool.
fl Check the thickness and number of
shims.
3) Remove spool (18) from cover (16).
4) Remove oil seal (19) from cover (16).
5) Remove plug (20).
6) Remove valve assembly (21).
012406
7) Disassembly valve assembly according to

the following procedure.
i) Remove sleeve (22), spring (23) and
valve (24).
ii) Remove stopper (25) and spring (26).
iii) Remove stopper (27), spring (28) and
shims (29) from valve (30).
shims.
30-101
(9)
ASSEMBLY OF TRANSMISSION SHIFT VALVE ASSEMBLY
012406
30-102
(9)
fl Wash all parts carefully and confirm that they

are free from flaws. Apply engine oil to their
sliding surfaces, then reassemble.
1. Inching spool assembly
1) Assemble the valve assembly according to
the following procedures.
i) Install shims (29), spring (28) and stop-
per (27) to valve (30).
fl Reuse the shims removed when dis-
assembled.
fl Free height of spring: 33.9mm
ii) Install spring (26) and stopper (25).
fl Free height of spring: 22mm
iii) Install valve (24), spring (23) and sleeve
(22).
fl Free height of spring: 26mm
2) Install valve assembly (21) to body (6).
3) Fit the O-ring, then install plug (20).
Plug: 93.1 – 122.5Nm {9.5 – 12.5kgm}
4) Fit oil seal (19) to cover (16).
8 Seal lip: Grease (G2-LI)
5) Install spool (18) to cover (16).
6) Fit the O-ring, then install shims (17) and
cover (16) together with spool.
8 O-ring: Grease (G2-LI)
012406
fl Reuse the shims removed when disas-

sembled.
7) Install yoke (15) and secure it with nut (14).
fl When installing the yoke, adjust dimen-
sion a.
• Dimension a: 27mm
Nut: 27 – 34Nm {2.8 – 3.5kgm}
2. Speed spool assembly

1) Fit oil seal (13) to body (6).
8 Seal lip: Grease (G2-LI)
2) Install spool (12).
sion b.
• Dimension b: 27mm
Nut: 27 – 34Nm {2.8 – 3.5kgm}
4) Fit O-ring, then install plug (9).
Plug: 34.3 – 44.1Nm {3.5 – 4.5kgm}
5) Fit the O-ring, then install two detent as-
semblies (8).
Detent assembly:
14.7 – 19.6Nm {1.5 – 2kgm}
30-103
(9)
3. F-R spool assembly

1) Install detent assembly (7) to body (6).
Detent assembly:
14.7 – 19.6Nm {1.5 – 2kgm}
2) Fit oil seal (5).
Seal lip: Grease (G2-LI)
sion c.
• Dimension c: 27mm
Nut: 27 – 34Nm {2.8 – 3.5kgm}
5) Fit O-ring, then install plug (1).
Plug: 34.3 – 44.1Nm {3.5 – 4.5kgm}
012406
30-104
(9)
DISASSEMBLY AND ASSEMBLY TRANSMISSION PRESSURE VALVE
REMOVAL OF TRANSMISSION
PRESSURE VALVE ASSEMBLY
1. Remove side step (1) and side cover (2).
1
2
CED00070
2. Disconnect tube (3).

3
3. Remove transmission pressure valve assembly
(4). 4
012406
CED00098
INSTALLATION OF TRANSMISSION
PRESSURE VALVE ASSEMBLY
removal.
Mounting bolt:
27.9±3.4Nm {2.85±0.35kgm}
30-108
(9)
DISASSEMBLY OF TRANSMISSION PRESSURE VALVE ASSEMBLY
012406
1. Covers
Remove covers (1) and (2).
2. Quick return valve

1) Remove stopper (3) by using a forcing
bolt.
3) Remove stopper (5).
3. Modulating valve
1) Remove stopper (6) by using a forcing-
bolt.
2) Remove valve (7).
3) Remove shims (8) from valve (7).
shims.
4) Remove springs (9) and (10).
5) Remove stopper (11).
7) Remove valve (13), spring (14) and valve
(15) from spool (12).
30-110
(9)
ASSEMBLY OF TRANSMISSION PRESSURE VALVE ASSEMBLY

012406
1. Modulating valve
1) Install valve (15), spring (14) and valve (13)
to spool (12).
2) Install spool (12) to body (16).
3) Fit the O-ring, then install stopper (11).
4) Install springs (10) and (9).
5) Install shims (8) to valve (7).
fl Reuse the shims removed when disas-
sembled.
6) Install valve (7).
2. Quick return valve

3. Covers
Install covers (2) and (1).
30-111
(9)
DISASSEMBLY AND ASSEMBLY STEERING PISTON
REMOVAL OF STEERING
PISTON ASSEMBLY (CLUTCH,
BRAKE PISTON) 6
5
1. Remove external cover under fuel tank assem-
bly. 1 7
2
2. Disconnect spring (1), pressure detection hoses 9
(2) and (3), brake hose (4), and clutch hose (5) 3 4 10
8
of right clutch and brake piston assembly.
3. Disconnect spring (6), pressure detection hoses

(7) and (8), brake hose (9), and clutch hose (10)
CED00445
of left clutch and brake piston assembly.
4. Remove right clutch and brake piston assembly

(11).
5. Remove left clutch and brake piston assembly

(12).
012406
11
CED00446
INSTALLATION OF STEERING
BRAKE PISTON)
removal.
fl Adjust the clearance of the clutch and brake

piston. 12
CED00447
Adjusting clearance of clutch, brake piston.
30-112
(9)
DISASSEMBLY AND ASSEMBLY STEERING PISTON
DISASSEMBLY OF STEERING
BRAKE PISTON) 1 1
1. Blow in air from elbow (1) and push out pistons
(2) and (3).
2 3 q
¤ Put block [1] in contact with the tip of the
piston, and fill slowly with air.
2. Remove snap rings (4) and (5), then remove

dust seals (6) and (7).
CED00380
3. Remove seals (8) and (9).
4 8 10 9 5
012406
6 7
CED00381
ASSEMBLY OF STEERING
BRAKE PISTON)
1. Install seals (9) and (8) to body (10).
2. Assemble dust seals (7) and (6), and install snap

rings (5) and (4).
3. Coat inside of body with engine oil, and install

pistons (3) and (2).
30-113
(9)
DISASSEMBLY AND ASSEMBLY PARKING BRAKE CYLINDER
REMOVAL OF PARKING BRAKE

CYLINDER ASSEMBLY
1. Remove brake control valve assembly.
1
For details, see REMOVAL OF BRAKE CONTROL
VALVE ASSEMBLY.
2. Remove mounting bolts of center floor plate.
3. Remove deceleration pedal, and disconnect de-

celeration cable (1). 1
CDD00080
4. Disconnect brake rod (2) and inching rod (3) at

turnbuckle. 2
5. Remove brake pedal and floor plate assembly.
3 2
012406
CED00060
6. Disconnect 8 hoses (5) from block (4).

4
7. Remove block (4).
5
CED00123
8. Tighten nut (6), and retract spring inside cylin-

der (7).
fl Retract approx. 40 mm. 3
6
7
CED00124
30-114
9. Pull out pin (8), and remove brake cylinder as-

sembly (9).
9 8
CED00125
INSTALLATION OF PARKING
BRAKE CYLINDER ASSEMBLY
removal.
1
fl Adjust the decelerator pedal.
For details, see Adjusting deceleration pedal.
012406
2
fl Adjust the inching and brake pedal.
For details, see Adjusting inching, brake
pedal linkage.
3
fl Release the parking brake.
Procedure for releasing parking brake.
3 Parking brake cylinder nut:
51.5 ± 17.2 Nm (5.25 ± 1.75 kgm)
30-115
DISASSEMBLY OF PARKING BRAKE CYLINDER ASSEMBLY

5 4 9 8 7 6 12 11 3 10
d b
a c
1
q 2
CDD00436
1. Remove 2 cylinder cover mounting bolts (1) at

opposite corners (remove [a] and [b] or remove
[c] and [d]), then install 2 guide bolts [1] and fit
nuts.
fl For guide bolts [1], use bolts with an effec-
tive stroke of at least 70 mm.
fl After installing guide bolts [1], tighten nuts
(2).
2. Remove 2 remaining mounting bolts (1).
012406
3. Loosen nuts (2) of guide bolts [1] in turn and
release tension of spring (3).
fl Installed dimension of spring (3): 190 mm
fl Free length of spring (3): 256 mm 7 6
4. Remove cylinder cover (4), then remove piston

(5).
5. Disassembly of cylinder cover assembly

1) Remove snap ring (6) from cylinder cover
(4), then remove oil seal (7).
2) Remove backup ring (8) and O-ring (9).
6. Remove nut (10), then remove spring (3) and

rod (12) from cylinder case (11). 9 8
CDD00437
30-116
(9)
ASSEMBLY OF PARKING BRAKE CYLINDER ASSEMBLY

5 4 9 8 7 6 12 11 3 10
d b
a c
1
q 2
CDD00436
fl Clean all parts, and check for dirt or damage. 7 6

1. Assemble rod (12) and spring (3), then assem-

ble in cylinder case (11), and install nut (10).
2 Rod thread: Grease (G2-LI)
2 Inside surface of cylinder case (11):
Grease (G2-LI)
012406
2. Assembly of cylinder cover 9 8

CDD00437
1) Assemble O-ring (9) and backup ring (8).
2 O-ring (9): Grease (G2-LI)
2) Fit oil seal (7) and install snap ring (6).
3. Assemble piston (5) to cylinder cover (4).

4
2 Sliding surface of piston:
Coat thinly with engine oil.
q
4. Assemble cylinder cover (4) and piston (5) as-
sembly to cylinder case (11), and use 2 guide
bolts [1] in same way as for disassembly.
fl Set 2 guide bolts [1] at opposite corners
(insert at [a] and [b] or at [c] and [d]) and
tighten nuts (2) in turn to a position where 2
mounting bolts (1) can be installed.
5. After installing 2 mounting bolts (1), tighten nuts

(2) fully in turn.
6. Tighten 2 mounting bolts (1), then remove guide

bolts [1], and install remaining 2 mounting bolts
(1). 3
7. Tighten nut (10) to end face of cylinder case. 11

CDD00438
30-117
(9)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
REMOVAL OF FINAL DRIVE

ASSEMBLY
1. Remove track shoe assembly.
For details, see REMOVAL OF TRACK SHOE
ASSEMBLY.
2. Drain oil from final drive.

6 Final drive (each): 14 ¬
3. Drain oil from steering case.

q
6 Steering case: 80 ¬
CED00129
4. Using hydraulic jack (490kN{50 ton}), raise ma-

chine, then set stand [1] under steering case.
1
5. Remove guards (inside, outside) (1).
6. Install tool J1 to final drive assembly.
7. Using tool J1, sling final drive assembly (2),

and remove mounting bolts.
8. Lift off final drive assembly (2).

Final drive assembly (each): 390kg
012406
CED00130
D41E, P-6 Serial No.: B20001 – B20500

INSTALLATION OF FINAL
DRIVE ASSEMBLY J1

removal.
J1
• Refilling with oil

6 Final drive (each): 14 ¬ (SAE30CD) 2
Plug: 152.0±24.5Nm {15.5±2.5kgm}
CED00131
D41E, P-6 Serial No.: B20501 and up

• Refilling with oil
6 Steering case oil: 80 ¬ (SAE30CD)
2 Guard mounting bolt:

Guard mounting bolt:
277±32Nm {28.25±3.25kgm}
Final drive mounting bolt:

277±32Nm {28.25±3.25kgm}
30-118
(9)
DISASSEMBLY OF FINAL
DRIVE ASSEMBLY
Serial No.: B20001 – B20500 2
4a
• Floating seal
3
1. Remove sprocket (2) from final drive assembly 4b
(1). 1
2. Remove cage (3), then remove floating seal (4a).
3. Remove floating seal (4b) from case.
CDD00235
• Oil pan case, cover 6

4. Turn over final drive assembly (1), set on block 5
[1], then remove oil pan case (5).
5. Remove drive shaft cover (6).
q
q
012406
CDD00236
• Drive shaft, gear

6. Remove bolt (7), then remove holder (8).
7
8
CED00237
7. Using tool J6, pull out drive shaft assembly (9)

from case.
CED00238
30-119
(9)
J6
CED00239
8. Remove bearing inner race (10), then remove

collar (11). 10
11
012406
CDD00240
9. Raise gear (12) and pull out from case (13).
13
12
CED00241
10. Raise case (13) and remove drive shaft assem-

bly (9).
13
9
CED00242
30-120
(9)
11. Disassembly of drive shaft assembly

1) Remove collar (15) from drive shaft (14).
14
15
CED00243
2) Set to press, and using tool J3, pull out

bearing inner race (16) from drive shaft (14). 14
J3
16
012406
CED00244
• Pinion assembly 18 17
12. Remove cover (17), then remove oil seal and
bearing housing (18).
CDD00245
13. Disassembly of oil seal, bearing housing

1) Remove oil seal (19) from oil seal and bear- 18 19
ing cage (18).
2) Remove bearing outer race (20).
20
CDD00246
30-121
(9)
14. Remove pinion assembly (21) from case.

21
CED00247
15. Disassembly of pinion assembly

1) Using bearing puller, remove collar (22) and
bearing inner race (23). 24 23 22
2) Using bearing puller, remove bearing inner
race (24).
012406
CED00248
• Bearing outer race

16. Remove bearing outer races (25), (26), and (27) 25
from case.
27
26
CDD00249
30-122
(9)
ASSEMBLY OF FINAL DRIVE

ASSEMBLY
Serial No.: B20001 – B20500 25

1. Press fit bearing outer races (27), (26), and (25)
to case.
27
26
CDD00249
• Pinion assembly
2. Assembly of pinion assembly
1) Press fit bearing inner race (23) and collar 24 23 22
(22) to pinion.
2 End portion of spline: LG-6
fl Press-fitting force for collar (22):
7.06 – 47.27kN {0.72 – 4.82ton}
2) Press fit bearing inner race (24) to pinion.
012406
CED00248
3. Measuring preload of pinion assembly

1) Assemble pinion assembly (21) to case (13). 18
2) Press fit bearing outer race (20) to oil seal
and bearing housing (18). 20
fl Do not assemble oil seal (19) when do-
ing this.
3) Fit O-ring to oil seal and bearing housing
(18) and install to case. 13
fl Tighten the mounting bolts of oil seal 21
and bearing housing (18) to the speci-
fied torque.
CDD00250
Oil seal, bearing housing mounting
bolt: 66.2±7.4Nm {6.75±0.75kgm}
4) Set tool J7 to spline of pinion, then using
torque wrench, measure rotating torque. J7
fl Pinion rotating torque:
Max. 2.9Nm {0.3kgm}
CDD00251
30-123
(9)
5) Remove oil seal and bearing housing (18)

from case (13), then install oil seal (19), and 19
install case (13) again.
2 Press-fitting surface of oil seal: 18
fl Coat the inside of the housing thinly and
wipe off any gasket sealant that is
pushed out. 13

3 Oil seal, bearing housing mounting
CDD00252
bolt: 66.2±7.4Nm (6.75±0.75kgm)
6) Fit O-ring to cover (17) and install.
3 Cover mounting bolt: 18 17
66.2±7.4Nm (6.75±0.75kgm)
012406
CDD00245
• Drive shaft assembly

4. Assembly of drive shaft assembly
1) Using tool J4, press fit bearing inner race
(16) with press. J4
2) Install collar (15). 15
16
CDD00253 CED00254
5. Set drive shaft (9) in position, then raise gear

(12) to case (13) and assemble.
6. Raise case (13) and assemble to drive shaft (9). 12
fl Before assembling, align the holes of the
gear and the case.
13 9
CDD00255
30-124
7. Keep case raised, assemble collar (11) to drive

shaft (9), then set bearing inner race (10) to
drive shaft. 11 10
CED00256 CED00257
8. Using tool J5, press fit bearing inner race (10)

to drive shaft.
J5
012406
CED00258
9. Measuring preload of drive shaft

1) Without installing holder (8), raise final drive Torque wrench
case slightly and use torque wrench to meas-
ure rotating torque A.
2) Fit holder (8) and tighten with mounting
bolts.
fl When tightening the holder mounting
bolts, keep the final drive case held se-
curely in position.
2 Holder mounting bolt:
CDD00259
926.7 ± 103.0 Nm (94.5 ± 10.5 kgm)
3) Measure rotating torque again and check Torque wrench
rotating torque value is as follows.
fl Rotating torque value: 8
Max. A + 15.7 Nm (1.6 kgm)
CDD00260
30-125
4) Set dial gauge [1] in position, and using

lever, move gear, measure movement in and
out (axial clearance) of drive shaft.
fl In-and-out movement of drive shaft: q
Max. 0.25mm
CED00261
5) Fit O-ring to cover (6) and install to case. 6

5
10. Install oil pan case (5).
2 Mating surface of oil pan case:
2 Oil pan mounting bolt:
Oil pan mounting bolt:
198.6±31.9Nm {20.25±3.25kgm} q
q
012406
CDD00236
• Floating seal, sprocket

11. Turn over final drive assembly, and set on block.
J2
12. Using tool J2, install floating seal (4a).
fl When assembling the floating seal, clean
and remove all oil and grease from the O- 4a
ring and O-ring contact surface.
fl After installing the floating seal, check that
the angle of the seal is less than 1 mm.
CDD00262
30-126
(9)
13. Using tool J2, assemble floating seal (4b) to

cage (3).
fl For the precautions when installing the float-
ing seal, see the precaution for Step 12.
J2
4b
CDD00264
14. Assemble cage (3).

fl Before assembling cage (3), coat the mating 2
surface of floating seals (4a) and (4b) thinly
with engine oil. 4a
3
2 Cage mounting bolt: 4b
Thread tightener (LT-2) 1
3 Cage mounting bolt:

1084±74Nm {110.5±7.5kgm}
15. Install sprocket assembly (2) to final drive case

012406
(1). CDD00235
3 Sprocket mounting bolt:

1084±74Nm {110.5±7.5kgm}
30-127
3
DISASSEMBLY OF FINAL
DRIVE ASSEMBLY
Serial No.: B20501 – B40000, 50001and up
• Floating seal
1. Remove sprocket (2) from final drive assembly
(1).
2. Remove cage (3), then remove floating seal (4a).
3. Remove floating seal (4b) from case.
• Oil pan case, cover

4. Turn over final drive assembly (1), set on block
[1], then remove oil pan case (5).
5. Remove drive shaft cover (6).
012406
• Drive shaft, gear
6. Remove bolt (7), then remove holder (8).
7
8
CED00237
7. Using tool J6, pull out drive shaft assembly (9)

from case.
CED00238
30-127-1
(9)
J6
CED00239
8. Remove bearing inner race (10), then remove

collar (11).
012406
9. Raise gear (12) and pull out from case (13).
13
12
CED00241
10. Raise case (13) and remove drive shaft assem-

bly (9).
13
9
CED00242
30-127-2
(9)
11. Disassembly of drive shaft assembly

1) Remove collar (15) from drive shaft (14).
14
15
CED00243
2) Set to press, and using tool J3, pull out

bearing inner race (16) from drive shaft (14). 14
J3
16
012406
CED00244
• Pinion assembly
12. Remove oil seal and bearing housing (18).
13. Disassembly of oil seal, bearing housing

1) Remove oil seal (19) from oil seal and bear- 18 19
ing cage (18).
2) Remove bearing outer race (20).
20
CDD00246
30-127-3
(9)
14. Remove pinion assembly (21) from case.

21
CED00247
15. Disassembly of pinion assembly

1) Using bearing puller, remove collar (22) and
bearing inner race (23). 24 23 22
2) Using bearing puller, remove bearing inner
race (24).
012406
CED00248

16. Remove bearing outer races (25), (26), and (27)
from case.
30-127-4
(9)
ASSEMBLY OF FINAL DRIVE

ASSEMBLY

1. Press fit bearing outer races (27), (26), and (25)
to case.
• Pinion assembly
2. Assembly of pinion assembly
1) Press fit bearing inner race (23) and collar 24 23 22
(22) to pinion.
2 End portion of spline: LG-6
fl Press-fitting force for collar (22):
7.06 – 47.27kN {0.72 – 4.82ton}
2) Press fit bearing inner race (24) to pinion.
012406
CED00248
3. Measuring preload of pinion assembly

1) Assemble pinion assembly (21) to case (13).
2) Press fit bearing outer race (20) to oil seal
and bearing housing (18).
fl Do not assemble oil seal (19) when do-
ing this.
3) Fit O-ring to oil seal and bearing housing
(18) and install to case.
fl Tighten the mounting bolts of oil seal
and bearing housing (18) to the speci-
fied torque.
bolt: 66.2±7.4Nm {6.75±0.75kgm}
4) Set tool J7 to spline of pinion, then using
torque wrench, measure rotating torque.
fl Pinion rotating torque:
Max. 2.9Nm {0.3kgm}
30-127-5
(9)
5) Remove oil seal and bearing housing (18)

from case (13), then install oil seal (19), and
install again to case (13).
2 Press-fitting surface of oil seal:
fl Coat the inside of the housing thinly and
wipe off any gasket sealant that is
pushed out.
bolt: 66.2±7.4Nm {6.75±0.75 kgm}
• Drive shaft assembly

4. Assembly of drive shaft assembly
1) Using tool J4, press fit bearing inner race
(16) with press.
2) Install collar (15). 15
012406
CED00254
5. Set drive shaft (9) in position, then raise gear

(12) to case (13) and assemble.
6. Raise case (13) and assemble to drive shaft (9).
fl Before assembling, align the holes of the
gear and the case.
7. Keep case raised, assemble collar (11) to drive

shaft (9), then set bearing inner race (10) to
drive shaft. 11 10
CED00256 CED00257
30-127-6
(9)
8. Using tool J5, press fit bearing inner race (10)

to drive shaft.
J5
CED00258
9. Measuring preload of drive shaft

1) Without installing holder (8), raise final drive
case slightly and use torque wrench to meas-
ure rotating torque [A].
2) Fit holder (8) and tighten with mounting
bolts.
fl When tightening the holder mounting
bolts, keep the final drive case held se-
curely in position.
012406
Holder mounting bolt:
926.7±103.0Nm {94.5±10.5 kgm}
3) Measure rotating torque again and check
rotating torque value is as follows.
fl Rotating torque value:
Max. [A] + 15.7Nm {1.6 kgm}
4) Set dial gauge [1] in position, and using

lever, move gear, measure movement in and
out (axial clearance) of drive shaft.
fl In-and-out movement of drive shaft: q
Max. 0.25 mm
CED00261
30-127-7
(9)
5) Fit O-ring to cover (6) and install to case.
10. Install oil pan case (5).

2 Mating surface of oil pan case:
2 Oil pan mounting bolt:
Oil pan mounting bolt:
198.6±31.9Nm {20.25±3.25kgm}
• Floating seal, sprocket

11. Turn over final drive assembly, and set on block.
12. Using tool J2, install floating seal (4a).

fl When assembling the floating seal, clean
and remove all oil and grease from the O-
ring and O-ring contact surface.
fl After installing the floating seal, check that
the angle of the seal is less than 1 mm.
012406
13. Using tool J2, assemble floating seal (4b) to

cage (3).
fl For the precautions when installing the float-
ing seal, see the precaution for Step 12.
30-127-8
(9)
14. Assemble cage (3).

fl Before assembling cage (3), coat the mating
surface of floating seals (4a) and (4b) thinly
with engine oil.
2 Cage mounting bolt:
Cage mounting bolt:
1084±74Nm {110.5±7.5kgm}
15. Install sprocket assembly (2) to final drive case

(1).
Sprocket mounting bolt:
1084±74Nm {110.5±7.5kgm}
012406
30-127-9
(9)
DISASSEMBLY AND ASSEMBLY IDLER, RECOIL SPRING
REMOVAL OF IDLER, RECOIL

SPRING ASSEMBLY
1. Remove track shoe assembly.
For details, see REMOVAL OF TRACK SHOE
ASSEMBLY.
2. Pull out idler and recoil spring assembly (1),

then lift off rod.
1
Idler, recoil spring assembly: 200 kg
CED00140
3. Remove bolt (2) and separate idler (3) and re-

coil spring (4). 3
2 4
Idler: 95 kg
Recoil spring: 110 kg
012406
CDD00141
INSTALLATION OF IDLER,
RECOIL SPRING ASSEMBLY
removal.
2 Mounting bolt: Thread tightener (LT-2)
30-128
(9)
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
DISASSEMBLY OF RECOIL SPRING ASSEMBLY

4 1 3
6 2
9 7
8
5 10
13 14
11 12
17
16 18
15
CED00375
1. Remove lock plate (1), then remove seat (2) and

valve (3).
4
2. Remove yoke piston assembly (5) from recoil
spring assembly (4).
3. Disassembly of recoil spring assembly

1) Set recoil spring assembly (4) to tool M.
¤ The recoil spring is under large installed
load, so be sure to set the tool properly.
012406
Failure to do this is dangerous.

fl Installed load of spring: CED00376
88.53kN {9028kg}
2) Loosen locknut (6), then apply hydraulic
pressure slowly to compress spring, and
remove nuts (6) and (7).
fl Compress the spring to a point where
the nut becomes loose.
fl Release the hydraulic pressure slowly
and relieve the tension of the spring.
3) Remove pilot (9) and cylinder (10) from
spring (8), then remove snap ring (11), dust
seal (12), U-packing (13), and bushing (14)
from cylinder (10).
4. Disassembly of yoke piston assembly

1) Remove wear rings (16) from yoke piston
(15).
2) Remove snap ring (17), then remove U-pack-
ing (18).
30-129
(9)
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
ASSEMBLY OF RECOIL SPRING

ASSEMBLY
1. Assembly of yoke piston assembly
1) Assemble U-packing (18) to yoke piston (15),
and secure with snap ring (17).
2 U-packing: Grease (G2-LI)
2) Assemble wear rings (16).
2 Wear ring: Grease (G2-LI)
2. Assembly of recoil spring assembly
1) Using push tool [1], press fit bushing (14) to
cylinder (10).
fl Secure the cylinder with block [2].
2) Install U-packing (13) to cylinder (10).
3) Using push tool [3], install dust seal (12)
and secure with snap ring (11).
4) Assemble cylinder (10) and pilot (9) to spring
(8), and set to tool M.
5) Apply hydraulic pressure slowly to compress
spring, and set so that installed length of
spring is dimension “a”.
fl Installed length “a” of spring: 443mm
6) Set in position with nut (7), then lock with
nut (6).
fl Always secure nut (7) before tightening
012406
nut (6).
Nut (6): 328.5Nm {33.5kgm}
7) Remove recoil spring assembly (4) from tool.
3. Fill portion A inside cylinder (10) with at least
120 cc of grease to prevent air from accumulat-
ing.
4. Assemble yoke piston assembly (5) to recoil
spring assembly (4).
2 Sliding portion of yoke piston, wear ring:
Grease (G2-LI)
5. Fit valve (3) and seat (2), and secure with lock
plate (1).
fl Install the valve so that the fitting faces the
outside.
4 1 3
6 2
9 7
8
5 10
13 14
11 12
17
16 18
15
CED00375
30-130
(9)
DISASSEMBLY AND ASSEMBLY IDLER
DISASSEMBLY OF IDLER
ASSEMBLY
1. Remove dowel pin (1), then remove support
(2).
8
2. Remove floating seal (3) from support (2) and 6
idler (4).
7
3. Pull out idler (4) from shaft (5) and support
assembly (7).
fl It is filled with 150 cc. of oil, so drain the oil
at this point or lay a cloth to prevent the
area from becoming dirty.
4. Remove floating seal (6) on opposite side from 10

idler (4) and shaft (5) and support assembly (7).
1
5. Remove dowel pin (8), then remove support (7)
from shaft (5). 4 9
5
6. Remove bushings (9) and (10) from idler (4).
3
2
012406
CED00190
4 6
6 7
CED00191
9,10 4 5
8
CED00192 CED00193
30-131
(9)
ASSEMBLY OF IDLER
ASSEMBLY
1. Using tool L1-1, press fit bushings (9) and (10) L1-1
to idler (4).
9 10
4
CED00194 CED00195
2. Fit O-ring and install support (7) to shaft (5)

with dowel pin (8). 4 6
3. Using tool L1-2, install floating seal (6) to idler

(4) and shaft (5) and support assembly (7).
fl Coat the sliding surface of the floating seal
with oil, and be careful not to let any dirt or 5
dust get stuck to it.
fl Remove all grease and oil from the contact
surface of the O-ring and the floating seal.
6 7
012406
CED00191
7 5
CED00197
L1-2
CED00198
30-132
(9)
4. Assemble shaft (5) and support assembly (7) to

7 5
idler (4), then turn over.
4
5. Add oil between shaft (5) and idler (4).
5 Oil: 150 cc (EO30-R)
CED00197
6. Using tool L1-2, install floating seal (3) to idler

(4) and support (2).
fl Coat the sliding surface of the floating seal
with oil, and be careful not to let any dirt or
dust get stuck to it. 5
fl Remove all grease and oil from the contact
surface of the O-ring and the floating seal.
4
012406
CED00199
7. Install O-ring, then install support (2) with dowel

pin (1).
3
4 2
CED00200
8
6 L1-2
10 3
1
4 9
5
2
3
CED00202 CED00201
30-133
DISASSEMBLY AND ASSEMBLY TRACK SHOE
INSTALLATION OF TRACK
SHOE ASSEMBLY
removal.
q e
fl Track shoe tension: 20 – 30mm
r w
Master link mounting bolt:
Initial torque: 196±19.6Nm {20±2kgm}
Tightening angle: 180±20°
CED00228
fl When winding on the track shoe, use a bar and
make sure that the link does not come off the
sprocket.
When winding on, keep the track shoe pulled
and do not let it become loose.
fl Check that there is no dirt or dust on the thread
or mating surface of the master link.
fl Tighten the shoe bolts in the order [1] – [4].
012406
30-143
(9)
DISASSEMBLY AND ASSEMBLY ONE LINK
7) Coat press-fitting hole for pin in link (6) with

gasket sealant (198-32-19890), then continue
to press fit pin (2).
6
CED00484
8) Using tool R13, apply specified pushing pres-

R13
sure to links (3) and (4) and links (5) and (6). 6
fl Pushing pressure of pin, bushing: 588 4
kN (60 ton)
(Adjust the link press relief pressure and
set the pushing pressure.)
3 5
012406
CED00485
8. Vacuum test
Using tool R6, remove air from small plug hole
at end face of pins (1) and (2) and check sealing
performance.
fl Check that the airtightness is maintained for
5 seconds at a negative pressure of 695 ±
15 mmHg.
1 2 R6
CED00486
9. Charging with oil

1) Using tool R7, charge with oil (GO90)
through small plug hole in pin.
fl Be careful not to raise the pressure too
high when charging with oil. This will
have an adverse effect on the seal.
fl The oil will expand under heat, so be
careful not to charge with too much oil.
R7
CED00487
30-171
(9)
ONE LINK
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
2) Using tool R5, knock in small plug quickly.

fl Coat the outside circumference of the
small plug with GO90.
fl Knock in the plug to the following depth.
Depth from end face: 4.5±1mm
R5
CED00488
REMOVAL OF HYDRAULIC
PUMP ASSEMBLY 1
¤ Lower the work equipment to the ground and
stop the engine. Release the remaining pres-
sure in the circuit. For details, see TESTING
AND ADJUSTING, RELEASING REMAINING
PRESSURE IN HYDRAULIC CIRCUIT. Then
loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank.
012406
CDD00080
1. Drain oil from hydraulic tank.
Hydraulic tank: 37 ¬
2. Remove mounting bolts from center floor plate.
3. Remove decelerator pedal, and disconnect

decelerator cable (1).
3 2
4. Disconnect brake rod (2) and inching rod (3) at
turnbuckle.

CED00060
6. Disconnect 2 tandem pump inlet tubes (4).
7. Disconnect 2 tandem pump outlet tubes (5). 6
8. Remove tandem pump assembly (6).
5 4
CED00081
30-172
(9)
DISASSEMBLY AND ASSEMBLY STEERING PPC VALVE
REMOVAL OF STEERING PPC

VALVE ASSEMBLY
¤ Lower the work equipment to the ground and
stop the engine. Release the remaining pres-
sure in the circuit. For details, see TESTING
AND ADJUSTING, RELEASING REMAINING
PRESSURE IN HYDRAULIC CIRCUIT. Then
loosen the oil filler cap slowly to release the 1
pressure inside the hydraulic tank.
1. Lift off operator’s seat.
4 Operator’s seat: 45 kg CED00169
2. Remove bottom left cover of floor frame.
3. Disconnect 6 hoses (1).

fl Make match marks on each hose.
4. Remove stop plate (5) and disconnect lever (2).

1
012406
5. Remove 3 mounting bolts (3), then remove PPC

valve assembly (4). 3
4
INSTALLATION OF STEERING
CED00171
PPC VALVE ASSEMBLY
removal.
1
fl Adjust the steering lever linkage.
For details, see Adjusting steering lever link-
age.
• Refilling with oil (hydraulic tank)

Add oil through the oil filler to the specified
level.
30-189
7
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
Coat the sliding surfaces of all parts with en- U5
gine oil before installing. Be careful not to dam-
age the rod packings, dust seals, or O-rings
when assembling.
1. Piston rod assembly

1) Assembly of head assembly 13
i) Using tool U5, press fit bushing (13).
CED00179
ii) Using tool U6, assemble dust seal (12),

iii) Install packing (10). U6
iv) Install backup ring (9) and O-ring.
fl Do not try to force the backup ring
into position. Warm it in warm wa-
ter (50 – 60°C) before fitting it. 12
012406
CED00180
11
12
13
9 10
CED00178
2) Assembly of piston assembly

i) Set piston ring (8) on tool U4-1 and turn U4-2
handle 8 – 10 times to expand ring.
ii) Remove piston ring (8) from tool U4-1, U4-1
and install to piston (5). 8
iii) Using tool U4-2, compress piston ring 8
(8).
CED00181 CED00182
30-198
(9)
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
iv) Assemble wear ring (7).
CED00177
3. Piston rod assembly

1) Set piston rod to tool U1, and assemble
head assembly (6) and piston assembly (5),
then using tool U3, tighten nut (4). U3 5 3 6
Name of Width across Tightening

flats of nuts torque U1
cylinder (mm) Nm {kgm}
1,422±142.2
Blade lift 55 {145±14.5}
1,765±176.5
012406
Blade angle 60 {180±18.0}

CED00176
1,422±142.2
Blade tilt 55 {145±14.5}
fl Thoroughly clean the thread of the pis-

ton rod and remove all oil and grease
before assembling the nut.
2 Rod thread:
Thread tightener (Loctite N6262)
3
2) Set cylinder (1) to tool U1, and assemble
piston rod assembly (3) in cylinder.
2 Seal: Grease (G2-LI)
CED00175
3) Using pump or power wrench, tighten head

assembly (2) with tool U2.
U2 2 1
Head tightening torque
Name of cylinder Nm {kgm}
863±86.3
Blade lift {88±8.8} U1
1,030±103
Blade angle {105±10.5}
932±93.2
Blade tilt {95±9.5}
CED00174
30-199
(9)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
REMOVAL OF WORK
EQUIPMENT ASSEMBLY
¤ Release the remaining pressure in the circuit.
RELEASING REMAINING PRESSURE IN HY-
DRAULIC CIRCUIT. Then loosen the oil filler cap
slowly to release the pressure inside the hy-
draulic tank.
1. Lower blade to ground in flat area and set block

1 under work equipment frame.
q
CDD00132
2. Sling lift cylinder (1), then remove lock plate

(2), and remove rod mounting pin (3). 1
• Both left and right 3
012406
CED00133
3. Secure rod end of lift cylinder (1) to handle on

engine hood with rope.
• Both left and right
1
4. Remove cover (4).
CED00134
5. Disconnect 2 cylinder hoses (5).

• The hose on the left is the tilt cylinder hose.
• The hose on the right is the angle cylinder 5
hose.
CED00135
30-200
6. Sling work equipment assembly (6).

fl Use a chain block for the wire at the rear to
make it possible to adjust the balance.
6
CDD00136
7. Remove lock plate (7), and pull out frame mount-

ing pin (8).
8. Lift off work equipment assembly (6).
4 Work equipment assembly: 1500 kg
7
012406
8
CED00137
INSTALLATION OF WORK
EQUIPMENT ASSEMBLY
removal.
• Refilling with oil (hydraulic tank)

Add oil through the oil filler to the specified
level.
• Greasing
fl After completion of the installation, carry
out greasing of the mounting pins that were
removed.
30-201
DISASSEMBLY OF WORK
EQUIPMENT ASSEMBLY
¤ Set blocks [1], [2], and [3] under the work equip-
ment frame, and secure the work equipment
assembly. q
w e
CED00154
1. Blade
1) Remove cover (1) and cover (2) of angle 1
cylinder assembly from blade.
012406
CED00155
2) Sling angle cylinder assembly (3), then re-

move lock plate, and pull out head mount- 5
ing pin (4).
3) Raise angle cylinder assembly (3), then dis-

connect from blade, and move towards 4
frame end.
3
CED00156
4) Sling blade (5).

5) Remove lock plate, then remove pin (7) from
lever (16).
D41E-6 Serial No.: B20001 – B35110
D41E-6 Serial No.: 50001 – 50299
D41P-6 Serial No.: B20001 – B40000
D41P-6 Serial No.: 50001 – 50299
6) Remove mounting ring of cover (6), and re-

move cap (8).
7) Lift off blade (5).
Blade: 650 kg
30-202
(9)
D41E-6 Serial No.: B35111 – B40000

D41E-6 Serial No.: 50300 and up.
D41P-6 Serial No.: 50300 and up.
8) Remove 8 mounting bolts of cap (8), and lift

off blade (5).
fl Check the thickness, quantity, and posi-
tions of the inserted shims.
Blade: 650 kg
012406
2. Angle cylinder assembly

1) Sling angle cylinder assembly (3), and dis-
connect 2 hoses (9).
2) Remove lock plate, and pull out mounting

pin (10) at cylinder bottom end, then lift off
angle cylinder assembly (3).
Angle cylinder assembly: 105 kg
3. Tilt cylinder assembly

1) Remove cover (11) of tilt cylinder assembly.
11
CED00159
30-203
(9)
2) Sling tilt cylinder assembly (12), and remove

lock plate, then pull out cylinder head pin 13
(13).
3) Raise tilt cylinder assembly slightly, and dis- 12
15
connect 2 hoses (14).
4) Remove lock plate, and pull out cylinder bot-
tom pin (15), then lift off tilt cylinder assem-
bly (12).
Tilt cylinder assembly: 37 kg 14
CED00160
4. Lever, rod
1) Sling lever (16), remove lock plates, then 18
16
remove pins (17) and (18), and lift off lever
(16).
Lever: 32 kg
17
2) Remove lock plate, and pull out pin (19),
then remove rod (20). 20
012406
19
CED00161
5. Hoses
1) Remove covers (21) and (22) from frame,
then remove hose (23).
24 25
2) Remove covers (24) and (25) from frame, 26
then remove hose (26).
23
21 22
CED00162
30-204
(8)
ASSEMBLY OF WORK
EQUIPMENT ASSEMBLY
¤ Set blocks 1, 2, and 3 under the frame.
q
w
e
CED00163
1. Hoses, covers
1) Fit hose (26) to frame and install covers (25)
and (24). 24 25
2) Fit hose (23) to frame and install covers (22) 26
and (21).
23
012406
21 22
CED00162
fl When installing the hoses to the frame in Clip 555

240 120 Angle cylinder
Steps 1) and 2), install according to the dia- bottom side
gram on the right.
Angle cylinder
550 head side
Adjust hose length

between these Clip
points
550 Tilt cylinder
head side
240 120
Tilt cylinder
555
bottom side
Clip
CED00164
2. Lever, rod
1) Raise lever (16), align with frame, then in- 18
16
stall pin (18), and lock pin with lock plate.
4 Lever: 32 kg
2) Assemble rod (20), then install pins (19) and 17

(17), and lock pins with lock plates.
20
19
CED00161
30-205
3. Tilt cylinder
1) Raise tilt cylinder assembly (12), then as-
semble to frame and install mounting pin
(15) at cylinder bottom end. 12
Tilt cylinder assembly: 37 kg
2) Lock pin (15) with lock plate, then connect 14

hoses (14).
14 15
CED00165
3) With cylinder raised, install cover (11).

16 13
4) Assemble cylinder head to lever (16), then
install pin (13) and lock pin with lock plate.
11
012406
CED00166
4. Blade
1) Raise angle cylinder (3) and assemble bot-
tom end to frame, then install pin (10), and
3
lock pin with lock plate. 10
Angle cylinder assembly: 105 kg
2) Connect 2 hoses (9). 9

3) Raise blade (5), align with mount at frame
end.
CED00158
Blade: 650 kg
D41E-6 Serial No.: B20001 – B35110

D41E-6 Serial No.: 50001 – 50299
D41P-6 Serial No.: B20001 – B40000
D41P-6 Serial No.: 50001 – 50299
4) Install cap (8), then fit cover (6) and secure
with ring.
5) Align lever (16) and pin hole in mount at

top of blade, then install pin (7) and lock pin
with lock plate.
30-206
(9)
D41E-6 Serial No.: B35111 – B40000

D41E-6 Serial No.: 50300 and up.
D41P-6 Serial No.: 50300 and up.
6) Install cap (8).
fl Adjust the shim thickness according to
the following procedure so that clear-
ance "a" between bearing (B) and cap
(8) will be 0.5 mm.
i) Tighten the cap mounting bolts so
that the clearance between bearing
(B) and cap (8) will be even.
ii) Measure clearance "a" and select
shims so that their total thickness
will be clearance "a" + 0.5 mm.
• Standard shim thickness: 8 mm
• Kinds of shim thickness:
0.5 mm, 1.0 mm
iii) Insert the selected shims and install
cap (8).
Mounting bolt:
455 - 565 Nm {46.5 - 58 kgm}
fl Have the blade grip a block to stabi-
lize it.
7) Align lever (16) and pin hole in mount at
top of blade, then install pin (7) and lock pin
012406
with lock plate.
5. Cover
1) Raise angle cylinder assembly (3), align head 5
end with blade mounting pin hole, assem-
ble, then install pin (4) and lock pin with
lock plate.
4
3
CED00156
2) Install cover (2) to angle cylinder assembly

(3), and install cover (1) to blade.
1
6. Greasing
After assembly, apply grease (G2-LI) to all
mounting pins.
2
CED00155
30-207
(9)
DISASSEMBLY AND ASSEMBLY OPERATOR CAB
REMOVAL OF OPERATOR CAB

ASSEMBLY
6 5 3
1. Remove ROPS roof and guard.

For details, see REMOVAL OF ROPS, GUARD. 4
2. Remove knobs (1) and (2).

1 2
3. Remove ashtray (3), then remove box (4).
4. Remove panels (5), (6), and (7). CED00229
5. Remove left and right steps (8).
6. Remove left and right covers (9). 8
9
012406
CED00230
7. Remove meter cover (18) and duct (19).
8. Remove dashboard mounting bracket (10).
9. Open left cover and disconnect 3 washer hoses.

1
10. Disconnect connectors (11) (CN-26), (12), and

(13). 1 13
fl Although the connectors on D41E-6 and
D41P-6, Serial No. 50201 and up, are in-
12
stalled to positions different from this illus-
tration, they can be removed and installed
11
CED00232
30-211
(8)
11. Remove 19 cab mounting bolts. 2
012406
12. Lift off cab assembly (14) slowly. 3
14
Cab assembly: 285 kg
CED00234
30-212
(8)
INSTALLATION OF OPERATOR
CAB ASSEMBLY
removal.
1
fl When connecting each connector, take care
not to mistake its No.
fl When connecting each connector, install the

grommet securely to the through hole of
the cab.
2
fl Note that the 2 bolts at the front part of the
operator's cab are different in length from
the other bolts.
1) Install and tighten the mounting bolts of
dashboard mounting bracket (10).
2) Measure the internal pressure and sealing
performance of the operator's cab. For de-
tails, see TESTING AND ADJUSTING OP-
ERATOR'S CAB.
fl If water enters the cab during the seal-
ing performance test, seal the cab with
012406
gasket sealant A (Three bond 1207B).
3
fl If the operator's cab is removed from the
floor frame, prepare the following sealant
to secure pressurizing performance and seal-
ing performance.
14X-911-2521 : 1 piece (Seal (B))
14X-911-5911 : 5 pieces (Seals (C) - (G))
198-Z11-3960 : Three bond (1207B)
: 1 pieces (Gasket sealant (A))
30-212-1
(8)
• Sticking seal to air conditioner box

1) Remove dirt, oil, and grease from the top of
the floor frame to which gasket sealant (Part
A) will be applied.
2) Apply gasket sealant to the top of the floor
frame. (Right and left of air conditioner box
(32))
8 area A:
Gasket sealant (Three bond 1207B)
fl Apply up to thickness of 8 mm.
3) Apply adhesive LT-1A inside surface of seal

(B).
8 Inside surface of seal (B):
Adhesive (LT-1A)
012406
4) Fit seal (B) into the guide plate (33) of the
air conditioner box.
fl Pull seal (B) down and fit it, pressing
the gasket sealant applied in 2).
fl Fill the clearnce with adhesive (LT-1A)
between seal (B) and the floor frame
(Portion marked fl).
5) Apply grease (G2-LI) to the periphery of seal

(B) (sealing surface against the cab).
fl Apply the grease so that the cab will
slide well and the seal will not be moved
or deformed when the cab is installed.
30-212-2
(8)
• Installation of seal to cab mating face

1) Sling the cab assembly.
2) Remove dirt, oil, and grease from the seal
sticking face.
 Do not stand under the cab.
3) Referring to the figure, stick seals (C), (D),
(E), (F), and (G).
fl Stick the seals in the order of (C), (D),
(E), (F), and (G).
fl Project end "h" of seals (C) and (E) from
the end of the cab by 10 mm.
fl Take care that the seal will not be on
the spacer plate.
fl Lap parts "j" and "k" (joints) by 20 mm
over each other to eliminate clearance.
012406
• When installing the operator's cab, obey the

following points.
1) Lower the operator's cab assembly onto the
floor frame slowly.
fl Since the reaction force of the seal
sponge is large, lower the operator's cab
assembly slowly.
fl Check that the air conditioner duct seal
on the operator cab side is tightly in
contact with the air conditioner duct on
the dashboard side and there is not
clearance.
fl Since the clearance between the air con-
ditioner duct on the operator cab side
and the monitor is narrow, lower the
operator's cab assembly carefully.
2) Tighten the mounting bolts temporarily.
3) Check that the seal between air conditioner
box (32) and operator cab (14) is fitted se-
curely.
4) Check that there is not clearance at joint
”a” of the seal and floor frame.
30-212-3
(8)
REMOVAL AND INSTALLATION OF OPERATOR'S
DISASSEMBLY AND ASSEMBLY CAB GLASS (STUCK GLASS)
REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS

(STUCK GLASS)
012406
∗ Among the panes off window glass of the opera- (1): Front window glass
tor's cab, the one panel of (1) is stuck. (2): Both-sided adhesive tape
In this section, the procedure for replacing the
stuck glass is explained.
30-212-4
(8)
REMOVAL
1. Using seal cutter [1], cut the adhesive between

broken window glass (3) and operator's cab
(metal sheet) (4).
fl If a seal cutter is not available, make holes

on the adhesive and both-sided adhesive
tape with a drill and pass a fine wire (piano
wire, etc.) [2] through the holes. Grip the
both ends of the wire with priors [3], etc. (or
hold them by winding them onto something)
and move the wire to the right and left to
cut the adhesive and both-sided adhesive
tape. Since the wire may be broken by the
frictional heat, apply lubricant to it.
012406
(The following figure shows the operator's

cab of a wheel loader.)
fl If the window glass is broken finely, it may

be removed with knife [4] and a screwdriver.
fl Widening the cut with a screwdriver, cut
the adhesive and both-sided adhesive tape
with knife [4].

2. Remove the window glass.
30-212-5
(8)
INSTALLATION
1. Using a knife and scraper [5], remove the re-

maining adhesive and both-sided adhesive tape
from the metal sheets (glass sticking surfaces)
of the operator's cab.
fl Remove the adhesive and both-sided adhe-
sive tape to a degree that they will not affect
adhesion of the new adhesive. Take care
not to scratch the painted surfaces.
(If the painted surfaces are scratched, adhe-
sion will be lowered.)
2. Remove oil, dust, dirt, etc. from the sticking

surfaces of cab (4) with white gasoline.
fl If the sticking surfaces are not cleaned well,
the glass may not be stuck perfectly.
fl Clean the all black part on the back side of
the window glass.
fl After cleaning the sticking surfaces, leave
them for at least 5 minutes to dry.
012406
3. Stick both-sided adhesive tape (3) along the in-
side edges of the front window glass sticking
section.
fl Do not remove the release tape of the both-
sided adhesive tape on the glass sticking
side before sticking the glass.
fl When sticking the both-sided adhesive tape,
do not touch the cleaned surface as long as
possible.
fl Take care that the both-sided adhesive tape
will not float at each corner of the window
frame.
fl Do not lap the finishing end of both-sided
adhesive tape (3) over the starting end but
make clearance a of about 5 mm between
them.
30-212-6
(8)
4. Position the new window glass.

1) Using tool X1, set the window glass to the
sticking position. Check the clearance be-
tween the window glass and the operator's
cab on the right, left, upper, and lower sides,
and then adjust it evenly.
fl Position front window glass (1) from in-
side of operator's cab (4). Adjust it so
that the difference between black coated
part and the metal sheet of operator's
cab (4) will be even on the right, left,
upper, and lower sides.
2) After positioning the glasses, stick tapes [6]
between front window glass (1) and opera-
tor's cab (4) and then draw positoning line
e.
3) Cut the tapes between window glasses (1)
and operator's cab (4) with a knife, and then
remove the window glasses.
fl Do not remove the tapes left on the win-
dow glasses and operator's cab before
installing the window glasses.
012406
5. Apply adhesive.
8 adhesive:
Sikaflex 256HV manufactured by
Sika Japan
fl Do not use prim7er.
fl The using limit of the adhesive is 6 months
after the date of manufacture. Do not use
the adhesive after this limit.
fl Keep the adhesive in a dark place where
the temperature is below 25°C.
fl Never heat the adhesive higher than 30°C.
fl When reusing the adhesive, remove the all
hardened part from the nozzle tip.
1) Break aluminum seal (6) of the outlet of
adhesive cartridge (5) and install the nozzle.
30-212-7
(8)
2) Cut the tip of the adhesive nozzle (7) so that

dimensions f and g will be as follows.
• Dimension f : 10 mm
• Dimension g: 15 mm
3) Set adhesive cartridge (5) to caulking gun

[7].
fl An electric caulking gun is more efficient.
012406
4) Remove release tape of the both-sided ad-
hesive tape (3a) on the glass side.
5) Apply adhesive (8) to the outside of both-

sided adhesive tape (2) of the operator's cab.
30-212-8
(8)
fl Apply adhesive (8) to dimension h and j

of both-sided adhesive tape (2) of op-
erator's cab (4).
• Dimension h : 10 mm
• Dimension j : 15 mm
fl Apply adhesive (8) higher than both-sided
adhesive tape (2).
fl Apply the adhesive evenly.
6. Install the front window glass.

1) Using tool X1, match front window glass
(1) to line e on positioning tapes [6] drawn
in step 5 and install it to operator's cab (4).
fl Since the window glass cannot be re-
moved and stuck again, stick it very care-
fully.
fl Stick the glass within 5 minutes after ap-
plying the adhesive.
2) After sticking the window glass, press all
012406
around it until it is stuck to the both-sided

adhesive tape.
fl Press the corners of the window glass
firmly.
3) Mask front window glass (1) and operator's
cab (4) with masking tapes [8].
4) Fill the clearance between front window
glass (1) and operator's cab (7) with caulk-
ing material (14) all around the window.
8 Caulking material:
SEKISUI SILICONE SEALANT
fl The using limit of the caulking material is
6 months after the date of manufacture.
Do not use the caulking material after
this limit.
30-212-9
(8)
5) After applying caulking material (9) to front

window glass (1), form it with the fingers as
shown in the following figure.
fl Use rubber spatula [9] to form the caulk-
ing material around the handrail, etc.
where it is difficult to form with the fin-
gers.
012406
30-212-10
(8)
7. Fix the window glasses (1).

1) Using styrene foam blocks [10] and rubber
bands [11], fix the front window glass to fit
it completely.
fl You may use sealing tapes to fix the front
window glass.
(The figure shows the operator's cab of a
hydraulic excavator.)
8. After installing the window glasses, remove the

primer and adhesive from them and the opera-
tor's cab.
fl Using white gasoline, wipe off the adhesive
before it is dried up.
fl When cleaning the glasses, do not give an
impact to them.
9. Protect the stuck window glasses.

1) Keep the stopper rubbers, styrene foam
012406
blocks, and rubber bands installed for 10

hours (at temperature of 20°C and humidity
of 65%).
2) After applying the adhesive, wait for a least
24 hours, before operating the machine ac-
tually.
30-212-11
(8)
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
REMOVAL OF FLOOR FRAME

ASSEMBLY
¤ Close the fuel supply piping valve.
1. Remove ROPS roof and guard.
For details, see REMOVAL OF ROPS ROOF,
GUARD.
2. Remove operator’s cab assembly. CED00082
For details, see REMOVAL OF OPERATOR CAB

ASSEMBLY.
3. Drain coolant.
4. Remove hood assembly. 2

3
BLY.
5. Lift off operator’s seat (1).
Operator’s seat: 45 kg
012406
6. Remove inside covers (bottom, left, right) of CED00083
floor frame.
7. Disconnect connectors (2) (CN-8) and (3) (CN- 8

21), from right side of engine. 7
9
4 5
8. Disconnect connectors (4) (CN-17) and (5) (CN-
20), from right side of engine, then remove bolts
(6) tightening holder and clamp.
9. Disconnect connector (7) (CN-18).
10. Disconnect 3 starting motor wires (8).

10 6
CED00084
11. Remove connector (9) (CN-66) from holder.
12. Remove 3 clamp bolts (10).
13. Disconnect 2 ground harness (11) from left side 13

of floor frame. 11

12
15. Remove bracket (13) of fuse box.
fl This is in order to remove the gear shift 14
lever cable.
16. Disconnect battery (+) wiring harness (14). 11

CED00085
30-213
(8)
17. Disconnect 2 gear shift lever cables (15) from

frame. 1
15
CED00086
18. Disconnect fuel control rod (16), then discon-

nect clutch assembly (17) from frame. 2 16
17
012406
CED00087
19. Disconnect 6 steering PPC hoses (18).

fl Make match marks on each hose.
18
CED00089
20. Disconnect main control valve control rods (19).

3 19
21. Disconnect safety rod (20).

fl Although the type of the turnbuckles on
D41E-6 and D41P-6, Serial No. 50201 and
up, is different from this illustration, they
can be removed and installed basically by
the procedure explained here. 20
CED00088
30-214
7
22. Remove mounting bolts of center floor plate.
23. Remove decelerator pedal, and disconnect de- 21

celeration cable (21).
CDD00090
24. Disconnect brake rod (22) and inching rod (23)

at turnbuckle.
23 22
012406
CED00091
26. Disconnect parking brake cable (24).
24
CED00092
27. Disconnect connector (25) from holder.
25
26
CED00093
30-215
(9)
29. Disconnect 2 air conditioner hoses (27).

the air conditioner gas (R134a) completely 27
28
30. Disconnect 2 heater hoses (28).
CED00094
31. Remove dashboard mounting bolts (29) (2 each

on left and right). 29
012406
CED00095
32. Remove floor frame mount bolts (30). 30
CDD00096
33. Lift off floor frame assembly (31).
Floor frame assembly: 350 kg 31
CED00097
30-216
(9)
INSTALLATION OF FLOOR
FRAME ASSEMBLY
removal.
fl Adjust the gear shift lever linkage.

For details, see, Adjusting gear shift lever
linkage.
fl Adjust the fuel control linkage.

Adjusting fuel control linkage.
fl Adjust the main control valve control link-

age.
Adjusting main control valve control link-
age.
fl Adjust the decelerator pedal.

For details, see Adjusting decelerator pedal.
fl Adjust the inching and brake pedals.

012406
For details, see Adjusting inching, brake

pedal linkage.
fl Adjust the parking brake lever linkage.

For details, see Adjusting parking brake link-
age.

ference.
circuit when installing the hose.
fl Check that there is an O-ring at the piping O-ring
CED00016
Tightening torque
11.8 – 14.7 Nm
16 x 1.5 (1.2 – 1.5 kgm)
19.6 – 24.5 Nm
22 x 1.5 (2.0 – 2.5 kgm)
29.4 – 34.3 Nm
24 x 1.5 (3.0 – 3.5 kgm)

30-217
(9)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
REMOVAL OF AIR
CONDITIONER COMPRESSOR
ASSEMBLY
¤ Bleed refrigerant gas from air conditioner. 2
1. Open engine left side cover (top), and remove

cover (bottom). 3
2. Remove wiring connector (1) (CN-14).

CED00043
3. Disconnect hoses (2) and (3). 1
the air conditioner gas (R134a) completely
fl Fit blind plugs to prevent dirt or water from 7
4. Loosen 4 mounting bolts (4).
5. Loosen adjustment bolt (5), and remove V-belt 6 4

(6) from pulley.
5
6. Remove air conditioner compressor assembly
012406
(7). 2
CED00044
30-218
(8)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
INSTALLATION OF AIR
CONDITIONER COMPRESSOR
ASSEMBLY
removal.

ference.
O-ring
circuit when installing the hose. CED00016
Tightening torque
11.8 – 14.7 Nm
16 x 1.5 (1.2 – 1.5 kgm)
19.6 – 24.5 Nm
22 x 1.5 (2.0 – 2.5 kgm)
012406
29.4 – 34.3 Nm
24 x 1.5 (3.0 – 3.5 kgm)
fl After installing the V-belt, adjust the belt

tension.
Testing and adjusting air conditioner com-
pressor belt tension.

30-219
(9)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER
REMOVAL OF AIR
CONDITIONER CONDENSER
ASSEMBLY 1
1. Open cover (1).
2. Disconnect air conditioner hoses (2) . 1

the air conditioner gas (R134a) completely CED00046
3. Remove mounting bolts, then tilt air conditioner

condenser assembly (3), and disconnect relay
(4), wiring harness clamp (5) and connectors
(6). 6
2
4. Remove air conditioner condenser assembly (3).
012406
CED00047
3
5
CED00048
30-220
(8)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER
INSTALLATION OF AIR
CONDITIONER CONDENSER
ASSEMBLY
removal.

ference.
fl Be careful not to let any dirt, dust, or water O-ring
circuit when installing the hose. CED00016
Tightening torque
11.8 – 14.7 Nm
16 x 1.5 (1.2 – 1.5 kgm)
19.6 – 24.5 Nm
22 x 1.5 (2.0 – 2.5 kgm)
012406
29.4 – 34.3 Nm
24 x 1.5 (3.0 – 3.5 kgm)
• Refilling with water

Add water through water filler to the specified
level.
fl Run the engine to circulate the water
through the system. Then check the water
level again.

30-221
(9)
DISASSEMBLY AND ASSEMBLY MONITOR
REMOVAL OF MONITOR
ASSEMBLY
1. Open cover (1) and disconnect connector (2),

then remove monitor assembly (3).
3
CED00121
INSTALLATION OF MONITOR
ASSEMBLY 1
• Carry out installation in the reverse order to 2
removal.
012406
CED00122
30-222
DISASSEMBLY AND ASSEMBLY DT CONNECTOR PIN
REMOVAL OF DT CONNECTOR
PIN
1. Using needle-nose pliers, tweezers, or pulling

tool X1, pull out wedge (1) from DT connector.
(Male side is shown in photo at right.)
2. Removing contact fixing claw (2) form contact

in connector with a flat-head screwdriver, tweez-
ers, or pulling tool X1, pull out wire and unlock
fixing claw.
012406
3. Pressing seal driver (grommet) (3), pull out wire

(4).
30-223
(9)
INSTALLATION OF DT
CONNECTOR PIN
1. Hold wire (4) by rear 30-mm part of crimped

contact with fingers.
2. Insert wire (4) in grommet of connector.

fl Insert the contact at the end of wire (4)
straight in the hole of the grommet until a
click is heard.
fl Insert the wire until a click (made when the
contact passes the fixing claw) is heard and
you feel the contact touch the bottom.
fl Pull the wire lightly in the pulling out direc-
tion to make sure that the contact at the
wire end will not be removed.
012406
3. After inserting the all wires, install wedge (1).
fl Install both male and female 3-pole pin con-

nectors with the arrows of the wedges in
the direction to the fitting parts of the con-
nector housing. (The male side is shown in
the picture at right.)
30-224
(9)
REMOVAL OF HD CONNECTOR
PIN
1. Select proper tool matching to wire size from

"Special tools list" and install it to wire from
which you are removing pin.
2. Slip in tool X1 between wire and connector seal

driver (1) until it touches contact and cannot go
any more.
fl Use a tool a little larger than the wire.
fl Take care not to break the contact
3. Pull out tool X1 and wire (2) together.

012406
INSTALLATION OF HD
CONNECTOR PIN
1. Hold wire (2) by rear 30-mm part of crimped

contact with fingers.
2. Insert wire in grommet of connector.

fl Insert the contact straight in the hole of the
grommet until a click is heard.
fl Insert the wire until a click (made when the
contact passes the fixing claw) is heard and
you feel the contact touch the bottom.
fl Pull the wire lightly in the pulling out direc-
tion to make sure that the contact at the
wire end will not be removed.
30-225
(9)
DISASSEMBLY AND ASSEMBLY REPAIR PROCEDURE FOR WIRING HARNESS
REPAIR PROCEDURE FOR

WIRING HARNESS
1. Remove cover from wire.

fl For the length of the part to be stripped, see
the following table.
Wire size Length to be

JIS SAE stripped (mm)
0.5 2 – 24AWG 3.96 – 5.54
0.5 – 0.85 16 – 20AWG 6.35 – 7.92
1.25 – 2.0 14 – 16AWG 6.35 – 7.92
2.0 – 3.0 12 – 14AWG 5.64 – 7.21
8.0 8 – 10AWG 10.9 – 12.5
15.0 6AWG 10.9 – 12.5
2. Remove pin (1) of crimping tool X2.
3. Raise and turn knob (2) to select a size match-

ing to the wire (The AWG sizes in the above
table are indicated on tool X2).
012406
4. Loosen locknut (3) and turn adjustment screw
(4).
5. Insert contact (5) in crimping tool X2.

fl Set the top of contact (5) flush with top a of
the tool by turning adjustment screw (4),
then tighten locknut (3).
6. Insert wire (6) in contact (5).
7. Hold handle to crimp contact.

fl Operate the handle to the stroke end, and it
opens automatically.
30-226
(9)
MAINTENANCE STANDARD
40 MAINTENANCE STANDARD
Damper, universal joint ............................... 40- 2

Hydraulic+power train pump ...................... 40- 3
Transmission ................................................ 40- 5
Transmission control valve ......................... 40-11
Bevel gear shaft, steering clutch,
steering brake ........................................ 40-16
Steering PPC valve ....................................... 40-18
Steering piston ............................................. 40-19
Priority valve ................................................. 40-20
Brake valve ................................................... 40-21
Parking brake cylinder ................................. 40-22
Final drive ..................................................... 40-24
012406
Track frame, recoil spring ........................... 40-26

Idler ................................................................ 40-27
Track roller .................................................... 40-28
Carrier roller ................................................. 40-29
Track shoe .................................................. 40-29-1
Main control valve ....................................... 40-30
Work equipment cylinder ............................ 40-36
Work equipment ........................................... 40-38
40-1
(9)
MAINTENANCE STANDARD DAMPER, UNIVERSAL JOINT
DAMPER, UNIVERSAL JOINT
3 66.2±7.4Nm
(6.75±0.75kgm)
012406
1
SDD00889
Unit: mm
No. Check item Criteria Remedy
Outside diameter of oil Standard size Tolerance Repair limit

1 Correct
seal contact surface of 0
65 64.9 or replace
coupling –0.046
Face runout, radial runout Face runout: Max. 1.0 (at ø115.06), Radial runout: Max. 1.5
— (When damper output shaft and transmission input shaft Adjust
of coupling are rotated at the same time)
40-2
MAINTENANCE STANDARD HYDRAULIC+POWER TRAIN PUMP
HYDRAULIC+POWER TRAIN PUMP

SAR (2) 36 + 28
1 1
4 2 2
3 3
012406
3 117.7±19.6Nm 3 66.7±6.9Nm 3 117.7±19.6Nm

(12±2kgm) (6.8±0.7kgm) (12±2kgm)
SED00890
Unit: mm
Type Standard clearance Clearance limit

1 Side clearance SAR (2) 36
0.100 – 0.150 0.19
SAR (2) 28
Clearance between inside dia- SAR (2) 36
2 meter of plain bearing and 0.06 – 0.125 0.20
outside diameter of gear shaft SAR (2) 28
Replace
Type Standard size Tolerance Repair limit
3 Depth of drive in pin SAR (2) 36 0
12 —
SAR (2) 28 –0.5
4 Rotating torque of spline 5.9 – 135.3 Nm (0.6 – 13.8 kgm)

shaft
Standard Permissible
Type Rotating Discharge discharge discharge
speed pressure amount
amount
Discharge amount
– Oil: EO10-CD SAR (2) 36 20.6 MPa —
2 100 ¶/min 93 ¶/min
Oil temperature: 45 – 55°C {210 kg/cm }
3,000 rpm
SAR (2) 28 2.9 MPa
2 81 ¶/min 72 ¶/min
{30 kg/cm }
40-3
(9)
MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION
(1/3)
Y
012406
3 24.5±4.9Nm
(2.5±0.5kgm)
A
Y
C C
A
3 277.0±31.9Nm
(28.25±3.25kgm) SDD00891
40-5
(9)
(2/3)
11 10 9 1 7
3 30.5±3.5Nm
(3.15±0.35kgm)
3 66.5±7.5Nm
(6.75±0.75kgm)
3
176.5±19.5Nm
(18±2kgm)
012406
64±5Nm
(6.5±0.5kgm)
3 269.5±24.5Nm
(27.5±2.5kgm)
2a 2b 12 3a 12 3b 4 13 14 5 15 6
No.1 No.2 No.3 No.4 No.5
R F 3rd 2nd 1st

A-A
8
C-C
SAD00892
40-6
(9)
Unit: mm
Standard Tolerance Standard Clearance

Clearance between size Shaft Hole clearance limit
1 lubrication valve piston
and clutch housing –0.020 +0.027 0.020 –
12.0 0.077
–0.030 0 0.057
Standard size Repair limit
Free Installed Installed Free Installed
2a No. 1 clutch spring length length load length load
(large) (x5)
111.8 N 95.1 N
25.0 23.1 23.5
(11.4 kg) (9.7 kg)
2b No. 1 clutch spring 17.55 10.9

111.8 N
16.5
95.1 N
(small) (x5) (11.4 kg) (9.7 kg)
3a No. 2 clutch spring 18.65 16.8

67.7 N
17.5
57.9 N
(large) (x5) (6.9 kg) (5.9 kg)
3b No. 2 clutch spring 22.93 11.8

67.7 N
21.6
57.9 N
(small) (x5) (6.9 kg) (5.9 kg)
4 No. 3 clutch spring (x5) 108.8 N 92.2 N

29.0 21.6 27.3
(11.1 kg) (9.4 kg)
012406

23.7 15.1 22.3
(12.0 kg) (10.2 kg)

35.0 25.4 32.9
(10.5 kg) (8.9 kg)
18.9 N 17.9 N Replace

7 Lubrication valve spring 25.4 23.6 24.6
(1.93 kg) (1.83 kg)
8 Cooler bypass valve spring 45.4 N 43.1 N

34.3 20.3 33.3
(4.63 kg) (4.4 kg)
Standard size Tolerance Repair limit
9 Thickness of clutch disc
3.0 ±0.1 2.5
10 Thickness of clutch plate 3.2 ±0.1 2.9
Thickness of pressure
11 3.2 ±0.1 2.9
plate
No. 1,2 clutch overall
12 assembly thickness 31.0 ±0.32 28.3
(disc, plate: 5 each)
No. 3 clutch overall
(disc x 3, plate x 4)
40-7
(3/3)
012406
40-8
(9)
Unit: mm
Width 4.5 –0.01

Dimensions of 4.05
–0.03
16 No. 1 housing
seal ring
Thickness 5.2 ±0.12 5.05
Width 4.5 –0.01 4.05

Dimensions of –0.03
17 No. 2, 3 carrier
seal ring
Thickness 5.6 ±0.15 5.45
–0.01 Replace
Width 4.0 3.60
18
cage seal ring
012406
Thickness 4.6 ±0.12 4.35
Width 2.375 0 2.14

19 output shaft
seal ring
Thickness 2.2 ±0.1 2.05
Outside diameter of input

20 coupling oil seal contact 90.0 0 89.9 Repair hard
surface –0.087
chrome
Outside diameter of output plating
21 shaft oil seal contact 75.0 0 74.9 or replace
surface –0.074
Backlash between No. 1 –
22 No. 4 sun gear and 0.10 – 0.27
planetary pinion
Backlash between No. 1 –
23 No. 4 planetary pinion and 0.11 – 0.29
ring gear
Backlash between PTO
24 drive gear and pump drive 0.14 – 0.36 Replace
gear
25 Backlash between bevel 0.18 – 0.23

pinion and bevel gear
26 Side clearance of No. 1 – 0.35 – 0.80 (Both sides)

No. 4 planetary pinion
Standard shim thickness
27 between bearing cage and 0.7
seal cage
Adjust shim
28 between bearing cage and 1.0
rear housing
40-9
(9)
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
TRANSMISSION CONTROL VALVE

(1/3)
3 30.5±3.5Nm 3 30.5±3.5Nm
(3.15±0.35kgm) (3.15±0.35kgm)
D
D
012406
3 24.5±9.8Nm 3 30.5±3.5Nm
(2.5±1kgm) (3.15±0.35kgm)
3 14.7±4.9Nm 3 11.25±1.45Nm 3 24.5±9.8Nm

(1.5±0.5kgm) (1.15±0.15kgm) (2.5±1kgm)
C C
B B
3 14.7±4.9Nm
(1.5±0.5kgm)
A
3 30.5±3.5Nm
(3.15±0.35kgm)
SDD00894
40-11
(9)
(2/3)
2 8 9 3 7 4
10
A-A
6 11 5
012406
1
3 39.2±4.9Nm
(4.0±0.5kgm)
3 30.5±3.5Nm
(3.15±0.35kgm)
3 17.15±2.45Nm 1
(1.75±0.25kgm)
B-B SDD00895
40-12
(9)
Unit: mm

1 directional spool, speed
spool and valve body –0.020 +0.011 0.020 –
14.0 0.061
–0.030 0 0.041
012406
Clearance between –0.035 +0.013 0.035 –

2 modulating load piston 28.0 0.078
and valve body –0.045 0 0.058
3 modulating valve and 22.0 0.078
valve body –0.045 0 0.058
4 modulating valve 12.0 0.068
and piston –0.030 0 0.048
5 quick return valve and 25.0 0.253
valve body –0.200 0 0.233 Replace
6 quick return valve and 14.0 0.076
valve body –0.045 0 0.056

Modulating valve piston length length load length load
7
spring
5.70 N 5.4 N
26.0 19.0 25.2
{0.581 kg} {0.55 kg}
Modulating valve spring 253.8 N 241.1 N

8 64.0 41.5 62.1
(large) {25.88 kg} {24.59 kg}
Modulating valve spring 46.8 N 44.4 N

9 60.5 41.5 58.7
(small) {4.77 kg} {4.53 kg}
10 (inside load piston) at 1.0 (adjustment in pressure for each 0.5 mm shim:
modulating valve spring 61.7 KPa {0.629 kg/cm2})
Adjust shim
11 (valve end) at modulating 0.0 (adjustment in pressure for each 0.5 mm shim:
valve spring 11.9 KPa {0.121 kg/cm2})
40-13
(9)
(3/3)
012406
40-14
(9)
Unit: mm

012406

size Shaft Hole clearance limit
Clearance between
12 inching spool and cover
0 +0.027
14.0 0 – 0.054 0.074
–0.027 0
13 inching valve and valve 25.0 0.078
body –0.045 0 0.058

14 10.0 0.065
inching valve and piston –0.030 0 0.045

15 21.0 0.151
inching valve and stopper –0.110 0 0.131 Replace
Inching valve spring length length load length load
16
(spool end)
24.5 N 23.3 N
22.0 18.0 21.3
{2.5 kg} {2.38 kg}
Inching valve spring 76.4 N 72.7 N

17 33.9 20.0 32.9
(valve end) {7.8 kg} {7.41 kg}
Inching valve piston spring 5.7 N 5.4 N

18 26.0 19.0 25.2
{0.58 kg} {0.552 kg}
18 Standard shim thickness 1.0 (adjustment in pressure for each 0.5 mm shim:
at inching valve spring 35.0 KPa {0.357 kg/cm2})
Adjust shim
Standard shim thickness 1.0 (adjustment in pressure for each 0.5 mm shim:
20
at inching valve cover 18.3 KPa {0.187 kg/cm2})
40-15
(9)
MAINTENANCE STANDARD BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE
BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE

D41E, P-6 Serial No.: B20001 - B20500
3 25.5±2.0Nm 3 66.2±7.4Nm
(2.6±0.2kgm) (6.75±0.75kgm)
1 2 7
012406
3 4 5 6 8
3 110.3±12.3Nm 3 66.2±7.4Nm
(11.25±1.25kgm) (6.75±0.75kgm)
SAD00897
40-16
(9)
Unit: mm

Thickness of brake plate Replace
5.0 4.7
1
Tolerance Repair limit
012406
Correct
Distortion of brake plate
Within 0.3 0.6 or replace

2 Thickness of brake lining
6.3 5.0
Replace
Thickness of clutch plate
5.0 4.7
3
Correct
Distortion of clutch plate or replace
Within 0.3 0.6

4 Thickness of clutch lining
6.0 5.0
Standard clearance Clearance limit

Backlash between sun Replace
5
gear and planetary pinion 0.13 – 0.33 —
Clearance between
6 planetary pinion and 0.15 – 0.35 —
ring gear
7 Backlash between bevel Adjust

0.18 – 0.25 —
gear and pinion or replace
Standard shim thickness: 2.0
Reference when assembling new bearing
8 Preload of taper roller Starting torque: 2.4 – 3.9 Nm {0.24 – 0.40 kgm}
Adjust
bearing of bevel gear shaft
Load at tip of bevel gear teeth: 13.7 – 22.6 N {1.4 – 2.3 kg}
40-17
1
012406
40-2
40-17-1
(9)
Unit: mm

Thickness of brake plate Replace
5.0 4.7
1
012406
Correct
Distortion of brake plate
Within 0.3 0.6 or replace

2 Thickness of brake lining
6.3 5.5
Replace
Thickness of clutch plate
5.0 4.7
3
Correct
Distortion of clutch plate or replace
Within 0.3 0.6

4 Thickness of clutch lining
6.0 5.5

Backlash between sun Replace
5
gear and planetary pinion 0.13 – 0.33 —
Clearance between
6 planetary pinion and 0.15 – 0.35 —
ring gear
7 Backlash between bevel Adjust

0.18 – 0.25 —
gear and pinion or replace
Standard shim thickness: 2.0
Reference when assembling new bearing
8 Preload of taper roller Starting torque: 2.4 – 3.9 Nm {0.24 – 0.40 kgm}
Adjust
bearing of bevel gear shaft
Load at tip of bevel gear teeth: 13.7 – 22.6 N {1.4 – 2.3 kg}
40-3
40-17-2
(9)
MAINTENANCE STANDARD STEERING PPC VALVE
STEERING PPC VALVE
012406
Unit: mm

Free length Installed Installed Free Installed
1 Metering spring x O.D. length load length load
(ports P1, P2)
2.8 N 2.2 N
25.07 x 8.14 24.9 —
{0.282 kg} {0.226 kg} Replace
spring if
Metering spring 2.8 N 2.2 N damaged
2 25.1 x 8.14 24.9 —
(ports P3, P4) {0.282 kg} {0.226 kg} or deformed
Centering spring 17.7 N 14.1 N

3 42.48 x 15.5 34 —
(ports P1, P2) {1.8 kg} {1.44 kg}
4 Centering spring 50.35 x 15.5 34

55.9 N
—
44.7 N
(ports P3, P4) {5.7 kg} {4.56 kg}
40-18
6
MAINTENANCE STANDARD STEERING PISTON
STEERING PISTON
012406
Unit: mm

Clearance between
1 cylinder and brake piston
–0.030 +0.025 0.030 –
45 0.1 Replace
–0.060 0 0.085

2 40 0.1
cylinder and clutch piston –0.060 0 0.085
40-19
(9)
MAINTENANCE STANDARD PRIORITY VALVE
PRIORITY VALVE
4 3 68.6±9.8Nm
(7±1kgm)
3 68.6±9.8Nm
(7±1kgm)
3 1 2 5
012406
SDD00900
Unit: mm

Clearance between
1 priority valve and body
–0.035 +0.013 0.035 –
19 0.08
–0.045 0 0.058

2 12 0.07
priority valve and piston –0.03 0 0.048

Free Installed Installed Free Installed Replace
Priority valve spring length length load length load
3
(large)
137.8 N 130.4 N
60.6 37.5 58.8
(14.05 kg) (13.3 kg)
Priority valve spring 115.3 N 109.8 N

4 (small) 53.5 37.5 51.9
(11.76 kg) (11.2 kg)
Priority valve spring 5.7 N 5.4 N

5 26 19 25.2
(0.58 kg) (0.55 kg)
40-20
MAINTENANCE STANDARD BRAKE VALVE
BRAKE VALVE
012406
Unit: mm

Clearance between
1 brake valve and body
–0.020 +0.021 0.020 –
19 0.07
–0.030 0 0.051

2 9 0.08
brake valve and piston –0.04 0 0.055
3 parking brake valve 19 0.08
and body –0.043 0 0.056

Free Installed Installed Free Installed Replace
4 Brake modulating spring length length load length load
48.2 N 46.1 N
39.55 36 38.4
(4.92 kg) (4.7 kg)
Brake valve return spring 146.7 N 139.3 N

5 52 39 50.4
(14.96 kg) (14.2 kg)
Parking brake valve return 16.7 N 15.7 N

6 spring 36.5 28.5 35.4
(1.7 kg) (1.6 kg)
40-21
(9)
MAINTENANCE STANDARD PARKING BRAKE CYLINDER
PARKING BRAKE CYLINDER
3 71±17.2Nm
(7.25±1.75kgm)
012406
3 71±17.2Nm
(7.25±1.75kgm) 2 1 SDD00902
Unit: mm

1 parking brake cylinder
and body –0.030 +0.030 0.030 –
70 0.11
–0.060 0 0.090
Standard size Repair limit Replace
2 Parking brake spring length length load length load
4.88 KN 4.64 KN
256 190 248.3
{498 kg} {473 kg}
40-22
(9)
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
D41E, P-6 Serial No.: B20001 - B20500 fl The diagram shows the D41P-6.
012406
40-24
(9)
012406 MAINTENANCE STANDARD FINAL DRIVE
Unit: mm
Wear of sprocket tooth Standard size Tolerance Repair limit

1 tip diameter
708.7 ±2.0 697
Wear of sprocket tooth 0

2 633.2 619
root diameter –5 Rebuild
Standard size Repair limit or replace
Wear of sprocket tooth
3
tip width 40 32
4 Wear of sprocket tooth 62 54

root width
Outside diameter of No. 1
5 pinion oil seal contact 75 74.9
surface
Replace
6 Backlash between No. 1
0.22 — 0.52
pinion and No. 1 gear

7 Thickness of tread Rebuild
20.6 – 13.5 or replace
40-25
1
MAINTENANCE STANDARD FINAL DRIVE
012406
40-4
40-25-1
(9)
012406 MAINTENANCE STANDARD FINAL DRIVE
Unit: mm
Wear of sprocket tooth Standard size Tolerance Repair limit

1 tip diameter
708.7 ±2.0 697
ª1 633.2 619
Wear of sprocket tooth 0
2
root diameter –5 Rebuild
ª2 628.8 614.5
or replace
Wear of sprocket tooth
3
tip width 40 32
4 Wear of sprocket tooth 54

62
root width
Outside diameter of No. 1
5 pinion oil seal contact 75 74.9
surface
Replace
6 Backlash between No. 1
0.22 — 0.52
pinion and No. 1 gear
7 Thickness of tread ª1 20.6 13.5 Rebuild

– or replace
ª2 28.4 11
ª 1: Serial No. B20501 – 50200

ª 2: Serial No. 50201 and up
40-5
40-25-2
6
MAINTENANCE STANDARD TRACK FRAME, RECOIL SPRING
TRACK FRAME, RECOIL SPRING

D41E-6 Serial No.: B20001–B20980 fl The diagram shows the D41E-6.
D41P-6 Serial No.: B20001–B20983
012406
Unit: mm
Item Repair limit

Curvature 7 (for every length of 3,000)
1 Deformation of track frame Correct
Torsion 3 (for every length of 300)
Opening of idler 5
2 Recoil spring x O.D. length load length load Replace
88.5 KN 78.8 KN
557 x 193 443 544
{9,028 kg} {8,035 kg}

Replace
3 adjustment cylinder
bushing
and bushing –0.030 +0.270 0.091 –
65 1.0
–0.078 +0.061 0.348
40-26
(9)
MAINTENANCE STANDARD IDLER
IDLER
D41E-6 Serial No.: B20001–B20980
D41P-6 Serial No.: B20001–B20983
Unit: mm

012406
Outside diameter of idler

1
protruding portion 527 —
2 Outside diameter of idler 471

489
tread surface Rebuild
or replace
3 Width of idler protruding 60
69
portion
4 Width of idler tread 39

34.5
surface
5 Overall width of idler 138 128

Clearance between shaft size Shaft Hole clearance limit
Replace
6 and bushing
bushing
–0.250 +0.074 0.250 –
54 1.5
–0.280 0 0.354

7 Play in axial direction
0.06 – 0.5 (one side) 1.5
Clearance between guide Replace

8 0.29 – 2.71 5.0
plate and frame plate
Clearance between support

9 0.7 – 4.5 7.0
and frame plate

18 9 or replace
40-27
(9)
MAINTENANCE STANDARD IDLER
IDLER
D41E-6 Serial No.: B20981 – B40000, 50001and up
D41P-6 Serial No.: B20984 – B40000, 50001and up
Unit: mm

012406
Outside diameter of idler

1
protruding portion 527 —
2 Outside diameter of idler 471

489
tread surface Rebuild
or replace
3 Width of idler protruding 69 60
portion
4 Width of idler tread 39

34.5
surface
5 Overall width of idler 138 128

Replace
6 and bushing
bushing
–0.250 +0.074 0.250 –
54 1.5
–0.280 0 0.354

7 Play in axial direction
0.06 – 0.5 (one side) 1.5
Clearance between guide Replace

8 1.0 3.0
plate and frame plate
Clearance between support

9 2.0 5.0
and frame plate

18 9.0 or replace
40-27-2
40-7
(9)
MAINTENANCE STANDARD TRACK ROLLER
TRACK ROLLER
Serial No.: B20001 – B40000
Serial No.: 50001 – 50074
012406
Unit: mm

Outside diameter of
1
track roller 175 150
2 Outside diameter of flange 198 —

(outside) Rebuild
or replace
3 Width of track roller tread 34.5 40.5
surface
4 Width of flange 18 13
Overall width of track

5 178 —
roller

Replace
6 and bushing
bushing
–0.250 +0.030 0.250 –
50 1.5
–0.270 0 0.300

7 Play in axial direction Replace
0.29 – 0.71 (one side) 1.5

59 46.5 or replace
40-28
(9)
MAINTENANCE STANDARD TRACK SHOE
TRACK SHOE
LUBRICATED TRACK LINK (1/2)
SINGLE SHOE, SWAMP SHOE
Serial No.: B20001 – B40000
Serial No.: 50001 – 50200
012406
fl P portion shows the link of bushing press fitting end.
ª1. Single shoe

ª2. Swamp shoe (for D41P)
40-12
40-29-1
(9)
MAINTENANCE STANDARD MAIN CONTROL VALVE
MAIN CONTROL VALVE

3 SPOOL VALVE (BLADE LIFT, TILT, ANGLE)
D41E,P-6
(1/5)
3 66.2±7.4Nm
(6.75±0.75kgm)
C A D B
E E
J J
X
H H
012406
G
C A F F
D B
X SAD00908
40-30
(9)
(2/5)
3 44.1±4.9Nm
(4.5±0.5kgm)
3 44.1±4.9Nm
(4.5±0.5kgm)
012406
3 147±9.8Nm A-A
(15±1kgm)
3 53.9±4.9Nm
(5.5±0.5kgm)
B-B
SAD00909
40-31
(9)
(3/5)
3 139.7±22.1Nm
(14.25±2.25kgm)
2
3
3 139.7±22.1Nm
(14.25±2.25kgm)
C-C 3 39.2±4.9Nm
(4.0±0.5kgm)
3 29.4±4.9Nm
(3.0±0.5kgm) 3
39.2±4.9Nm
(4.0±0.5kgm)
012406
3 23.5±3.9Nm
(2.4±0.4kgm)
3 39.2±4.9Nm E-E
(4.0±0.5kgm) 3 39.2±4.9Nm
(4.0±0.5kgm)
D-D
SAD00910
Unit: mm

Pressure compensation x O.D. length load length load
1 valve spring for lift
55.9 ± 3.3 N 45.1 N Replace
33.4 x 14.4 21.5 — spring if
{5.7 ± 0.34 kg} {4.6 kg}
damaged
Pressure compensation 34.3 ± 2.0 N 27.5 N or deformed
2 valve spring for tilt, angle 31.9 x 14.4 21.5 —
{3.5 ± 0.2 kg} {2.8 kg}
Flow control spring 27.7 ± 2.9 N 22.6 N

3 30.9 x 5.2 20.0 —
for lift {2.82 ± 0.3 kg} {2.3 kg}
40-32
(9)
(4/5)
3 98±9.8Nm
(10±1kgm)
3 39.2±4.9Nm
(4.0±0.5kgm)
3 9.8±2.0Nm
2 (1.0±0.2kgm)
3 1.5±0.2Nm 3 29.4±4.9Nm
(0.15±0.02kgm) (3.0±0.5kgm)
F-F
3 17.2±2.5Nm
4 3 (1.75±0.25kgm)
012406
3 34.5±4.9Nm
(3.5±0.5kgm)
3 168.2±24.0Nm
(17.15±2.45kgm)
G-G
SAD00911
Unit: mm

1 LS selector spring x O.D. length load length load
13.5 ± 0.78 N 10.8 N

24.5 x 9.5 16 —
{1.38 ±0.08 kg} {1.1 kg}
133.4 ± 7.8 N 106.9 N Replace

2 Unload spring 32.1 x 20.7 20 —
{13.6 ± 0.8 kg} {10.9 kg}
3 Lift spool ring 98.1 ± 5.9 N 78.5 N

53.3 x 23.3 33.5 —
{10.0 ± 0.6 kg} {8 kg}
4 Lift detent spring 56.9 ± 3.4 N 45.1 N

27.7 x 8.5 22 —
{5.8 ± 0.35 kg} {4.6 kg}
40-33
(9)
(5/5)
3 17.2±2.5Nm
(1.75±0.25kgm)
3 17.2±2.5Nm
(1.75±0.25kgm)
H-H
012406
2
J-J
SAD00912
Unit: mm

1 Tilt spool spring x O.D. length load length load
98.1 ± 5.9 N 78.5 N Replace

55.7 x 22.3 26.5 —
{10.0 ±0.6 kg} {8 kg}
2 Angle spool spring 49.0 ± 2.9 N 39.2 N

52.4 x 22.1 26.5 —
{5.0 ± 0.3 kg} {4 kg}
40-34
(9)
4 SPOOL VALVE (BLADE LIFT, TILT, ANGLE, RIPPER)

D41E-6
(1/5)
012406
40-22
40-35-1
(9)
(2/5)
012406
40-23
40-35-2
(9)
(3/5)
012406
Unit: mm

Pressure compensation x O.D. length load length load
1 valve spring for lift
55.9 ± 3.3 N 45.1 N
33.4 x 14.4 21.5 —
{5.7 ± 0.34 kg} {4.6 kg}
Pressure compensation 34.3 ± 2.0 N 27.5 N

2 valve spring for tilt, angle, ripper 31.9 x 14.4 21.5 — Replace
{3.5 ± 0.2 kg} {2.8 kg}
Flow control spring 27.7 ± 2.9 N 22.6 N

3 30.9 x 5.2 20.0 —
for lift {2.82 ± 0.3 kg} {2.3 kg}
4 LS selector spring 13.5 ± 0.8 N — 10.8 N

24.5 x 9.5 16.0
{1.38 ± 0.08 kg} {1.1 kg}
5 Unload spring 33.4 ± 7.8 N 100.9 N

32.1 x 20.7 20.0 —
{13.6 ± 0.8 kg} {10.9 kg}
40-24
40-35-3
(9)
(4/5)
012406
Unit: mm
98.0 ± 5.9 N 78.5 N

1 Lift spool spring 53.3 x 23.3 33.5 —
{10.0 ± 0.6 kg} {8 kg}
56.9 ± 3.4 N 45.1 N

2 Lift detent spring 27.7 x 8.5 22 —
{5.8 ± 0.35 kg} {4.6 kg}
Replace
3 Tilt spool spring x O.D. length load length load
98 ± 5.9 N 78.5 N
55.7 x 22.3 26.5 —
{10.0 ±0.6 kg} {8.0 kg}
40-25
40-35-4
(9)
(5/5)
012406
Unit: mm

1 Angle spool spring x O.D. length load length load
4.9 ± 2.9 N 45.1 N Replace

52.4 x 22.1 26.5 —
{0.5 ±0.3 kg} {4 kg}
2 Ripper spool spring 98 ± 5.9 N 78.5 N

55.7 x 22.3 26.5 —
{10.0 ± 0.6 kg} {8 kg}
40-26
40-35-5
(9)
MAINTENANCE STANDARD WORK EQUIPMENT CYLINDER
WORK EQUIPMENT CYLINDER

• BLADE LIFT CYLINDER
• BLADE TILT CYLINDER
012406
• BLADE ANGLE CYLINDER
40-36
(9)
012406 MAINTENANCE STANDARD WORK EQUIPMENT CYLINDER
Unit: mm

–0.025 +0.164 0.032 –

Clearance Lift 50 0.551
–0.087 +0.007 0.251
1 between piston
rod and bushing –0.030 +0.163 0.036 –
Tilt 55 0.567
–0.104 +0.006 0.267
–0.030 +0.262 0.097 –

Angle 65 0.666
–0.104 +0.067 0.366
–0.030 +0.142 0.110 –

Lift 50 1.0
–0.076 +0.080 0.218
Clearance
between piston –0.025 +0.039 0.025 – Replace
2 Tilt 40 0.5
rod bushing –0.064 0 0.103 bushing
and pin
–0.030 +0.039 0.030 –
Angle 50 0.5
–0.076 0 0.115
–0.030 +0.142 0.110 –

Lift 50 1.0
–0.076 +0.080 0.218
Clearance
between –0.025 +0.039 0.025 –
3 Tilt 40 0.5
cylinder bottom –0.064 0 0.103
bushing and pin
Angle –0.030 +0.039 0.030 –
50 0.5
–0.076 0 0.115
40-37
MAINTENANCE STANDARD WORK EQUIPMENT
WORK EQUIPMENT
012406
40-38
(9)
012406 MAINTENANCE STANDARD WORK EQUIPMENT
Unit: mm

1 bushing and tilt cylinder
mounting pin –0.025 +0.039 0.025 –
40 0.5
–0.064 0 0.103
–0.025 +0.039 0.025 –

2 Clearance at ball portion 45
–0.064 0.103
0.5
of tilt link connection 0
Clearance between tilt link –0.025 +0.039 0.025 –
3 and ball portion of blade 40
–0.064 0.103
0.5
connection 0
Clearance between –0.025 0.025 –
+0.039
4 bushing and angle cylinder 50 0.5 Replace
mounting pin –0.087 0 0.126
Clearance between U-frame –0.250 +1.500 0.500 –
5 center cap and ball portion 110 —
of blade connection –0.750 +0.250 2.250
Clearance between –0.025 0.105 –
6 bushing and lift cylinder +0.142
50 1.0
mounting pin –0.064 +0.080 0.206
7 U-frame connection pin 70 1.0
and boss –0.076 0 0.130
8 U-frame connection pin 70 1.0
and frame bushing –0.076 +0.100 0.250
9 Standard shim thickness 3 Adjust

of U-frame center cap
40-39
(9)
MAINTENANCE STANDARD WORK EQUIPMENT
CUTTING EDGE, END BIT
3 260±34Nm
(26.5±3.5kgm)
2 1
012406
3
SDD00918
Unit: mm

1 Height of cutting edge
160 110
Replace
2 Height of end bit 160 110
3 Width of end bit 380 —
40-40
90 OTHERS
Power train hydraulic system diagram .... 90- 3

Power train hydraulic circuit diagram ...... 90- 5
Work equipment hydraulic
sysytem diagram ...................................90- 7
Work equipment hydraulic
circuit diagram ....................................... 90- 9
Actual electric wiring diagram .................. 90- 9 -1

With cab (Serial No.: B20001 – B40000,
50001 – 50200) ......................................... 90-11
With cab (1/2) (Serial No.: 50201 and up) .... 90-11-2
012406
With cab (2/2) (Serial No.: 50201 and up) .... 90-11-4
Without cab (Serial No.: B20001 – B40000,
50001 – 50200) ......................................... 90-13
Cab electrical circuit diagram
(Serial No.: B20001 – B40000,
50001 – 50200) ......................................... 90-15
Cab electrical circuit diagram
(Serial No.: 50201 and up)...................... 90-17
90-1
(9)
OTHERS ACTUAL ELECTRIC WIRING DIAGRAM
ACTUAL ELECTRIC WIRING DIAGRAM

*1. D41E-6 Serial No.: B20981 – B4000
D41P-6 Serial No.: B20984 – B4000
012406
90-9-1
(9)
WITH CAB
Serial No.: B20001 – B40000
Serial No.: 50001 – 50200 *1. Serial N0.: B20501 – B40000
012406
90-11
(9)
WITHOUT CAB
Serial No.: B20001 – B40000
Serial No.: 50001 – 50200 *1. Serial No.: B20501 – B40000
012406
90-13
(9)
OTHERS ELECTRICAL CIRCUIT DIAGRAM
CAB ELECTRICAL CIRCUIT DIAGRAM

Serial No.: B20001 – B40000
Serial No.: 50001 – 50200
012406
90-15
(9)

D41e 6

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SEBM007009

MACHINE MODEL SERIAL NUMBER

• D41E,P-6 mounts the S6D102-1 engine.

01 GENERAL .............................................................................. 01-1

10 STRUCTURE AND FUNCTION ............................................ 10-1

20 TESTING AND ADJUSTING ................................................ 20-1

30 DISASSEMBLY AND ASSEMBLY ....................................... 30-1

40 MAINTENANCE STANDARD............................................... 40-1

‡ Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are not revised at this time.

LIST OF REVISED PAGES

Revision Revision Revision Revision Revision

‡ 00- 8 ‡ 10- 3 (9) 10- 41 ‡ 10- 67 (9) ‡ 20- 2 (9)

30- 90 30-135 30-191 ‡ 40- 11 (9) 90- 9 (1)

‡ 30-120 (9) 30-160 30-212-4 (8) 40- 29 (1)

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

VOLUMES When a manual is revised, an edition mark

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

Slinging near the edge of the hook may cause

• If a part cannot be smoothly removed from the

★ The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Before carrying out the following work, release Type 1

k Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets, rubber

• Used as lubricant for sliding portion (to

STANDARD TIGHTENING TORQUE

6 10 11.8 – 14.7 1.2 – 1.5

16 24 235 – 285 23.5 – 29.5

27 41 1150 – 1440 118 – 147

6 10 5.9 – 9.8 0.6 – 1.0

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat Tightening torque

14 19 24.5 ± 4.9 2.5 ± 0.5

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque (Nm {kgm})

02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Thread diameter Width across flat Tightening torque (Nm {kgm})

08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES

ELECTRIC WIRE CODE

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal

15 84 0.45 13.36 7.0 59 Starting (Glow plug)

40 85 0.80 42.73 11.4 135 Starting

60 127 0.80 63.84 13.6 178 Starting

100 217 0.80 109.1 17.6 230 Starting