Manual D41e-P-6 PDF

SEBM028803
D41E,P -6
MACHINE MODEL SERIAL NUMBER
D41E-6 B40001 and up
D41P-6 B40001 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 SA6D102E-2 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) (3)
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
90 OTHERS ................................................................................ 90-1
00-2 D41E, P-6

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 (3) 10- 9 10-52 10- 97 20-123 (1)

00- 2 10-10 10-53 10- 98 20-124 (1)
‡ 00- 2-1 (3) 10-12 10-54 10- 99 20-125 (1)
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10- 6 10-49 10-94 20-120 (1) ‡ 20-221 (3)
10- 7 10-50 10-95 20-121 (1) ‡ 20-222 (3)
10- 8 10-51 10-96 20-122 (1) ‡ 20-223 (3)
D41E, P-6 00-2-1

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‡ 20-225 (3) 20-308 (1) 20-512 (1) ‡ 30- 52 (3) 30-107 (1)
‡ 20-226 (3) 20-310 (1) 20-513 (1) ‡ 30- 53 (3) 30-108 (1)
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20-241 (1) 20-326 (1) ‡ 30- 10 (3) ‡ 30- 67 (3) 30-123 (1)
20-242 (1) 20-327 (1) 30- 12 (1) ‡ 30- 68 (3) 30-124 (1)
20-243 (1) 20-328 (1) 30- 13 (1) ‡ 30- 69 (3) 30-125 (1)
20-244 (1) 20-329 (1) 30- 14 (1) ‡ 30- 69-1 (3) 30-126 (1)
20-245 (1) 20-330 (1) 30- 15 (1) 30- 70 (1) 30-127 (1)
20-246 (1) 20-331 (1) 30- 16 (1) 30- 71 (1) 30-128 (1)
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fi 20-249 (3) 20-334 (1) 30- 19 (1) 30- 74 (1) 30-131 (1)
fi 20-250 (3) 20-336 (1) 30- 20 (1) 30- 75 (1) 30-132 (1)
fi 20-250-1 (3) 20-337 (1) 30- 21 (1) 30- 76 (2) 30-133 (1)
fi 20-250-2 (3) 20-338 (1) 30- 22 (1) 30- 77 (2) 30-134 (1)
20-251 (1) 20-401 (1) 30- 23 (1) 30- 78 (2) 30-135 (1)
20-252 (1) 20-402 (1) 30- 24 (1) 30- 79 (2) 30-136 (1)
20-253 (1) 20-403 (1) 30- 25 (1) 30- 80 (2) 30-137 (1)
20-254 (1) 20-404 (1) 30- 26 (1) 30- 81 (2) 30-138 (1)
20-255 (1) 20-405 (1) 30- 27 (1) 30- 82 (2) 30-139 (1)
20-256 (1) 20-406 (1) 30- 28 (1) 30- 83 (2) 30-140 (1)
20-257 (1) 20-407 (1) 30- 29 (1) 30- 84 (2) 30-141 (1)
20-258 (1) 20-408 (1) ‡ 30- 30 (3) 30- 85 (1) 30-142 (1)
20-259 (1) 20-409 (1) 30- 31 (1) 30- 86 (1) 30-143 (1)
20-260 (1) 20-410 (1) 30- 32 (1) 30- 87 (1) 30-144 (1)
20-261 (1) 20-411 (1) ‡ 30- 33 (3) 30- 88 (1) 30-145 (1)
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20-263 (1) 20-413 (1) 30- 35 (1) 30- 90 (1) 30-147 (1)
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20-265 (1) 20-415 (1) 30- 37 (1) 30- 92 (1) 30-149 (1)
20-266 (1) 20-416 (1) 30- 38 (1) 30- 93 (1) 30-150 (1)
20-267 (1) 20-417 (1) 30- 39 (1) 30- 94 (1) 30-151 (1)
20-268 (1) 20-418 (1) 30- 40 (1) 30- 95 (1) 30-152 (2)
20-269 (1) 20-419 (1) 30- 41 (1) 30- 96 (1) 30-153 (2)
20-270 (1) 20-501 (1) 30- 42 (1) 30- 97 (1) 30-154 (2)
20-271 (1) 20-502 (1) 30- 43 (1) 30- 98 (1) 30-155 (1)
20-272 (1) 20-504 (1) 30- 44 (1) 30- 99 (1) 30-156 (2)
20-273 (1) 20-505 (1) 30- 45 (1) 30-100 (1) 30-157 (2)
20-301 (1) 20-506 (1) 30- 46 (1) 30-101 (1) 30-158 (1)
20-302 (1) 20-507 (1) 30- 47 (1) 30-102 (1) 30-159 (1)
20-303 (1) 20-508 (1) 30- 48 (1) 30-103 (1) 30-160 (1)
20-305 (1) 20-509 (1) 30- 49 (1) 30-104 (1) 30-161 (1)
20-306 (1) 20-510 (1) 30- 50 (1) 30-105 (1) 30-162 (1)
00-2-2 D41E, P-6

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30-163-1 (2) 40- 40
30-163-2 (2) 40- 41
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30-166 (1) 40- 45
‡ 30-167 (3) 40- 46
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30-169 (1) 40-48
‡ 30-170 (3) 40-49 (1)
‡ 30-171 (3) 40-50
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30-175 (2) 40-55
30-176 (2) 40-56
30-177 (2) 90- 1
30-178 (2) 90- 3
30-179 (2) 90- 4
30-180 (2) 90- 5
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30-182 (2) 90- 9
40- 1 90-11
40- 2 90-13 (1)
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D41E, P-6 00-2-3

(3)
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
01 GENERAL
Specification drawing ................................. 01- 2

Specifications ............................................... 01- 4
Weight table ................................................. 01- 8
Table of fuel, coolant and lubricants ........ 01-10
D41E, P-6 01-1

GENERAL SPECIFICATION DRAWING
SPECIFICATION DRAWING
D41E-6 D41P-6
Item Unit
Standard Width Standard Width
blade blade blade blade
Operating weight with ROPS canopy kg 10,840 10,920 11,410 11,490
(Excluding operator)
with ROPS cab kg 11,410 11,490 11,800 11,880
Engine model — Komatsu SA6D102E-2 diesel engine
Engine rated horsepower kw {HP} 82 {110}
At angle of 0 ° mm 4,880 4,895

A Overall lenth
At max. angle mm 6,210 6,340 6,230 5,805
B Overall height mm 2,900
At angle of 0 ° mm 3,045 3,350 3,045 3,350

C Overall width
At max. angle mm 2,420 2,510 2,490 2,990
Travel speed Forward km/h 2.3 / 4.2 /7.1

(1st/2nd/3rd)
Reverse km/h 2.9 / 5.2 / 8.8
01-2 D41E, P-6

GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model D41E-6 D41P-6
Serial No. B40001 and up B40001 and up
Bare tractor kg 8,710 9,140

Operating
weight
With power angle tiltdozer kg 10,590 11,320

With width blade power angle tilt
kg (12,190) (12,770)
+ Ripper + 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 2.3 2.3

Speed ranges
Forward 2nd km/h 4.2 4.2

Performance
Forward 3rd km/h 7.1 7.1

Reverse 1st km/h 2.9 2.9
Reverse 2nd km/h 5.2 5.2
Reverse 3rd km/h 8.8 8.8
Bare tractor KPa {kg/cm2} 33.67 {0.34} 23.31 {0.24}

pressure
Ground
With power angle tiltdozer KPa {kg/cm2} 40.94 {0.42} 28.89 {0.29}
With width blade power angle
KPa {kg/cm2} (47.13 {0.48}) (32.56 {0.33})
tilt + Ripper + 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 2,675 2,675

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

With ROPS cab installed mm 2,900 2,900
With ROPS canopy installed mm 2,900 2,900
With canopy installed mm 2,780 2,780
Note: The values for the weight and ground pressure in ( ) are reference values.
01-4 D41E, P-6

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 365 365
(to bottom of undercover)
Name SA6D102E-2
Type 4-cycle, water-cooled, in-line, vertical type,
direct injection, with turbocharger
with aftercooler
No. of cylinders – bore x stroke mm 6 – 102 x 120

Piston displacement ¬ {cc} 5.9 {5,900}
Rated horsepower KW/{HP}/rpm 82/{110}/2,300
Performance
Max. torque Nm/{kgm}/rpm 478/{48.7}/1,300

Engine
High idling speed rpm 2,600

Low idling speed rpm 950
Min. fuel consumption
g/KWh{g/HPh} 227 {167}
ratio
Starting motor 24V, 5.5 KW

Alternator 24V, 60A
Battery 12V, 110Ah x 2
Radiator core type 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
D41E, P-6 01-5

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,
single grouser,
700 mm —
44 on each side,
pitch: 171.5 mm
Power train pump Gear type (SAR(2)-28)

Cooling fan drive pump Gear type (SAR(1)-20)
Hydraulic pump Gear type (SAR(2)-36)

Theoretical discharge amount ¬/min 90
2
Max. discharge pressure MPa{kg/cm } 20.6 {210}
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
Hydraulic cylinders

Blade tilt cylinder

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 D41E, P-6

Hydraulic type angle tiltdozer

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

Work equipment
1,020 1,095 (*1)

Performance
Max. lowering depth (from ground) mm 480 405 (*1)

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

Blade height mm 1.060
Blade cutting angle deg 57
*1. The values are dimension from tip of track shoe.
D41E, P-6 01-7

(3)
GENERAL WEIGHT TABLE
WEIGHT TABLE
¤ This weight table is for use when handling components or when transporting the machine.
Unit: kg
Engine, damper assembly 546 546
• Engine assembly 516 516
• Damper assembly 26 26
• Engine mount parts (wiring) 1.5 1.5
Radiator assembly (including oil cooler) 72 72
• Oil cooler assembly (for hydraulic oil) 4.7 4.7
• Fan and fan motor assembly 30 30
Fuel tank assembly 120 120
Universal joint 7 7
Transmission assembly (including valve) 275 275
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
• Idler assembly 144 x 2 144 x 2
• Track roller assembly 35 x 12 35 x 14
• Carrier roller assembly 15 x 2 15 x 2
01-8 D41E, P-6

GENERAL WEIGHT TABLE
Unit: kg
Track shoe assembly (each side)
• 510 mm, single shoe (wet type link) 910 —
• 700 mm, single shoe (wet type link) — 1,175
Hydraulic tank assembly 42 42
Main control valve 25 25

(Lift + tilt + angle)
Operator's seat 45 45
Power angle tiltdozer assembly 1,475 1,475
• Blade 716 716
• Dozer frame 573 573
• Tilt cylinder assembly 30 30
• Angle cylinder assembly 95 95
Blade lift cylinder assembly 35 x 2 35 x 2
Hydraulic, power train pump assembly 13 13

Cooling fan drive pump assembly 5 5
ROPS cab assembly 220 250
FLoor frame assembly 240 240
Cab assembly 410 285
ROPS canopy assembly 350 340
D41E, P-6 01-9

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 86 104 122°F
FLUID –30 –20 –10 0 10 20 30 40 50°C Specified Refill
SAE 30CE,CF-4
SAE 10WCE,CF-4
SAE 10W-30CE,CF-4
Engine oil pan SAE 15W-40CE,CF-4 21.3 19

SAE 5W-40CE,CF-4
SAE 5W-30CE,CF-4
SAE 0W-30CE,CF-4
Damper case SAE 30 1.1 1.1
Engine
Transmission case oil 22 19
SAE 30
Steering clutch case 74 74
SAE 10W
Final drive case (each) 13 13
SAE 10W
Hydraulic oil system SAE 10W-30 80 44
SAE 15W-40
Idler (each) SAE 30 0.165 0.165
Track roller (each) 0.255 0.255

Gear oil GO 140
Carier roller (each) 0.20 0.20
Grease fiting Grease NLGI No.2 — —
Diesel ASTEM D975 No. 2

Fuel tank 250 —
fuel ASTEM D975 No.1
Cooling system
(including sub tank) Coolant Add antifreeze 30 —
01-10 D41E, P-6

GENERAL TABLE OF FUEL, COOLANT AND LUBRICANTS
NOTE:
(1) When fuel sulphur content is less than 0.5%,
change oil in the oil pan every periodic main-
tenance hours described in this manual.
Change oil according to the following table
if fuel sulphur content is above 0.5%.
Change interval of oil in

Fuel sulphur content
engine oil pan
0.5 to 1.0% 1/2 of regular interval
Above 1.0% 1/4 of regular interval
(2) When starting the engine in an atmospheric

temperature of lower than 0°C, be sure to
use engine oil of SAE10W, SAE10W-30 and
SAE15W-40, even though an atmospheric
temperature goes up to 10°C more or less in
the day time.
(3) Use API classification CD as engine oil and if
API classification CC, reduce the engine oil
change interval to half.
(4) There is no problem if single grade oil is
mixed with multigrade oil (SAE10W-30, 15W-
40), but be sure to add single grade oil that
matches the temperature in the table on the
left.
(5) We recommend Komatsu genuine oil which
has been specifically formulated and ap-
proved for use in engine and hydraulic work
equipment applications.
fl Use API classification CD, CE or CF-4 as en-
gine oil.
ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Institute
Specified capacity: Total amount of oil includ-

ing oil for components and
oil in piping.
Refill capacity: Amount of oil needed to refill
system during normal inspection
and maintenance.
D41E, P-6 01-11

10 STRUCTURE AND FUNCTION
Radiator, oil cooler .................................... 10- 2

Engine control ............................................ 10- 4
Power train ................................................. 10- 6
Power train system ................................... 10- 7
Power train hydraulic piping drawing .... 10- 8
Damper, universal joint ............................ 10- 9
Transmission control ................................. 10- 10
Transmission .............................................. 10- 12
Transmission control valve ...................... 10- 21
Steering, brake, inching control .............. 10- 30
Bevel gear shaft, steering clutch,
steering brake ...................................... 10- 32
Steering ppc valve ..................................... 10- 42
Steering piston ........................................... 10- 46
Priority valve .............................................. 10- 47
Brake valve ................................................. 10- 49
Power train oil filter .................................. 10- 53
Final drive ................................................... 10- 54
Frame assembly ......................................... 10- 56
Track frame ................................................ 10- 57
Recoil spring .............................................. 10- 58
Work equipment hydraulic piping diagram ... 10- 59
Work equipment control ........................... 10- 60
Hydraulic tank, filter .................................. 10- 62
Main control valve ..................................... 10- 64
Clss .............................................................. 10- 75
Cooling fan drive motor ........................... 10- 88
Fan controller ............................................. 10- 95
Work equipment ........................................ 10- 96
Air conditioner ........................................... 10- 97
Engine control system .............................. 10- 98
Machine monitor system .......................... 10- 99
Cooling fan control system ...................... 10-103
Sensors ....................................................... 10-107
D41E, P-6 10-1

STRUCTURE AND FUNCTION RADIATOR, OIL COOLER
RADIATOR, OIL COOLER
1. Radiator core assembly A. Power train oil cooler inlet port

2. Inlet hose B. Power train oil cooler outlet port
3. Sub-tank
4. Outlet hose
5. Lower tank
(with built-in power train oil cooler)
6. Cooling fan
7. Cooling fan drive motor
8. Fan guard
9. Water filler cap
10. Drain plug
11. Power train oil cooler
12. Hydraulic oil cooler
13. Cushion
14. Boss
10-2 D41E, P-6

STRUCTURE AND FUNCTION RADIATOR, OIL COOLER
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
D41E, P-6 10-3

STRUCTURE AND FUNCTION ENGINE CONTROL
ENGINE CONTROL
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
A: Low idling
B: High idling
C: High idling
D: Low idling
10-4 D41E, P-6

STRUCTURE AND FUNCTION POWER TRAIN
POWER TRAIN
Outline
• The power produced by engine (1) has its • The direction of turning of the machine is
torsional vibration reduced by damper (2), changed by disengaging the power at steer-
then passes through universal joint (3), and ing clutch (10) on the side to which the steer-
is transmitted to the input shaft of transmis- ing and directional lever is operated to steer
sion (7). the machine. The radius of the turn is con-
• Transmission (7) has 3 forward speeds and trolled by steering brake (11).
3 reverse speeds provided by the combina- A wet type, single disc, hydraulically boosted
tion of the planetary gear system and the type is used for steering clutch (10) and
hydraulic system. The gear shift lever is steering brake (11).
used to select a speed range to match the
load. When the speed range is selected, • The power coming from steering units (8),
two sets of clutches are engaged and the (9), (10), and (11) is transmitted to final drive
power is transmitted from the output shaft (12).
through bevel gear (8) to bevel gear shaft The speed is reduced in final drive (12) by a
(9). single-stage spur gear and rotates sprocket
(13) to drive track (14) and move the ma-
• The power transmitted to bevel gear shaft chine.
(9) is connected and disconnected by steer-
ing clutch (10) and steering brake (11) to
change the direction of travel of the ma-
chine.
10-6 D41E, P-6

STRUCTURE AND FUNCTION POWER TRAIN SYSTEM
POWER TRAIN SYSTEM
1. Engine (SA6D102E-2) 9. Bevel gear shaft

2. Damper 10. Steering clutch
3. Universal joint 11. Steering brake
4. Power train pump (SAR(2)28) 12. Final drive
5. Hydraulic pump (SAR(2)36) 13. Sprocket
6. PTO 14. Track
7. Transmission 15. Cooling fan drive pump (SAR(1)20)
8. Bevel gear
D41E, P-6 10-7

STRUCTURE AND FUNCTION POWER TRAIN HYDRAULIC PIPING DRAWING
POWER TRAIN HYDRAULIC PIPING DRAWING
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
10-8 D41E, P-6

STRUCTURE AND FUNCTION DAMPER, UNIVERSAL JOINT
DAMPER, UNIVERSAL JOINT
1 12
2
11
3 4
10
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
D41E, P-6 10-9

STRUCTURE AND FUNCTION TRANSMISSION CONTROL
TRANSMISSION CONTROL
Lever positions 1. Safety lever (parking lever)

A: Neutral 2. Brake valve
B: FORWARD 3. Steering, directional, speed lever
C: REVERSE 4. Steering PPC valve
D: Left swing 5. Transmission control valve
E: Right swing
F: 1st Outline
G: 2nd • Control of the transmission is carried out
H: 3rd using the steering, directional, and speed
lever.
10-10 D41E, P-6

STRUCTURE AND FUNCTION TRANSMISSION
TRANSMISSION
B C D E F
H G
A I J 3 4 L 5
Y C C
2
X
1
B
K A B SDD00800
10-12 D41E, P-6

B-B
C-C
X
SDD00801
1. Transmission case A. From brake valve (drain)

2. Coupling B. To REVERSE clutch
3. Power train pump C. Oil inspection port
4. Hydraulic pump D. To FORWARD clutch
5. Transmission control valve E. To 2nd clutch
F. To 3rd clutch
G. From priority valve
H. To 1st clutch
I. To oil cooler
J. From oil cooler
K. To power train pump
L. From steering PPC valve (drain)
D41E, P-6 10-13

A. No. 1 sun gear G. No. 2 ring gear M. No. 4 planetary pinion

(No. of teeth: 27) (No. of internal teeth: 72/ (No. of teeth: 18)
B. No. 1 planetary pinion No. of external teeth: 56) N. No. 4 ring gear
(No. of teeth: 20) H. No. 3 sun gear (No. of internal teeth: 72/
C. No. 1 ring gear (No. of teeth: 34) No. of external teeth: 56)
(No. of internal teeth: 67) J. No. 3 planetary pinion O. No. 5 hub (No. of teeth: 56)
D. No. 1 ring gear (No. of teeth: 19) P. Bevel pinion
(No. of internal teeth: 72/ K. No. 3 ring gear (No. of teeth: 13)
No. of external teeth: 56) (No. of internal teeth: 72/ X. PTO drive gear
E. No. 2 sun gear No. of external teeth: 56) (No. of teeth: 75)
(No. of teeth: 34) L. No. 4 sun gear Y. PTO driven gear
F. No. 2 planetary pinion (No. of teeth: 36) (No. of teeth: 69)
(No. of teeth: 19)
10-14 D41E, P-6

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
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.)
D41E, P-6 10-15

Operation of disc clutch

• A disc clutch mechanism, consisting of pis- 6a 6b
3
ton (2), plate (3), disc (4), pin (5), and piston 2
4
return springs (6a) and (6b) is used to lock
8
ring gear (1).
The internal teeth of the disc mesh with the 7
external teeth of the ring gear. 1
The plate is meshed with pin (5), which is 5
locked by housings (7) and (8) and the pro-
truding notched portion of the outside di-
ameter of the plate.
SAD00803
Clutch engaged (locked)

• The oil from the control valve passes 3
through the port of housing (7) and is sent 2
4
under pressure to the back of piston (2).
The piston presses plate (3) and disc (4)
7
together. The resulting friction force stops
the rotation of the disc, and this locks ring 1
gear (1), which is meshed with the internal
teeth.
SAD00804
Clutch disengaged (free)

• When the oil from the control valve is shut 6a 6b
off, piston (2) is returned to its original po- 3
2
sition by piston return springs (6a) and (6b). 4
This releases the friction between plate (3)
and disc (4), and ring gear (1) is returned to
neutral. 1
SAD00805
10-16 D41E, P-6

TRANSMISSION OF POWER IN TRANSMISSION

FORWARD 1st
No. 2, No. 5 clutches actuated

No. 2 ring gear locked, No. 4 carrier and No. 5
ring gear connected
The No. 2 and No. 5 clutches are actuated, No. No. 4 carrier (2) and No. 5 hub (3) are con-
2 ring gear (1) is locked, and No. 4 carrier (2) nected, so sun gear (7), ring gear (8), No. 4
and No. 5 hub (3) are connected. carrier (2), No. 5 hub (3), and No. 5 piston hous-
No. 2 ring gear (1) is locked, so the rotation ing (9) form one unit.
from the engine passes through input shaft (4) The rotation of No. 2, 3 carrier (6) is in the same
and No. 2 sun gear (5) (the speed is reduced direction of rotation as the input shaft, and is
and the rotation is in the same direction as transmitted to output shaft (10).
input shaft (4)), and this rotation is transmitted
to No. 2, 3 carrier (6).
D41E, P-6 10-17

REVERSE 1st
No. 1, No. 5 clutches actuated

No. 1 ring gear locked, No. 4 carrier and No. 5
ring gear connected
The No. 1 and No. 5 clutches are actuated, No. The rotation of ring gear (14), which is meshed
1 ring gear (11) is locked, and No. 4 carrier (2) with No. 2, 3 carrier (6) is transmitted to No. 2,
and No. 5 hub (3) are connected. 3 carrier (6).
No. 1 ring gear (11) is locked, so No. 1 carrier The rotation of No. 2, 3 carrier (6) is in the same
(12), which is meshed with No. 1 ring rear (11) direction of rotation as with F1, and is transmit-
is also locked. The rotation from the engine ted to output shaft (10).
passes through input shaft (4) and sun gear Output shaft (10) rotates in the opposite direc-
(13), is transmitted to ring gear (14) with the tion from input shaft (4).
speed reduced and the rotation in the opposite
direction from the rotation of the engine.
10-18 D41E, P-6

FORWARD 2nd
No. 2 and No. 4 clutches actuated

No. 2 and No. 4 ring gears locked
No. 2 and No. 4 clutches are actuated and No. 2 (In other words, the rotation is transmitted from
ring gear (1) and No. 4 ring gear (15) are locked. No. 3 sun gear (7) to output shaft (10).)
No. 2 ring gear (1) is locked, so the rotation The rotation of output shaft (10) is in the same
from the engine is in the same direction as the direction as the rotation of input shaft (4).
input shaft, and is reduced (the same as with
F1), and is transmitted to No. 2, 3 carrier (6).
No. 4 ring gear (15) is locked, so the rotation of
No. 2, 3 carrier (6) passes through No. 3 ring
gear (8), No. 4 carrier (2), and No. 4 sun gear
(16) in order, the speed increases, and is trans-
mitted to output shaft (10).
D41E, P-6 10-19

FORWARD 3rd
No. 2 and No. 3 clutches actuated

No. 2 and No. 3 ring gears locked
No. 2 and No. 3 clutches are actuated and No. 2
ring gear (1) and No. 3 ring gear (8) are locked.
No. 2 ring gear (1) is locked, so the rotation
from the engine is in the same direction as the
input shaft, and is reduced (the same as with
F1), and is transmitted to No. 2, 3 carrier (6).
No. 3 ring gear (8) is locked, so the rotation of
No. 2, 3 carrier (6) passes through No. 3 sun
gear (7), the speed increases, and it is transmit-
ted to output shaft (10).
The rotation of output shaft (10) is in the same
direction as the rotation of input shaft (4).
10-20 D41E, P-6

STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
TRANSMISSION CONTROL VALVE

P4
D D
a P1
C C
B B
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})
3.04 ± 0.15
N1
{31.0 ± 1.5}
3.09 ± 0.15
F1, R1
{31.5 ± 1.5}
3.14 ± 0.15
F2, R2, F3, R3
{32.0 ± 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.
D41E, P-6 10-21

10-22 D41E, P-6

20 21 22 23 24 25 26 27 28 29 30
C-C
31
D-D SDD00812
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
D41E, P-6 10-23

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
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”.
10-24 D41E, P-6

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-
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.
D41E, P-6 10-25

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

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.
10-26 D41E, P-6

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)
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.
D41E, P-6 10-27

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
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.
10-28 D41E, P-6

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.
D41E, P-6 10-29

STRUCTURE AND FUNCTION STEERING, BRAKE, INCHING CONTROL
STEERING, BRAKE, INCHING CONTROL
Lever and pedal positions 1. Brake pedal

A: Neutral 2. Rod (brake pedal)
B: Left clutch disengaged 3. Parking brake cylinder
C: Left clutch disengaged 4. Safety lever (parking lever)
Left brake applied 5. Brake valve
D: Right clutch disengaged 6. Steering, directional, speed lever
E: Right clutch disengaged 7. Steering piston
Right brake applied 8. Steering PPC valve
F: Brake released 9. Priority valve
G: Brake applied 10. Rod (inching pedal)
H: Free 11. Inching pedal
J: Lock 12. Shuttle valve
13. PPC last chance fillter
10-30 D41E, P-6

STRUCTURE AND FUNCTION STEERING, BRAKE, INCHING CONTROL
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
pedal is depressed further after the trans-
mission of power to the tracks is cut off, the
brake is actuated to stop the machine.
D41E, P-6 10-31

STRUCTURE AND FUNCTION BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE
BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE
1. Steering piston
2. Steering unit
3. Breather
10-32 D41E, P-6

D41E, P-6 10-33

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
10-34 D41E, P-6

21. Steering case

22. Top cover
23. Needle bearing
24. Eccentric camshaft
25. Torque receiving pin
D41E, P-6 10-35

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
• 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.
10-36 D41E, P-6

OPERATION OF STEERING CLUTCH
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.
D41E, P-6 10-37

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).
10-38 D41E, P-6

OPERATION OF STEERING BRAKE
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.
D41E, P-6 10-39

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.
10-40 D41E, P-6

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).
D41E, P-6 10-41

STRUCTURE AND FUNCTION STEERING PPC VALVE
STEERING PPC VALVE
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.
10-42 D41E, P-6

1. Link 7. Metering spring

2. Bearing 8. Centering spring
3. Piston 9. Valve
4. Plate 10. Body
5. Collar 11. Lever
6. Retainer
D41E, P-6 10-43

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
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.
10-44 D41E, P-6

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
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
D41E, P-6 10-45

STRUCTURE AND FUNCTION STEERING PISTON
STEERING PISTON
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.
10-46 D41E, P-6

STRUCTURE AND FUNCTION PRIORITY VALVE
PRIORITY VALVE
A B
C
A
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
D41E, P-6 10-47

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:
2.75 MPa (28 kg/cm2) (65 ¬/min)
10-48 D41E, P-6

STRUCTURE AND FUNCTION BRAKE VALVE
BRAKE VALVE
1. Parking brake valve

2. Main brake valve
3. Body
4. Return spring
5. Plug
6. Return spring
7. Valve
8. Piston
9. Shaft Outline
10. Modulating spring • The brake valve is in the circuit between the
11. Guide brake piston and power train pump through
the transmission modulating valve and pri-
A. Port Br (R) (to right brake piston) ority valve. It consists of the main brake
B. Port P (pump port) valve and the parking brake valve.
C. Port T2 (main brake valve drain) • When the brake pedal is depressed, oil flows
D. Port Br (L) (to left brake piston) to the brake piston, and the brake piston
E. Port T1 (parking brake valve drain) presses the disc and plate together to apply
F. Port Pac (to parking brake cylinder) the brake.
D41E, P-6 10-49

OPERATION
1. Brake released (safety lever free, brake pedal released)
12. Brake pedal 16. Brake eccentric camshaft

13. Brake piston 17. Parking brake spring
14. Safety lever 18. Shuttle valve
15. Parking brake cylinder
• 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 B passes
(12) pushes the rod, and guide (11), shaft through port A, enters parking brake cylin-
(9), and brake valve (7) are pushed to the der (15), through shuttle valve (18) and
right. pushes the cylinder piston to the right. This
The oil from the power train pump enters pushes the brake cylinder rod to the right,
port B and is stopped at port C. The oil from but no force is brought to bear on brake
brake piston (13) is drained from port D to eccentric camshaft (16) because of the ob-
port E, and the brake is released. long portion provided in the lever.
10-50 D41E, P-6

2. Brake applied (safety lever free, brake pedal depressed)
• 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 B, passes through ports receives a load in accordance with the
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
D41E, P-6 10-51

3. Safety lever LOCK (brake pedal released, safety lever at LOCK)
• 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 B and port A closes, and the
passage between port A and port E opens.
The oil from the power train pump enters
port B and stops.
• If the oil flowing to parking brake cylinder
(15) and forming the back pressure flows
from port A through port E 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.
10-52 D41E, P-6

STRUCTURE AND FUNCTION POWER TRAIN OIL FILTER
POWER TRAIN OIL FILTER
X
A
2
X
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
D41E, P-6 10-53

STRUCTURE AND FUNCTION FINAL DRIVE
FINAL DRIVE
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.
10-54 D41E, P-6

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).
D41E, P-6 10-55

STRUCTURE AND FUNCTION FRAME ASSEMBLY
FRAME ASSEMBLY fl The diagram shows the D41E-6.
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.
10-56 D41E, P-6

STRUCTURE AND FUNCTION TRACK FRAME
TRACK FRAME fl The diagram shows the D41E-6.
1. Idler • Track roller

2. Carrier roller
Qt'y Flange type and arrangement
3. Track frame
4. Sprocket D41E-6 6 S, D, S, S, D, S
5. Track roller guard
D41P-6 7 S, D, S, D, S, D, S
6. Track roller
D41E, P-6 10-57

STRUCTURE AND FUNCTION RECOIL SPRING
RECOIL SPRING
1. Support connection
2. Housing
3. Nut
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.
10-58 D41E, P-6

STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM

POWER ANGLE TILTDOZER
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. Cooling fan drive pump (SAR20)
5. Hydraulic filter 9. Hydraulic oil cooler
10. Cooling fan drive motor
11. Blade tilt cylinder
D41E, P-6 10-59

STRUCTURE AND FUNCTION WORK EQUIPMENT CONTROL
WORK EQUIPMENT CONTROL
Lever positions Outline

A: Blade HOLD • Control of the work equipment is carried
B: Blade LOWER out by operating work equipment control
C: Blade FLOAT lever (2), which moves a rod to move the
D: Blade RAISE spool of the main control valve (3).
E: Blade left tilt • If work equipment safety lever (1) is placed
F: Blade right tilt at the LOCK position, work equipment con-
G: Blade left angle trol lever (2) cannot be moved from the
H: Blade right angle HOLD position to the RAISE, TILT, or AN-
J: FREE GLE positions.
K: 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.
10-60 D41E, P-6

STRUCTURE AND FUNCTION HYDRAULIC TANK, FILTER
HYDRAULIC TANK, FILTER
2 B B
1 A-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
10-62 D41E, P-6

STRUCTURE AND FUNCTION HYDRAULIC TANK, FILTER
4 4A
4C 4B
B-B
B
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
D41E, P-6 10-63

STRUCTURE AND FUNCTION MAIN CONTROL VALVE
MAIN CONTROL VALVE

3-SPOOL VALVE (BLADE LIFT, TILT, ANGLE)
(1/5)
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)
10-64 D41E, P-6

(2/5)
2
6
5 3
A-A
4
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)
D41E, P-6 10-65

(3/5)
1 2
9 3
8 4
5
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
10-66 D41E, P-6

(4/5)
3
5
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
D41E, P-6 10-67

(5/5)
1 2
H-H
5 4
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
10-68 D41E, P-6

4-SPOOL VALVE (BLADE LIFT, TILT, ANGLE, RIPPER)

D41E-6
(1/5)
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. Port B4 (to ripper cylinder)
f. Safety valve circuit pressure release plug
g. Port A4 (to ripper cylinder)
h. Port A3 (to angle cylinder head)
j. Port A2 (to lift cylinder bottom)
k. Port A1 (to lift cylinder head)
m. Port P (from hydraulic pump)
n. LS pressure pickup plug
o. Port TS (to hydraulic tank)
p. Port T (to hydraulic tank)
10-70 D41E, P-6

(2/5)
1. Suction & safety valve 8. Suction valve (tilt cylinder)

2. Suction valve (lift cylinder) 9. Auxiliary valve port plug (lift)
3. Auxiliary valve port plug (lift) 10. Ripper spool
4. Auxiliary valve port plug (angle) 11. Angle spool
5. Suction valve (ripper cylinder) 12. Tilt spool
6. Suction valve 13. Lift spool
7. Suction valve (angle cylinder) 14. Main relief valve
D41E, P-6 10-71

(3/5)
1. Pressure compensation valve F (tilt) 12. Check valve (ripper)

2. Pressure compensation valve F (lift) 13. Check valve (angle)
3. Pressure compensation valve F (angle) 14. Safety valve circuit pressure release plug
4. Pressure compensation valve F (ripper) 15. LS pressure pickup plug
5. Pump pressure pickup plug 16. Pump pressure pickup plug
6. Pressure compensation valve R (ripper) 17. Suction & safety valve
7. Pressure compensation valve R (angle) 18. Main relief valve
8. Pressure compensation valve R (tilt) 19. LS selector piston
9. Pressure compensation valve R (lift) 20. LS bypass plug
10. LS selector piston 21. Unload valve
11. Unload valve
10-72 D41E, P-6

(4/5)
1. Suction valve (lift cylinder bottom end) 6. Auxiliary valve port plug
2. Auxiliary valve port plug 7. Suction valve (lift cylinder bottom)
3. Lift spool 8. Tilt spool
4. Pressure compensation valve F 9. Pressure compensation valve R
5. Pressure compensation valve R 10. Pressure compensation valve F
D41E, P-6 10-73

(5/5)
1. Auxiliary valve port plug 6. Suction valve (ripper cylinder)

2. Suction valve (angle cylinder head end) 7. Suction valve
3. Angle spool 8. Ripper spool
4. Pressure compensation valve R 9. Pressure compensation valve R
5. Pressure compensation valve F 10. Pressure compensation valve F
10-74 D41E, P-6

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.
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.
D41E, P-6 10-75

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.
10-76 D41E, P-6

FUNCTIONS, OPERATION OF VALVE

Hydraulic circuit diagram and names of valves
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
D41E, P-6 10-77

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.
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.
.
10-78 D41E, P-6

fl The diagram shows the operation for blade lift RAISE.
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.
D41E, P-6 10-79

• 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-
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.
10-80 D41E, P-6

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
D41E, P-6 10-81

fl The diagram shows the condition immediately after the lift cylinder has reached the end of its
stroke.
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.
10-82 D41E, P-6

fl This diagram shows the condition when port A1 is under heavy load and port A2 is under
light load.
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-
D41E, P-6 10-83

2. Main relief valve

Function
• If the oil goes above the specified pres-
sure, the main relief valve acts to set A B
the maximum pressure for the work
equipment circuit and to protect the cir-
cuit by draining the oil to the tank.
Operation
d1 d2
• Port A is connected to the pump circuit
and port B is connected to the drain cir- 1 2
SAD00874
cuit. The pressure oil passes through
diameter d1 and the hole in poppet (1),
acts on the different area of diameter d2
“d1 < d2”, and main valve (2) is seated. A B a
• If the pressure at port A reaches the set

pressure of spring (4), pilot poppet (3)
opens, so the oil flows around pilot pop-
pet (3), passes through drill hole "a", 3 4
and is drained from port B. SAD00875
A B C
• When pilot poppet (3) is opened, the

pressure in spring chamber C drops, so
poppet (1) moves to the right. Poppet
(1) is seated at the tip of pilot poppet
(3), and the oil passes through throttle
b
"b" and is drained from the drill hole. 1 3
SAD00876
A B C
• Compared with the pressure at port A,

the pressure in spring chamber C is low,
so main valve (2) opens, and the oil
flows from port A to port B to prevent
any abnormal pressure.
2
SAD00877
10-84 D41E, P-6

3. Suction & safety valve

Function
• If there should be any shock, and abnor-
A B C
mal pressure is generated in the cylin-
der, the safety valve acts to protect the
cylinder and other hydraulic equipment
by relieving the abnormal pressure.
Operation as safety valve

• Port A is connected to the cylinder cir- 2 3
d1 d2 d3 d4
cuit and port B is connected to the drain SAD00878
circuit. The hydraulic pressure at port A
is sent to port C from the hole in poppet
(3). Safety valve (2) is seated to the left A C a D
because of the relationship d2 < d3.
The relationship between the size of the
diameter of the cross-sectional surface
(cross-sectional area) is d4 > d1 > d3 >
d2.
• If any abnormal pressure is generated

at port A and the pressure reaches the
set pressure of spring (5), pilot poppet 1 4 5
SAD00879
(4) opens, and the oil in chamber C goes
from chamber D through outside circum-
ference portion "a" of suction valve (1),
and is drained. b C D
• When pilot poppet (4) is opened, the

pressure in chamber C drops, so poppet
(4) moves to the right. Poppet (3) is
seated at the tip of pilot poppet (4), and
the oil passes through throttle "b" and
is drained from the drill hole. 4
3
SAD00880
A B C
• The pressure in chamber C is lower than

the pressure at port A, so safety valve
(2) moves to the right, and the oil flows
from port A to port B to prevent the
generation of any abnormal pressure.
• Even if any abnormal pressure is gener-
ated, the relationship of suction valve
(1), which has a larger cross-sectional
diameter, is d1 < d4, so it is not actu- 1 2
d1 d4
ated. SAD00881
D41E, P-6 10-85

Operation as suction valve

• If any negative pressure is generated in
the cylinder circuit, port A is connected A B E C
to chamber C, so negative pressure
forms in both of them. The tank pres-
sure of port B is applied to port E, so
the hydraulic pressure of suction valve
(1) becomes greater by an amount equal
to the difference in area of d4 and d3.
This overcomes the tension of spring
(6) and moves suction valve (1) to the
right. As a result, oil flows from port B
to port A and prevents negative pres- 1 6
d3 d4
sure from forming at port A. SAD00882
4. Suction valve
Function
• This valve prevents the formation of B
negative pressure in the cylinder circuit. 1
A
Operation
• Port A is connected to the cylinder cir-
cuit and port B is connected to the drain
circuit. If any negative pressure if gen-
erated at port A, main poppet (1) is
opened by the difference in area of d1
and d2, so oil flows from port B to port
A to prevent negative pressure.
d1 d2
SAD00883
10-86 D41E, P-6

STRUCTURE AND FUNCTION COOLING FAN DRIVE MOTOR
COOLING FAN DRIVE MOTOR

LMF16
P: From fan pump Specifications

T: From oil cooler to tank Model : LMF16
TC: To hydraulic tank Capacity : 16.0
Rated speed : 1,900
Rated flow : 30.4 ¬/min
Cracking pressure of check valve: 0.013 MPa {0.13 kg/cm2}
10-88 D41E, P-6

1. Output shaft 12. Maine bearing

2. Case 13. Oil seal
3. Thrust plate 14. Flow control valve spring
4. Piston assembly 15. Flow control valve spool
5. Cylinder block 16. Suction safety valve spring
6. Center spring 17. Suction safety valve
7. Valve plate 18. ON-OFF pilot valve
8. End cover 19. Reversible valve spool
9. Sub bearing 20. Reversible valve spring
10. Retainer shoe 21. Proportional solenoid pilot valve
11. Retainer guide
D41E, P-6 10-89

1. HYDRAULIC MOTOR
Function
• This hydraulic motor is a swash plate-
type axial piston motor, which converts
the pressure of the hydraulic oil sent
from the hydraulic pump into revolution.
Principle of operation
• The oil sent from the hydraulic port flows
through valve plate (7) into cylinder
block (5).
This oil can flow on only one side of the
Y-Y line connecting the top dead center
and bottom dead center of the stroke of
piston (4).
• The oil sent to one side of cylinder block
(5) presses pistons (4) (2 or 3 pieces)
and generates force F1 (F1 kg = P kg/
cm2 x π/4 D2 cm2).
• This force is applied to thrust plate (2).
Since thrust plate (2) is fixed to the an-
gle of Eo degrees to the output shaft (1),
the force is divided into components F2
and F3.
• The radial component F3 generates
torgue against the Y-Y line connecting
the top dead center and bottom dead
center (T = F3 x ri).
• The resultant of this torque [T = ∑ (F3 x
ri)] rotates the cylinder block (5) through
the piston.
• Since the cylinder block (5) is coupled
with the output shaft by means of spline,
the output shaft revolves to transmit the
torque.
10-90 D41E, P-6

2. Safety-suction valve (2) When motor stops

1) Suction function • If the engine stops and the input
• If negative pressure is applied to the speed of pump (23) becomes 0 rpm,
inlet port of the motor, cavitation the pressurized oil from pump (23)
occurs. is not supplied to port P any more.
When the negative pressure is ap- The oil is not supplied to the MA
plied to the inlet port of the motor, side of the motor and the motor
the safety-suction valve supplies speed lowers gradually to 0 rpm.
pressurized oil from the outlet side • If the motor shaft keeps rotating be-
to prevent the cavitation. cause of inertia while the inflow of
the pressurized oil into port P is de-
Operation creased, negative pressure is applied
(1) When motor starts to the inlet port. In this case, safety-
• The pressurized oil from pump (23) suction valve (17) supplies the pres-
is supplied to port P and the pressurized oil from port T to the MA
sure on the MA side rises. Then, side to prevent cavitation.
starting torque is generated in the
motor, which starts rotation. The oil
on the outlet MB side of the motor
returns through port T to the tank.
D41E, P-6 10-91

2) Safety valve function

Function
• The discharge pressure of pump (23)
may rise high when the engine is
started.
• Safety-suction valve (17) is installed
to protect the fan system circuit.
• If the discharge pressure of pump
(23) rises higher than the set pres-
sure of safety-suction valve (17), the
seat (16) of safety-suction valve (17)
opens to let the oil escape into path
E of port T to prevent the pressure
at the discharge port from rising
abnormally.
10-92 D41E, P-6

3. Operation of reversible valve
1) When reversible valve ON-OFF solenoid 2) When reversible valve ON-OFF solenoid
is turned off is turned on
• If reversible valve ON-OFF solenoid • If reversible valve ON-OFF solenoid
(24) is turned OFF, the pressurized (24) is turned ON, ON-OFF selector
oil from pump (23) is shut off by valve (25) changes and the pressu-
ON-OFF selector valve (25) and port rized oil from pump (23) flows
C is connected to the tank circuit. through port C into spool chamber
• As a result, reversible valve spool D.
(19) is pushed to the right by revers- • The pressurized oil in chamber D
ible valve spring (20) and motor port pushes reversible valve spool (19)
MA opens. Then, the pressurized to the left against reversible valve
oil flows in and the motor starts for- spring (20). As a result, motor port
ward (right-handed) rotation. MB opens and the pressurized oil
flows in and the motor starts reverse
(left-handed) rotation.
D41E, P-6 10-93

4. Flow control valve (Steplessly variable type) Operation

Function • The upstream pressure of the throttle is ap-
The flow control valve supplies the oil dis- plied to X side of flow control valve spool
charged from the pump to the motor by the (15) and the downstream pressure of the
necessary quantity and returns the excess throttle is applied to Y side. The differen-
to the tank. tial pressure between before and after throt-
• As shown in Fig. 1, motor speed N rises tle E made by the inflow is applied to flow
in proportion to inflow of oil Q. When control valve spring (14).
the inflow of oil is Q1, the motor speed In Fig. 1, if the inflow exceeds Q0, the dif-
is B rpm. ferential pressure between before and after
• To reduce the noise and loss in the fan flow control valve spool (15) increases
motor, the fan speed must be kept con- above the installed load of flow control valve
stant, regardless of the inflow of the oil. spring (14) and the path from P to T in flow
• The flow control valve is installed inter- control valve spool (15) opens. As a result,
nally to keep the fan speed constant for the excess oil in part Z is discharged through
the above purpose. the flow control valve and the motor speed
Even if the inflow increases from Q0 to is kept constant from A to C.
Q1, the speed is kept constant from A to • The flow control valve of this motor is
C rpm. steplessly variable.
As shown in Fig. 2, this valve can change
the motor speed steplessly between A' and
C' by changing the command current be-
tween motor speeds A and C.
10-94 D41E, P-6

STRUCTURE AND FUNCTION FAN CONTROLLER
FAN CONTROLLER
Input and output signals

CN90
No. Signal name Input/Output
1. Controller power source (24 V) Input
2. Thermistor signal (+) Input
3. Solenoid (+) Output
4. Solenoid (–) Output
5. Thermistor signal (GND) Input
6. Controller power source (GND) Input
D41E, P-6 10-95

STRUCTURE AND FUNCTION WORK EQUIPMENT
WORK EQUIPMENT
1. Blade
2. Angle cylinder
3. Lift cylinder
4. U-frame
5. Tilt cylinder
6. Rod
7. Tilt link
10-96 D41E, P-6

STRUCTURE AND FUNCTION AIR CONDITIONER
AIR CONDITIONER
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
D41E, P-6 10-97

STRUCTURE AND FUNCTION ENGINE CONTROL SYSTEM
ENGINE CONTROL SYSTEM

SAFETY MECHANISM WHEN STARTING ENGINE
1. Battery Function
2. Battery relay • Neutral safety parking brake limit switch (5)
3. Starting switch is linked to travel lock lever (6) so that the
4. Fuse box steering circuit will not be turned ON and
5. Neutral safety parking brake limit switch the engine will not start when travel lock
6. Travel lock lever lever (6) is not in the LOCK position.
7. Safety relay • If travel lock lever (6) is set in the LOCK
8. Starting motor position, the steering/directional/gear shift
9. Engine stop solenoid lever is automatically returned to the NEU-
10. Timer TRAL position.
11. Solenoid relay • If starting switch (3) is turned to the ON
position, timer (10) operates and solenoid
relay (11) is turned on and a current flows
in engine stop solenoid (9) and the fuel line
is opened.
• Even after timer (10) stops, engine stop so-
lenoid (9) keeps holding itself. If starting
switch (3) is turned to the OFF position, the
fuel is cut out and the engine stops.
10-98 D41E, P-6

STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
MACHINE MONITOR SYSTEM
• 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.
D41E, P-6 10-99

MONITOR PANEL
1 2 3 4 5
1. Service meter
2. Service meter indicator
3. Engine coolant temperature gauge
4. Power train oil temperature gauge
5. Fuel level gauge
6. Alarm buzzer cancel switch indicator
7. Alarm buzzer cancel switch
8. Warning lamp
9. Power train oil temperature caution
lamp
10. Engine preheating indicator
11. Engine oil pressure caution lamp
12. Battery charge caution lamp
13. Engine coolant temperature caution
lamp
13 12 11 10 9 8 7 6
SDD00220
Outline 2. CAUTION items

• The monitor panel consists of the monitor These light up or flash when there is any
group, which gives a warning if any abnor- abnormality.
mality occurs in the machine, and theservice The warning lamp and alarm buzzer flash
meter and gauge group, which displays the or sound together depending ont he item
condition of the machine. The service meter that is abnormal.
and fuel level gauge are driven directly by a fl The flashing interval for the monitor and
signal from the machine, but for the other warning lamp is approx. 0.8 seconds each
items, a microcomputer installed in the panel repeated ON and OFF.
processes the signal from vArious sensors
and displays the result. 3. Alarm buzzer cancel switch
The items displayed on the indicator type If any abnormality is detected and alarm
gauges and monitor portion are shown in buzzer sounds, it is possible to stop the
the table in MONITOR PANEL DISPLAY. buzzer temporarily by pressing the buzzer
cancel switch. In this case, the alarm buzzer
Operation cancel switch indicator lights up. If the can-
1. Turnning on power (turning starting cel switch is pressed again after the buzzer
switch to ON) has been stopped, the buzzer will sound
1) All caution monitor items light up for 3 again and the cancel indicator will go out. If
seconds. another abnormality is detected when the
2) The warning lamp lights up for 3 sec- buzzer has been temporarity stopped, the
onds and the alarm buzzer sounds for 1 alarm buzzer will sound again and the can-
second. cel switch will go out.
10-100 D41E, P-6

Monitor panel display (gauge group)
Meter Engine coolant temperature Power train oil temperature Fuel level
Gauge scale
4. Gauge display portion

This consists of analog type meters with an indicator. The coolant temperature and power train
oil temperature gauges are driven by a microcomputer, and the area showing the normal operat-
ing range of the machine is made larger to make operations at the limit of the range easier.
The red zone for the water and oil temperature is a warning area which uses a caution LED,
caution lamp, and caution buzzer.
Connector terminal (signal table)
Connector No. Connection Connector No. Connection
1-1 Power source 24 V 2-1 Engine water temperature
1-2 GND 2-2 Power train oil temperature
1-3 — 2-3 Fuel level
1-4 Charge 2-4 GND
1-5 Starting switch (c) 2-5 Model selection 3
1-6 Preheating signal 2-6 —
1-7 Working lamp switch 2-7 Alarm output
1-8 Engine oil pressure 2-8 —
1-9 — 2-9 —
1-10 — 2-10 —
1-11 — 2-11 —
1-12 — 2-12 —
1-13 Model selection 0
1-16 —
D41E, P-6 10-101

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
104°C Turn off Turn off OFF
Engine
coolant 104°–107°C Flashes Red Flashes OFF
temperature
SKD00622 Above
109°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)
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
10-102 D41E, P-6

STRUCTURE AND FUNCTION COOLING FAN CONTROL SYSTEM
COOLING FAN CONTROL SYSTEM
1. Battery Outline
2. Fan reverse rotation controller • The fan reverse rotation controller (2) and
3. Fan rotation direction selector switch fan rotation controller (6) control the hy-
4. Fan operation check lamp draulic cooling fan according to the coolant
5. Water temperature sensor temperature input from water temperature
6. Fan rotation controller sensor (5) and the rotation mode selected
7. Fan drive motor with fan rotation direction selector switch
8. Fan reverse rotation solenoid valve (3).
9. Fan speed solenoid valve
10. Fan drive pump
D41E, P-6 10-103

FUNCTION
Fan speed control
• The signal from water temperature sensor
(5) is input through fan reverse rotation con-
troller (2) to fan rotation controller (6).
• Fan rotation controller (6) outputs a control
current to fan speed solenoid valve (9) ac-
cording to the signal from water tempera-
ture sensor (5) so that the fan speed will be
matched to the coolant temperature.
Below 85°C 1,000 rpm

85°C - 95°C 1,000 - 2,050 rpm (Proportional control)
Above 95°C 2,100 rpm
(When oil temperature is 50°C and engine runs at rated speed)
Fan rotation direction control Forward rotation mode

• When the key switch is at the ON position • The fan rotates forward. This mode is se-
and the engine is stopped, the forward, re- lected normally.
verse, or cleaning mode can be selected with
fan rotation direction selector switch (3) Reverse rotation mode
• The signal of fan rotation direction selector • The fan rotates in reverse. It can be used as
switch (3) is output as a fan reverse rotation a reversible fan. Since the fan efficiency is
solenoid control signal to fan reverse rota- lowered in this mode, however, the engine
tion solenoid valve (8) by fan reverse rota- can overheat easily. Accordingly, use of
tion controller (2). this mode is allowed only in cold districts.
• If fan rotation direction selector switch (3) is
operated while the engine is running, its Cleaning mode
input signal is ignored to protect fan motor • The fan rotates at full speed in this mode,
(7) and fan reverse rotation controller (2) regardless of its rotation direction and wa-
flashes fan operation check lamp (4) to no- ter temperature. Accordingly, dirt caught in
tify the operator that the operation of the the radiator fins is blown off.
switch is ignored. • The cleaning interval of the radiator fins can
be lengthened by using this mode periodi-
cally.
10-104 D41E, P-6

COMPONENT OF SYSTEM
FAN REVERSE ROTATION CONTROLLER
1.Controller
2.Connector
Input and output signals [CN87]
Pin Pin
Signal name Input/output Signal name Input/output
No. No.
1. — — 7. Fan reverse rotation solenoid valve output
2. Reverse rotation mode signal Input 8. Power source (24 V) Input
3. Cleaning mode signal Input 9. Thermistor signal Input
4. Alternator terminal R signal Input 10. Thermistor signal output
5. Switch ineffective lamp output 11. Fan rotation controller power source output
6. Power source (24 V) — 12. GND —
D41E, P-6 10-105

FAN ROTATION CONTROLLER
1. Controller
2. Connector
Input and output signals [CN90]
Pin
Signal name Input/output
No.
1. Power source (24 V) —
2. Thermistor (+) Input
3. Solenoid (+) output
4. Solenoid (–) output
5. Thermistor (–) Input
6. GND —
Fan reverse rotation solenoid valve

Fan rotation speed solenoid valve
fl See the section of the solenoid valves.
10-106 D41E, P-6

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 — —
D41E, P-6 10-107

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-
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.
10-108 D41E, P-6

FUEL LEVEL SENSOR
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.
D41E, P-6 10-109

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
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.
D41E, P-6 20-1

1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
Machine type D41E,P-6
Engine SA6D102E-2
Standard value
Item Measurement conditions Unit Service limit value
for new machine
High idling 2,600 ± 50 2,600 ± 50
Engine speed Low idling rpm 950 ± 50 950 ± 50
Rated speed 2,300 2,300
At sudden acceleration Bosch Max. 4.0 6.5

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 Min. 2.41 1.69
Compression pressure 2
40 – 60°C {kg/cm }
(Engine speed) {Min. 24.6} {17.2}
(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 0.34 – 0.59 0.245
{kg/cm2}
{3.5 – 6.0} {2.5}
At low idling Min. 0.147 0.078

{Min. 1.5} {0.8}
Oil temperature Whole speed range

°C 90 – 112 120
(inside oil pan)
Before compression
Fuel injection timing ° 9 9
top dead center
20-2 D41E, P-6

1
(3)
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
Engine slow
Fuel control lever Tip of lever knob ↔ Full
mm 133 – 167 133 – 167
• 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 ↔
Left, right tilt 45 ± 10 45 ± 10
HOLD ↔Left,
deg 15 ± 2.5 15 ± 2.5
right angle
Engine slow 63.7 ± 24.5 98
• Engine stopped → Full N {6.5 ± 2.5} {10}
Fuel control lever
• Center of lever knob Engine full {kg} 33.3 ± 19.6 63.7
→ Slow {3.4 ± 2.0} {6.5}
• 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 • Center of lever knob {kgm} 3.2 ± 1.0 4.9
2nd ↔ 3rd
{0.33 ± 0.1} {0.5}
Operating effort
• 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}
D41E, P-6 20-3

1
Cate-
• Engine at rated 3.04 ± 0.15 —

Neutral
• Power train oil {31.0 ± 1.5}
Modulating relief temperature: 3.09 ± 0.15 —
F1, R1 {31.5 ± 1.5}
pressure 70 – 80°C
3.14 ± 0.15 —
F2•3, R2•3
Hydraulic pressure
{32.0 ± 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 +0.6
– 0.5 {27 +6
–5 } {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 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 D41E, P-6

1
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
Hydraulic drift mm/

Max. 50 Max. 100
(Blade lift) 15 min
• Engine stopped
Work equipment
• Hydraulic oil temperature: 45 - 55°C

• 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
Motor speed • Hydraulic oil temperature: 80°C rpm 2,000
+100
0 2,000
+200
– 100
Fan
STD +2.9 +4.9

Circuit oil MPa 18.6 – 1.0 18.6 –2.9
pressure {kg/cm2} +30
{190
+50
{190 –10 } – 30 }
D41E, P-6 20-5

1
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
* 1 Engine oil presure signal signal
pressure signal signal
H: 3.5 – 30V Monitor *1 *2 *3
L: Approx. 0V item CN49 (8) CN49 (5) CN49 (4) * 4
* 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.
* 3 Alternator Starting switch ON
signal CN49 (1) – (2) 20 – 30V
A Starting switch OFF
H: 27.5 – 30V (+24V input)
0V
L: Max. 5V
Machine monitor
* 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
104°C Approx. 3.4 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.
20-6 D41E, P-6

1

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 CN28 switch ON and
temperature (1) – (2) check display.
3) Connect
socket.
Display portion
Machine panel
Fuel level Sensor

resistance
E Approx. 82 kΩ
1/10 Approx. 70 kΩ
Measure resistance
F Approx. 12 kΩ
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 CN28 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}
D41E, P-6 20-7

1

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

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

Alternator some time.
20-8 D41E, P-6

1
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
Measurement of engine speed ............................................................................................................. 20-108
Adjusting fuel control linkage ............................................................................................................... 20-109
Adjusting decelerator pedal linkage .................................................................................................... 20-110
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 .......................................................... 20-117
Adjusting brake pedal linkage .............................................................................................................. 20-121
Adjusting inching pedal linkage ........................................................................................................... 20-122
Adjusting parking brake linkage ........................................................................................................... 20-123
Adjusting work equipment control linkage and safety lever linkage .............................................. 20-125
Measuring power train oil pressure ..................................................................................................... 20-126
Testing and adjusting work equipment circuit pressure ................................................................... 20-130
Measuring and adjusting fan motor speed and drive circuit oil pressure ..................................... 20-131
Measuring fan speed ............................................................................................................................. 20-132
Testing and adjusting track shoe tension ........................................................................................... 20-133
Measuring leakage inside cylinder ....................................................................................................... 20-134
Bleeding air from hydraulic cylinder ................................................................................................... 20-135
Procedure for releasing parking brake ................................................................................................ 20-136
Testing and adjusting operator's cab .................................................................................................. 20-137
D41E, P-6 20-101

1
(3)
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
Water, 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 799-401-2320 Hydraulic gauge 1.0 MPa {10 kg/cm2}

C
790-261-1311 Adapter —
2
790-261-1321 Adapter —
3 799-101-5220 Nipple 10 mm P=1.25
Blow-by pressure
Blow-by pressure E 799-201-1504 4.9 KPa {500 mmH2O}
gauge
F Commercially —
Valve clearance Thickness gauge
available
1 799-201-9001 Handy smoke checker Bosch index: 0 – 9

Exhaust color G
2 Commercially —
Smoke meter
available
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 D41E, P-6

1
(3)
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}
fl The firing order is as follows: 1-5-3-6-2-4
BED00026
5 6 3 4
BED00027
D41E, P-6 20-103

1
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
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 D41E, P-6

1
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-
JECTION PUMP.
D41E, P-6 20-105

1
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.
¤ 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.
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
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 D41E, P-6

1
TESTING AND ADJUSTING MESURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL

PRESSURE
1. Remove oil pressure sensor, then install oil pres-

sure gauge C1 (1.0 MPa {10 kg/cm2}).
2. Start the engine, and measure the oil pressure

at low idling and high idling.
C1
TLD00025
D41E, P-6 20-107

1
TESTING AND ADJUSTING MEASUREMENT OF ENGINE SPEED
MEASUREMENT OF ENGINE
SPEED
¤ When measuring, take care not to touch a rotat-

ing part.
fl Measure the engine speed under the following

condition.
1) Cooling water temperature: In operating
range
2) Power train oil temperature: 70 – 90°C
3) Hydraulic oil temperature: 45 – 55°C
1. Remove the floor plate at operator's seat.

2. Install probe 1 of the tachometer and set it
toward drive shaft (1).
fl Set the stand to the brake pedal bracket
A
from the side.
3. Stick a piece of aluminum foil to the drive shaft.
4. Connect probe (1) and tachometer A by the ca-
ble.
5. Run the engine and measure the "high idling
speed and low idling speed".
TLD00010
20-108 D41E, P-6

1
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL LINKAGE
ADJUSTING FUEL CONTROL LINKAGE
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",
"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.
D41E, P-6 20-109

1
TESTING AND ADJUSTING ADJUSTING DECELERATOR PEDAL LINKAGE
ADJUSTING DECELERATOR PEDAL LINKAGE
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
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 D41E, P-6

1
TESTING AND ADJUSTING ADJUSTING STEERING, DIRECTIONAL, GEAR SHIFT LEVER
ADJUSTING STEERING,
DIRECTIONAL, GEAR SHIFT
LEVER
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.
fl Dimension "a": 295.5 mm
2) Start the engine and check the oil pressure a
1
when the steering lever is operated fully to
the left or right.
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
ii) Put stopper bolt (6) in contact with
spool (5), then turn back 90°. (Turn
to the left.)
iii) Tighten locknut (7).
20-112 D41E, P-6

1
TESTING AND ADJUSTING ADJUSTING STEERING, DIRECTIONAL, GEAR SHIFT LEVER
(3) Speed and directional cable b 9

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

(10) and (11) at the lever end to the
following dimension.
fl Dimension "c": 205.2 mm
(4) Check that each speed range engages
properly.
11
10
BED00058
D41E, P-6 20-113

1
TESTING AND ADJUSTING TESTING MAIN BRAKE AND PARKING BRAKE
TESTING MAIN BRAKE AND PARKING BRAKE

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
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.
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 D41E, P-6

1
TESTING AND ADJUSTING TESTING MAIN BRAKE AND PARKING BRAKE
2. Testing effect of parking brake

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 di-
rectional lever at neutral and depress
brake pedal (6).
2) With the machine stopped by the blade, re-

lease brake pedal (6) and lock parking brake
lever (4).
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.
D41E, P-6 20-115

1
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.
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 D41E, P-6

1
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.
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 pis-
ton (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 mesh-
ing of the serration one notch and in-
stall 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}
D41E, P-6 20-117

1
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.
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 pis-
ton (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 mesh-
ing of the serration one notch and in-
stall 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}
20-118 D41E, P-6

1
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 re-
placed.
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
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).
D41E, P-6 20-119

1
[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.
• Because of the structure of the link, if the clear-

ance is adjusted with the adjustment bolt after
the brake lining is worn, the main brake is ad-
justed, but the parking brake is not adjusted.
(See the diagram on the right.)
If adjustment bolt (2) is tightened in the di-

rection 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 adjust-
ment bolt must not be used to adjust the brake.
20-120 D41E, P-6

1
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
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.
D41E, P-6 20-121

1
TESTING AND ADJUSTING ADJUSTING INCHING PEDAL LINKAGE
ADJUSTING INCHING PEDAL LINKAGE
5 7 3
6 4
BED00043
fl Tighten the locknuts of the rods and cables se-

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

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

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
20-122 D41E, P-6

1
TESTING AND ADJUSTING ADJUSTING PARKING BRAKE LINKAGE
ADJUSTING PARKING BRAKE LINKAGE
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.
D41E, P-6 20-123

1
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.
20-124 D41E, P-6

1
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
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
D41E, P-6 20-125

1
TESTING AND ADJUSTING MEASURING POWER TRAIN OIL PRESSURE
MEASURING POWER TRAIN

OIL PRESSURE
¤ Stop the machine on level ground, lower the
work equipment completely to the ground and
apply the parking brake.
fl When measuring the hydraulic pressure, remove
all the sand and dirt from around the nipples
and plugs.
fl Raise the power train oil temperature to 70 –
80°C before measuring.
Refer to the diagram and table below to install

oil pressure gauge C1 to the nipple for the cir-
cuit to be measured.
Table of centralized pressure pick-up port

positions and gauge to use when measuring
hydraulic pressure
6 1
No. Measurement location Gauge
1 Transmission modulating relief

pressure
2 Inching valve actuating pressure
3 Right clutch actuating pressure 5.9 MPa
{60 kg/cm2} 5 4 3 2
4 Left clutch actuating pressure
BED00066
5 Right brake actuating pressure

6 Left brake actuating pressure
1. Measuring transmission oil pressure C1

1) Measuring modulating relief pressure
i) Install oil pressure gauge C1 to pressure
detection plug (2).
ii) With the joystick at the neutral position,
measure the modulating relief pressure
with the engine at low idling and high
idling.
fl Note that the 1st speed (No. 5 clutch)
is actuated. Therefore, if the oil pres- BED00070
sure is defective, place in 2nd or 3rd

speed to measure the oil pressure.
20-126 D41E, P-6

1
2) Measuring clutch circuit pressure (1st, 2nd,

3rd clutch)
i) Install oil pressure gauge C1 to the pres-
sure detection plug.
ii) With the joystick at the 1st, 2nd, or 3rd
position, measure the clutch circuit pres-
sure with the engine at low idling and
high idling.
3) Measuring clutch circuit pressure (F, R Combination of speed ranges and clutches
clutch) used
Clutch
¤ The machine will move, so it is best to No. 1 No. 1 No. 2 No. 3 No. 4 No. 5
jack up the machine when measuring. (R) (F) (3rd) (2nd) (1st)
However, if there is no way to jack up F1 fi fi
the machine, check that the operation is
safe and measure while traveling. F2 fi fi
i) Install oil pressure gauge C1 to the pres- F3 fi fi
sure detection plug.
ii) With the joystick at the F or R position, F4 fi fi
measure the clutch circuit pressure with F5 fi fi
the engine at low idling and high idling.
F6 fi fi
[Reference]
i) If the oil pressure is defective for all the
clutches, the modulating relief valve or
power train pump is probably defective.
ii) If the oil pressure is defective for spe-
cific clutches, there is probably oil leak-
age from that clutch or the control valve
(spool) is defective.
• In this case, when shifting from a
normal clutch to a clutch with defec-
tive oil pressure, if the oil pressure
drops momentarily and then recov-
ers slightly, the control valve is prob-
ably normal.
fl If it is possible to check the move-
ment of the spool, it is possible to
make a more accurate judgement.
D41E, P-6 20-127

1
4) Measuring inching valve actuating pressure

i) Install oil pressure gauge C1 to pressure
detection plug (2).
ii) With the joystick at the neutral position,
measure the oil pressure when the inch-
ing pedal is depressed and when it is
not depressed with the engine at low
idling and high idling.
fl The oil pressure when the inching
pedal is not depressed is the same
as the modulating relief pressure.
5) Measuring clutch piston actuating pressure

i) For the left clutch, install oil pressure
gauge C1 to pressure detection plug (4);
for the right clutch, install oil pressure
gauge C1 to pressure detection plug (3).
ii) Place the joystick at the neutral position 6 1
or operate it to the left or right, and
measure the oil pressure with the en-
gine at low idling and high idling.
fl When the joystick is at the neutral
position, the maximum oil pressure
is output, and when the joystick is
operated, the pressure drops. 5 4 3 2
(When the joystick is operated fully, BED00066
the pressure drops to almost 0 MPa
{0 kg/cm2}.
6) Measuring brake piston actuating pressure

Note: The brake oil pressure when the joy-
stick is operated is different from the
brake oil pressure when the brake
pedal (inching pedal) is operated.
i) For the left brake, install oil pressure
gauge C1 to pressure detection plug (6);
for the right brake, install oil pressure
gauge C1 to pressure detection plug (5).
ii) Place the joystick at the neutral position
or operate it to the left or right, and
measure the oil pressure with the en-
gine at low idling and high idling.
fl When the joystick is at the neutral
position, the pressure is almost 0
MPa {0 kg/cm2}; when the joystick is
operated, pressure is output. (When
the joystick is operated fully, the
maximum oil pressure is output.)
20-128 D41E, P-6

1
iii) Measure the oil pressure when the brake

pedal or inching pedal is depressed with
the engine at low idling and high idling.
fl Set the parking brake to the RE-
LEASED position when measuring.
fl When the pedal is operated, the left
and right brakes are operated at the
same time.
D41E, P-6 20-129

1
TESTING AND ADJUSTING TESTING AND ADJUSTING WORK EQUIPMENT CIRCUIT PRESSURE

WORK EQUIPMENT CIRCUIT
PRESSURE
1
¤ Stop the machine on level ground, lower the
work equipment completely to the ground and
apply the parking brake.
fl When installing the oil pressure gauge, remove
all the sand and dirt from around the plug.
1. Measuring main relief pressure

fl Oil temperature when measuring: 45 – 55°C
1) Remove the floor plate, then remove plug
BED00067
(1) (PT1/8) for measuring the pump discharge
pressure, and install oil pressure gauge C1
(39.2 MPa {400 kg/cm2}).
2) Operate the blade lift, tilt, and angle cylin-
ders to the end of their stroke to relieve the
circuit, and measure the oil pressure. C1
fl There is a safety valve installed only in
the angle cylinder circuit. If the oil pres-
sure is low when the angle cylinder is
relieved, there is probaly a drop in the
set pressure of the safety valve.
BED00075
2. Adjusting main relief valve

1) Loosen locknut (3) of main relief valve (1)
and turn adjustment nut (4) to adjust. 1
¤ Never remove adjustment nut (4). If it is

loosened excessively, it will come off the
threaded part. Take extreme care when loos-
ening it.
fl Turn the adjustment screw as follows.
• To INCREASE pressure, turn
CLOCKWISE
• To DECREASE pressure, turn BED00068
COUNTERCLOCKWISE
fl Amount of adjustment for one turn of
adjustment screw: 19.6 MPa {200 kg/cm2}
Locknut:
44.1 ± 4.9 Nm {4.5 ± 0.5 kgm}
Cap: 44.1 ± 4.9 Nm {4.5 ± 0.5 kgm}
20-130 D41E, P-6

1
MEASURING AND ADJUSTING FAN MOTOR SPEED
TESTING AND ADJUSTING AND DRIVE CIRCUIT OIL PRESSURE
MEASURING AND ADJUSTING

FAN MOTOR SPEED AND
DRIVE CIRCUIT OIL PRESSURE
Measuring and adjusting circuit oil pressure
¤ When measuring, take care not to touch the
fan.
fl Oil temperature at measurement: 80°C
Measurement
1. Open the grille.
2. Remove oil pressure pickup plug (1) and install

nipple (1) (PT 1/8) in the oil pressure gauge C1,
and then connect oil pressure gauge C1.
3. Disconnect stepless speed changer connector

(CN99).
4. Run the engine at high idling and measure the

circuit oil pressure.
D41E, P-6 20-131

1
TESTING AND ADJUSTING MEASURING FAN SPEED
MEASURING FAN SPEED
1. Open the grille and remove the right upper fan

guard.
2. Install stand (1), probe (2), and reflector tape (3)

which are components of multitachometer A.
fl Make reflector tape (3) and probe (2) face
each other and set the distance between
them to 100 mm or less.
3. Connect probe (2) and multitachometer (5) by

cable (4).
4. Disconnect stepless speed changer connector

(CN99).
5. Close the grille, run the engine at high idling,

and measure the fan speed.
20-132 D41E, P-6

1
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.
¤ 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.
D41E, P-6 20-133

1
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.
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.
20-134 D41E, P-6

1
TESTING AND ADJUSTING BLEEDING AIR FROM HYDRAULIC CYLINDER
BLEEDING AIR FROM

HYDRAULIC CYLINDER
fl When operating the hydraulic cylinders for the
first time after replacing or reassembling the
cylinders or piping, always bleed the air from
the hydraulic cylinders as follows.
1) Start engine and run at low idling for approx.

5 minutes.
2) Run the engine at low idling, and operate

each cylinder to the end of its stroke 4 – 5
times.
fl When operating the hydraulic cylinder,
stop the piston rod 100 mm from the
end of its stroke. Do not relieve the cir-
cuit under any circumstances.
3) Run the engine at high idling and repeat

Step 2), then run the engine at low idling
and operate the piston rod to the end of its
stroke to relieve the circuit.
D41E, P-6 20-135

1
TESTING AND ADJUSTING PROCEDURE FOR RELEASING PARKING BRAKE
PROCEDURE FOR RELEASING

PARKING BRAKE
2
fl When releasing the parking brake manually, do
as follows. 1
1) Remove the brake control valve assembly.

For details, see REMOVAL OF BRAKE CON-
TROL VALVE ASSEMBLY.
2) Disconnect hose (1) and move brake lock (2)

to the side.
3) Tighten nut (3) of the parking brake cylinder BED00054
and extend the rod approx. 40 mm.

fl This operation relieves the parking brake.
fl Width across flats: 32 mm
BED00055
20-136 D41E, P-6

1
TESTING AND ADJUSTING TESTING AND ADJUSTING OPERATOR'S CAB

OPERATOR'S CAB
fl Enter the testing and adjusting items after in-
stallation of the operator's cab assembly.
1. Measure the internal pressure of the cab.
• Criterion: Measured value † 58.9 Pa {6 mmH2O}
• Engine speed: High idle
• Fan motor speed: Fan 100% speed mode
fl For the change to the fan 100% speed
mode, see "Special functions of monitor
panel (EMMS), "8. Adjustment mode".
• Air conditioner fan switch: High
• EXTERNAL/INTERNAL air changeover
switch: EXTERNAL position
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.
1] Prepare a transparent vinyl hose.
• Inside diameter: 6 mm, Length:
3,000 mm
2] Secure the inside end of the hose to the
top of the back seat with a tape.
3] Remove bolt (1) under the left console
box. Pass the other end of the hose
through the bolt hole and take it out of
inspection cover (2) on the left side of
the cab.
4] Seal the hole of bolt (1) with tape (3).
5] Pour water in the hose up to about half.
6] Set the water level in the vinyl hose out
of the cab to that in the cab.
7] Run the engine at high idle with the fan
at the 100% speed and measure water
level difference "c". (Value "c": Pa
{mmH2O})
fl [a] side: Inside of cab (Pressurized)
[b] side: 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 (4).
4) Check around the dashboard carefully.
fl If water leaks, caulk the leaking part and
check again.
D41E, P-6 20-137

1
(3)
3. Testing door lock

Close the door and check the relationship be-
tween the operator's cab and door. If there is
any fault, repair it.
1) Check of current condition
fl Check both sides, 2 places on each side.
• Stick adhesive tape [1] 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 operator'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.
2) Adjusting (Adjusting installed height of
damper rubber)
• Increase or decrease of shims (5) under
damper rubber (1) to adjust the height
of the damper rubber properly.
4. Testing door lock (Door link)
Close the door and check the relationship be-
tween the operator's cab and door. If there is
the following fault, repair it.
• When the door open lever (on the inside of
the door) or the door knob (on the outside
of the door) is operated, the door does not
open or it is heavy to open.
• When the door is closed, the door bounds
and does not close.
1) Remove plate (4) from the door link.
2) Check that door link bolts and nuts (5), (6),
(7), (8), (9), and (10) are tightened.
fl If they are loosened, tighten them to the
following tightening torque.
Tightening torque of M8 nut (Width
across flats: 13 mm) (5), (19):
27 - 34 Nm {2.8 - 3.5 kgm}
Tightening torque of M6 hexagon
socket head bolt (Width across flats
of socket: 4 mm) (6): 9.8 Nm {1.0 kgm}
Tightening torque of M28 nut (Width
across flats: 36 mm) (7):
11.8 - 14.7 Nm {1.2 - 1.5 kgm}
8 Threads: Adhesive (LT-2)
Tightening torque of M6 bolt (Width
11.8 - 14.7 Nm {1.2 - 1.5 kgm}
Tightening torque of M8 hexagon
socket head bolt (Width across flats of
socket: 5 mm) (9): 25.5 Nm {2.6 kgm}
Tightening torque of M6 bolt (Width
11.8 - 14.7 Nm {1.2 - 1.5 kgm}
20-138 D41E, P-6
1
(3)
3) Check the engagement of the latch and

striker.
• Move the door in the closing direction
and check that latch (12) in lock assem-
bly (11) on the door side is aligned with
striker (13) on the cab side.
fl If the latch and striker are not aligned,
adjust them according to the following
procedure.
1] Loosen the mounting bolts of striker (13)
and tighten them again lightly. Then,
open and close the door 2 - 3 times to
align latch (12) with striker (13).
2] After tightening the mounting bolts per-
manently, check that latch (12) is aligned 5) Check stroke "b" of door open lever
with striker (13). (15) and adjust rod end (16) and plate
4) Check of clearance in lock assembly open (17) so that the lock assembly will open
lever when the lever stroke is at the speci-
Check clearance "a" in lock assembly open fied value.
lever (14) and adjust it to the standard range. • Lever stroke "b": 7 ± 2 mm
• Clearance "a": 0.5 ± 0.2 mm
fl If clearance "a" is above the standard
range: The door is heavy to open.
fl If clearance "a" is below the standard
range: The door is heavy to close.
D41E, P-6 20-139

1
(3)
fl Procedure for adjusting rod end

1] Loosen locknut (5).
2] Turn nut (19) to adjust.
• If the nut is turned to move up rod end
(16), lever stroke "b" and clearance "a"
in the lock assembly open lever are in-
creased. (The door will become heavy
to open.)
• If the nut is turned to move down rod
end (16), lever stroke "b" and clearance
"a" in the lock assembly open lever are
reduced. (The door will become light to
open.)
3] Tighten locknut (5).

Tightening torque of locknut (5), (19)
(M8, Width across flats: 13 mm):
27 - 34 Nm {2.8 - 3.5 kgm}
fl Procedure for adjusting plate

1] Loosen bolt (6).
2] Move and adjust plate (17).
• If plate (17) is moved up, lever stroke
"b" and clearance "a" in the lock assem-
bly open lever are reduced. (The door
will become light to open.)
• If plate (17) is moved down, lever stroke
"b" and clearance "a" in the lock assem-
bly open lever are increased. (The door
will become heavy to open.)
3] Tighten bolt (6).
Tightening torque of bolt (6) (M6,

Width across flats of socket: 4 mm):
9.8 Nm {1.0 kgm}
20-140 D41E, P-6

1
(3)
6) Apply grease (GII-LI) to latch (12).

fl If latch (12) is not greased, the door open
lever and door knob become heavy.
7) Operate the door open lever (on the inside

of the door) and door knob (on the outside
of the door) and check that the door is opens
and closes smoothly.
If the door does not open or close smoothly
(If the door open lever is heavy), perform
the adjustment procedure again from 1).
• Operating effort of door open lever:
49 ± 19.6 N {5 ± 2 kg}
5. Check of open lock

Check the relationship between the operator's
cab and door while the door is locked open. If
there is any fault, adjust the open lock.
1) Check of current condition
1] Check the relationship between open
lock latch (3) and striker (4) in direction
B.
fl Move the door in the opening direc-
tion and check the engagement of
the latch and striker.
2] Check the installed height of the stopper

rubber. (Check both sides, 2 pieces on
each side.)
a. Lock the door open and move it in
the forward and reverse directions
to check that it does not have play.
b. Check that the operating effort of the
unlock lever is not heavy.
c. Check that striker (4) is not slant from
center "d" of the latch.
d. Check that latch and center "e" of
the striker are matched to each other.
• Normal: Deviation of "e" is 0.5 mm
or less.
2) Adjusting
1] Adjusting latch and striker
• Loosen the mounting bolts (7) of
striker (4) and adjust the striker so
that it will not slant, and then tighten
bolts (7).
D41E, P-6 20-141

1
(3)
2] Adjusting installed height of stopper rub-

ber
a. Loosen locknuts (10) and (11) of stop-
per rubber (8) (upper one) and (9)
(lower one).
b. If there is play, project (heighten) the

stopper rubber until the play is elimi-
nated.
fl If the door is not locked easily or the
unlock lever is heavy, return (lower)
the stopper rubber in the range that
the door does not have play.
c. Tighten the locknuts.
20-142 D41E, P-6

1
(3)
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
Types and locations of connectors ....................................................................................................... 20-215
Connector arrangement diagram .......................................................................................................... 20-220
Electric circuit diagram of each system ............................................................................................... 20-222
Connection table for connector pin numbers ..................................................................................... 20-227
T-adapter table ........................................................................................................................................ 20-250
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
D41E, P-6 20-201

1
(3)
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
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 D41E, P-6

1
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.
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?
D41E, P-6 20-203

1
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-
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 D41E, P-6

1
(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
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.
D41E, P-6 20-205

1
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.
(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 D41E, P-6

1
‡ 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
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.
• Connecting connectors (DT type connector)

Since the DT 8-pole and 12-pole DT type con-
nectors have 2 latches respectively, push them
in until they click 2 times.
1. Male connector, 2. Female connector
• Normal locking state (Horizontal): a, b, d
• Incomplete locking state (Diagonal): c
D41E, P-6 20-207

1
‡ 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.
(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 D41E, P-6

1
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.
(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.
D41E, P-6 20-209

1
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
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 D41E, P-6

1
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.
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.
D41E, P-6 20-211

1
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
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 D41E, P-6

1
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
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).
D41E, P-6 20-213

1
<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
(*A) 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. (*B) 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.
(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 D41E, P-6

1
TROUBLESHOOTING TYPES AND LOCATIONS OF CONNECTORS
TYPES AND LOCATIONS OF CONNECTORS

fl The addresses in the following table are the addresses used in the connector arrangement
drawing (3-dimensional drawing) and electric circuit diagram.
Address
Connector Connector No. of E mode M mode
type pins Location Arrangement Wiper system
No. drawing system system diagram
diagram diagram
CN1 DT 2 Rear lamp I-7 R-4
CN1 DT 4 Additional lamp power supply (Cab specification) H-9
CN2 DT 2 Additional rear lamp (Cab specification) E-9 R-4
CN2 KES1 2 Left rear speaker (Cab specification) H-8
CN3 DT 2 Fuel level sensor I-8 E-4
CN4 DT 4 Intermediate connector I-6 O-4 E-3
CN4 KES1 2 Right rear speaker (Cab specification) G-9
CN5 DT 2 Left head lamp A-4 A-5 A-5
CN6 DT 2 Right head lamp B-5 A-4 A-4
CN6 AMP-1 1 Glass with heater wire (EU specification) G-9
CN7 KES 1 Horn B-1 A-4
CN7 Y-PA 9 Radio (Cab specification) K-9
CN8 X 12 Intermediate connector D-1 C-2 C-5
CN8 DT 2 Accessory (12-V power supply) K-9
CN9 KES 2 Washer motor (Cab specification) C-6 A-2
CN9 Y-3 3 Switch of glass with heater wire (Cab specification) K-8
CN10 M 2 Additional lamp switch K-8
CN11 M 2 Intermittent wiper switch J-9 E-8
CN12 KES 2 Washer motor (Cab specification) C-6 B-2
CN12 KES1 6 Rear wiper switch (Cab specification) J-9 D-8
CN13 DT 6 Intermediate connector C-6 B-2
CN13 KES1 6 Right door wiper switch (Cab specification) J-9 C-8
CN14 DT 2 Air conditioner compressor (Cab specification) C-1 Q-8
CN14 KES1 6 Front wiper switch (Cab specification) J-8 C-8
CN15 DT 2 Engine water temperature sensor C-1 Q-8 F-6
CN15 KES1 6 Left door wiper switch (Cab specification) J-8 B-8
CN16 DT 2 Starting motor C-1 P-8 E-8
CN16 KES1 2 Room lamp (Cab specification) J-7
CN17 DT 4 Intermediate connector (Right door wiper motor) (Cab specification) J-6 B-3
CN18 DT 4 Intermediate connector (Additional lamp) (Cab specification) D-8
CN19 Terminal 1 Ground (Floor frame) Q-3
CN19 DT 4 Washer connector (Cab specification) L-5 E-8
CN20 DTHD 1 Cab power supply (Cab specification) L-6 O-1
I-3
CN21 DTHD 1 Cab backup power supply (Cab specification) L-6 N-1
G-1
D41E, P-6 20-215

1
Address
diagram diagram
CN22 DT 2 Horn switch E-9 E-1
CN23 DT 3 Neutral limit switch I-7 R-3 F-4
CN23 DT 6 Front wiper (Cab specification) D-8 E-3
CN24 DT 2 Relay (For engine stop solenoid) B-8 M-8
CN24 DT 4 Intermediate connector (Right door wiper motor) (Cab specification) L-5 B-2
CN25 Y-4 4 Light relay K-8
CN26 DT 4 Intermediate connector (Machine body - cab) (Cab specification) I-6 C-3
CN26 Y-6 6 Intermittent relay for left door wiper (Cab specification) K-8 A-7
CN27 DT 3 Backup alarm limit switch I-7 O-4
CN27 J-5 5 Intermittent selector relay for left door wiper (Cab specification) L-7 A-6
CN28 DT 2 Power train oil temperature sensor F-1 F-6
CN28 Y-6 6 Intermittent relay for front wiper (Cab specification) L-8 A-5
CN29 J-5 5 Intermittent selector relay for front wiper (Cab specification) L-7 A-4
J-3
CN30 DT 4 Intermediate connector A-9 C-5
CN30 Y-6 6 Intermittent relay for right door wiper (Cab specification) L-8 E-7
CN31 DT 12 Intermediate connector J-3 C-6 C-6
L-7
CN31 J-5 5 Intermittent selector relay for right door wiper (Cab specification) A-9 E-6
CN32 DT 12 Intermediate connector J-4 D-7 C-7
Y-6 6 L-8
CN32 Intermittent relay for rear wiper (Cab specification) A-9 E-5
CN33 DT 4 Intermediate connector J-3 I-3
CN33 J-5 5 Intermittent selector relay for rear wiper (Cab specification) L-7 E-4
A-8
CN34 SWP 2 Diode K-1 H-2
CN34 Y-4 4 Relay for glass with heater wire (Cab specification) L-8
CN35 — 4 Converter L-8
CN36 AMP-1 1 Glass with heater wire (EU specification) I-8 H-2
CN36 KES 4 Electromagnetic relay (Cab specification) J-1
CN37 KES 4 Air conditioner relay (Cab specification) J-1 J-2
CN37 KES1 4 Rear wiper motor (Cab specification) H-9 E-1
CN38 DT 3 Bimetal timer J-1 C-8
CN39 KES 3 Blower resistor (Cab specification) K-1 K-2
CN40 SWP 6 Travel speed indicator lamp J-4 A-5
CN41 DT 2 Buzzer K-2 D-8 B-8
CN42 SWP 2 Diode M-7
CN43 KES 4 Pressure switch (Cab specification) K-1 I-2
CN44 KES 4 Blower switch (Cab specification) J-4 K-2
CN45 KES 3 Air conditioner switch (Cab specification) J-4 G-2
CN46 KES 4 Glow plug switch L-2 C-8
20-216 D41E, P-6

1
Address
diagram diagram
CN47 KES 4 Rear lamp switch L-2 A-8
CN48 KES 4 Head lamp switch L-2 A-8 A-8
CN49 AMP040 16 Monitor panel L-4 A-6 A-6
CN50 AMP040 12 Monitor panel L-3 A-6 A-6
CN52 Terminal 1 Relay (Engine stop solenoid) B-9
CN53 Terminal 1 Relay (Engine stop solenoid) C-9
CN54 DT 2 Backup alarm I-8 R-3
CN57 KES 2 Blower motor (Cab specification) K-1 J-2
CN58 DT 12 Intermediate connector D-1 N-7 E-7
CN60 DT 3 Engine stop solenoid D-6 O-9
CN61 DT 3 Limit switch (1st gear speed detection) H-2 E-1
CN62 DT 3 Limit switch (3rd gear speed detection) H-2 F-1
CN63 DT 3 Intermediate connector (Additional light) I-6 Q-2
CN64 YAZAKI 2 Diode M-1 E-1
CN65 YAZAKI 2 Diode M-1 E-1
CN66 DT 4 Timer (For engine stop solenoid) B-9 M-8
CN67 KES 2 Fusible link D-1 N-7
CN68 SWP 2 Diode O-7
CN69 SWP 2 Diode O-7 E-9
CN70 SWP 2 Diode L-2 D-8 B-9
CN71 KES 4 Fan reverse switch L-2 D-8
CN75 DT 8 KOMTRAX Q-5 E-4
CN76 DT 8 KOMTRAX I-3 P-4 E-5
CN81 Terminal 1 Battery relay (–) terminal A-6 P-3 E-3
CN82 Terminal 1 Battery relay (+) terminal B-7 P-2 F-2
CN83 Terminal 1 Battery relay input terminal A-6 P-3 E-3
CN84 Terminal 1 Battery relay output terminal A-6 P-2 E-2
CN85 YAZAKI 2 Fusible link I-3 O-1
CN86 DT 2 Switch ineffective lamp K-5 D-8
CN87 DT 12 Solenoid relay circuit J-2 H-9
A-9
CN88 SHINAGAWA 6 Relay (Additional light) I-5 P-1
CN89 J-5 6 Relay (KOMTRAX) I-5 O-1
CN90 DT 6 Fan controller I-5 Q-6
CN91 Terminal 1 Starting motor E-1 O-9 E-9
CN93 DTHD 1 Machine body power supply G-2
CN95 DT 2 Fan reverse solenoid A-2 B-3
CN97 SWP 2 Diode Q-6
D41E, P-6 20-217

1
Address
diagram diagram
CN98 KES 4 Condenser relay D-8 Q-6
CN99 DT 2 Fan stepless speed changer solenoid B-5 B-3
CN100 DT 2 Intermediate connector C-8 P-6
CN101 Terminal 1 Ground (Cab) H-2 F-2
CN102 Terminal 1 Ground A-4
CN103 Terminal 1 Ground E-1 D-6 C-5
CN104 Terminal 1 Ground J-1 B-5
CN105 Terminal 1 Engine oil pressure switch E-1 F-7
CN106 Terminal 1 Ground D-7 N-7 F-9
CN107 Terminal 1 Heater relay inlet F-1 P-9 F-9
CN108 Terminal 1 Heater relay output F-1 Q-9 F-9
CN109 Terminal 1 Heater relay coil drive D-6 P-9 F-9
CN110 Terminal 1 Heater relay coil ground F-1 Q-9 F-9
CN111 Terminal 1 Starting switch (C) I-2 B-9 B-9
CN112 Terminal 1 Starting switch (ACC) H-2 B-9
CN113 Terminal 1 Starting switch (R1) I-1 B-9 B-9
CN114 Terminal 1 Starting switch (BR) I-1 B-9
CN115 Terminal 1 Starting switch (B) I-2 B-9 A-9
CN116 Terminal 1 Alternator (R) B-1 N-9 C-9
CN117 Terminal 1 Alternator (B) B-1 N-9 D-9
CN118 Terminal 1 Alternator (E) A-2 N-9 D-9
CN119 Terminal 1 Alternator (E circuit ground) C-1 N-8 D-8
ACC YAZAKI 2 Accessory (Cab specification) L-5
CIG YAZAKI 2 Cigarette lighter (Cab specification) L-5
CNFL DT 2 Rear right additional light (Cab specification) E-9
CNFR DT 2 Rear left additional light (Cab specification) D-8
CNRL DT 2 Front right additional light (Cab specification) H-8
CNRR DT 2 Front left additional light (Cab specification) G-9
FB1 Fuse BOX I-4 O-3 E-2
FB2 Fuse BOX I-5 O-3 E-2
GND1 Terminal 1 GND (Cab specification) K-8 C-1
GND2 Terminal 1 GND (Cab specification) K-8
GND3 Terminal 1 GND (Cab specification) L-7 E-3
GND4 Terminal 1 GND (Cab specification) G-9
20-218 D41E, P-6

1
TROUBLESHOOTING CONNECTOR ARRANGEMENT DIAGRAM
CONNECTOR ARRANGEMENT DIAGRAM
20-220 D41E, P-6

1
(3)
TROUBLESHOOTING CONNECTOR ARRANGEMENT DIAGRAM
D41E, P-6 20-221

1
(3)
TROUBLESHOOTING ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM
ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM

E MODE SYSTEM DIAGRAM
(1/2)
20-222 D41E, P-6

1
(3)
D41E, P-6 20-223

1
(3)
(2/2)
20-224 D41E, P-6

1
(3)
M MODE SYSTEM DIAGRAM
D41E, P-6 20-225

1
(3)
WIPER SYSTEM DIAGRAM
20-226 D41E, P-6

1
(3)
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
D41E, P-6 20-227

1 Å Å
SWP type connector

No. of
pins T-adapter
6 799-601-7050
8 799-601-7060
12 799-601-7310
14 799-601-7070
20-228 D41E, P-6

Å 1 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:

• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
D41E, P-6 20-229

1 Å 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
4 799-601-7120
6 799-601-7130
8 799-601-7390
20-230 D41E, P-6

Å 1 Å
S type connector
No. of
pins T-adapter
8 799-601-7140
10
799-601-7150
(White)
12
799-601-7350
(White)
16
799-601-7330
(White)
D41E, P-6 20-231

1 Å Å
S type connector
No. of
pins T-adapter
10
—
(Blue)
— —
12
799-601-7160
(Blue)
16
799-601-7170
(Blue)
20-232 D41E, P-6

Å 1 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

(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)
D41E, P-6 20-233

1 Å Å
MIC type connector

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

(Q’ty: 2) (Q’ty: 2)
21 799-601-2740

(Q’ty: 2) (Q’ty: 2)

—
(Q’ty: 50) (Q’ty: 50)
20-234 D41E, P-6

Å 1 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

—
(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)
D41E, P-6 20-235

1 Å 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
14 799-601-7530
— Part number: 08195-14210
18 799-601-7540
— Part number: 08195-18210
20 799-601-7550
— Part number: 08195-20210
20-236 D41E, P-6

Å 1 Å
L type connector
No. of
pins T-adapter
2 —
— —
Connector for PA
No. of
pins T-adapter
9 —
— —
Bendix MS connector
No. of
pins T-adapter
10 799-601-3460
— —
D41E, P-6 20-237

1 Å 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 —
4 —
08027-10420 (Black) 08027-10470 (Black)
6 —
08027-10620 (Black) 08027-10670 (Black)
20-238 D41E, P-6

Å 1 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
5 799-601-7360
— —
6 799-601-7370
— —
D41E, P-6 20-239

1 Å Å
F type connector
No. of
pins T-adapter
4 —
— —
20-240 D41E, P-6

Å 1 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

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
D41E, P-6 20-241

1 Å Å

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

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

799-601-9240

799-601-9240
20-242 D41E, P-6

Å 1 Å

Part No.
799-601-9250

799-601-9250

799-601-9260

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

08191-62205, 08191-62206 08191-63105, 08191-63106
D41E, P-6 20-243

1 Å Å

Part No.
799-601-9270

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

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
20-244 D41E, P-6

Å 1 Å

Part No.
799-601-9290

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290

08191-92205, 08191-92206 08191-93105, 08191-93106
D41E, P-6 20-245

1 Å 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
4 799-601-9040
6 799-601-9050
20-246 D41E, P-6

Å 1 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
Part number: 08192-1820 o (normal type) Part number: 08192-1810 o (normal type)
08192-2820 o (fine wire type) 08192-2810 o (fine wire type)
12GR : 799-601-9110
12B : 799-601-9120
10
12G : 799-601-9130
12BR : 799-601-9140
Part number: 08192-1920 o (normal type) Part number: 08192-1910 o (normal type)
08192-2920 o (fine wire type) 08192-2910 o (fine wire type)
D41E, P-6 20-247

1 Å Å
DTM Series connector

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

No. of
pins T-adapter
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)
20-248 D41E, P-6

Å 1 Å
DT Series connector
No. of
pins T-adapter
24 799-601-9360
— Part number: 7821-93-3110
40
799-601-9350
(A)
— Part number: 7821-93-3120
40
799-601-9350
(B)
— Part number: 7821-93-3130
D41E, P-6 20-249

1 Å
(3) 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
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
20-250
(3)
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
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
20-250-1
(3)
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
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
20-250-2
(3)
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 (incomplete combustion) .................................................................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
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
D41E, P-6 20-251

1
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
from his own inspection. (1) (2) (3)
[Troubleshooting]
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)
Questions
A (b)
(c)
(d)
(e)
B
C
Check item
i
shooting
ii
Trouble-
iii
20-252 D41E, P-6

1
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with !, 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
)
tion
the Cause column with # to use as reference
injec
for locating the cause of the failure. How-
sive
ever, do not use this when making calcula-
nce
tions to narrow down the causes.
xces
le
nozz
rfee
*2. Use the # in the Cause column as reference
nt
p (e
eme
img
r
inde
inte
for [Degree of use (Operated for long pe-
tion
pum
n tim
l
riod)] in the [Questions] section as reference.
er e
injec
, cyl
ger,
tion
As a rule, do not use it when calculating the
lean
ectio
char
ring
zed
injec
points for locating the cause, but it can be
air c
urbo
r inj
, sei
ston
included if necessary to determine the order
ctive
rope
ged
ged
n pi
ed t
for troubleshooting.
Defe
Clog
Clog
Wor
Seiz
Imp
* 1 Confirm recent repair history
*2 Degree of use Operated for long period
D41E, P-6 20-253

1
• Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three
symptoms have 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.
ad
d)
ion)
l. he
eize
• Excessive injection of fuel.
ject
d cy
er s
e in
lung
r an
seat
essiv
elem rence
arge
ck, p
lve
n tim nozzle
(exc
, va
h
p (ra
ent
terfe
boc
der
alve
ing
r
ed m ce
n
mp
uffle
r
ctio
pum
r, in
aran
n tu
ylin
of v
p
rope ized inje
n pis cleaner
arge
e
e cle
rope jection
ion
e
ing,
Legend
ctio
t
betw
ntac
ject
logg
: Possible causes (judging from Questions and check items) Clog urboch
valv
r
r inje
ton
e co
, se
e in
e in
air
age
: Most probable causes (judging from Questions and Check items)
d, c
r
ged
ged
ctiv
ctiv
ctiv
ed t
leak
: Possible causes due to length of use (used for a long period)
she
Clog
Defe
Defe
Defe
Wor
: Items to confirm the cause.

Seiz
Imp
Imp
Cru
Air
Confirm recent repair history
Degree of use Operated for long period
Suddenly became black
Color of exhaust gas
Question
Gradually became black

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 D41E, P-6

1
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
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.
D41E, P-6 20-255

1
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
r
Ambient 100% 90% 80% 75% 70%
filte
temperature
,v
ent
er
uze
r
r
20°C 1.28 1.26 1.24 1.23 1.22
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
d
• The specific gravity should exceed the value for the
fuel
l int
ston
e e
a
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

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
(*1.) Use a test stand

20-256 D41E, P-6
1
Replace Defe
ctive
Replace Defe regu Legend
D41E, P-6
lato
ctive r
Replace Defe alter
nato
ctive r
Replace Defe or d
eter
ctive iora
(*1.) Adjust Defe injec ted
batt
tive tion ery
nozz
Replace Defe
injec
tion le
tive t i m
Correct ing
TROUBLESHOOTING
Leak injec
age, tion
c pum
Clean l ogg p (ra
Clog ing, ck, p

Replace
ged
a ir br a i r in fu lung
Defe eath el pi er st
ctive er h ping uck)
Causes
feed ole i
pum n fu
p el ta
nk
: Possible causes (judging from Questions and check items)
1
20-257
S-1
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)
fl Standards for use of fuel Causes

AMBIENT TEMPERATURE
KIND OF
ed)
FLUID -22 -4 14 32 50 68 86 104 122˚F
-30 -20 -10 0 10 20 30 40 50˚C
seiz
ASTM D975 No.2
ger
key
Diesel fuel
nk
n
el ta
u
ASTM D975 No.1
aft,
l
ck, p
on
e sh
in fu
pist
p (ra
ng
iner
fl In winter, if ASTM D975 No.1 diesel oil is driv
noid
mp
ole
pipi
n
stra
not available, a 50-50 mixture of ASTM D975 pum
i
stra
u
nk
mp
h
sole
p
fuel
her
No. 2 diesel oil and kerosene can be used.
in ta
ump
eed
n pu
ed
ion
lter,
cut
reat
king
l us
Legend
en f
fuel
ject
p
ctio
el fi
uel
air b
feed
r fue
, lea
brok
e in
inje
ent
u
f
f
e
ged
rope
ged
ged
ged
ctiv
ctiv
ffici

ed,
ken
Clog
Defe
Clog
Defe
Clog
Clog
Insu

Seiz
Imp
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 D41E, P-6

1
TROUBLESHOOTING S-2
2) Exhaust smoke comes out but

engine does not start (Fuel is Causes
being injected)
.)
r, etc
k)
stuc
General causes why exhaust smoke comes out but
leve
ap
ray
engine does not start
ger
cker
nk c
e sp
stem
n
ater
e, ro
el ta
l u
ctiv
ck, p
• Lack of rotating force due to defective electri-
ry
ir he
(valv
el sy
ner
in fu
atte
defe
cal system
p (ra
ent
iner
er li
ke a
in fu
tem
b
e r
• Insufficient supply of fuel
hole
d
zle,
lem
n
stra
d
pum
rate
e sys
inta
a
n
r
noz
r
i
i
er e
, cyl
her
s
ump
erio
valv
ed
ical
ing,
ion
lter,
ion
lean
reat
ring
l us
Legend
t
ectr
ject
ed p
e
ken
ogg
el fi
ject
d
air b
air c
r fue
ston
e or
, bro
e in
e el
e, cl
u
e
n
f
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
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
D41E, P-6 20-259

1
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
ray
seat
nk c
e sp
lve
el ta
e
ctiv
d va
• Improper condition of fuel injection
renc
r
er
in fu
line
defe
• Improper fuel used
ung
e an
ent
g
terfe
iner
n
r
der
aine
pipi
e
hole
lem
zle,
p pl
valv
ranc
stra
r, in
ylin
noz
r
er e
fuel
pum
r, st
her
clea
t of
ump
arge
g, c
n
lean
reat
filte
king
ntac
ctio
tion
Legend
lve
ed p
h
i
c
r
air b
air c
urbo
uel
, lea
inje
r va
ston
e co
njec
e
f
f
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
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 D41E, P-6

1
TROUBLESHOOTING S-4
S-4 Engine stops during operations

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

Causes
• Overheating
c.)
r, et
k)
fl If there is overheating and the engine stops,
leve
stuc
carry out troubleshooting for overheating.
c k er
ger
ro d
nk
e, ro
plun
• Failure in power train
el ta
ent
key
ring
ting
ston
valv
,
ipm
i n fu
k
aft,
a
nec
c
p pi
ft be
m (
p (ra
ng
er
fl If the engine stops because of a failure in
equ
er
e sh
rain
con
hole
pipi
yste
pum
rain
in
the power train, carry out troubleshooting
ksha
pum
nk
r tra
ary
driv
p st
in
on,
lve s
fuel
for the chassis.
r, st
ther
in ta
r tra
eed
i
cran
l
gea
ion
pist
pum
i
p
x
c va
filte
king
pum
a
p au
Legend
ed f
owe
e
fuel
ject
zed
zed
r
zed
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
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
D41E, P-6 20-261

1
TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly

(Hunting)
General causes why engine does not rotate smoothly Causes
p
le
pum
• Air in fuel system
nozz
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
fl If hunting stops when electric governor rod is
er
gov
ontr
ove
in ta low
wee
iner
wee
rain
disconnected, carry out troubleshooting for the
hole
of g
t of
of c
t bet
o
stra
nk
t bet
chassis.
p st
is to
her
men
ion
ion
i
pum
ircui
,
circu
ilter
reat
eed
Legend
erat
erat
just
fuel
c
f
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
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 D41E, P-6

1
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
• Improper fuel used
lve
el ta
ctiv
e
d va
(if non-specified fuel is used, output drops)
tive
renc
in fu
r
defe
nge
• Lack of output due to overheating
efec
e an
ng
ent
iner
erfe
ump iner
u
r
hole
pipi
e
inde
zle,
d
lem
p pl
valv
ranc
stra
, int
ge,
a
fl If there is overheating and lack of output,
noz
, str
fuel
er e
pum
, cyl
her
rger
nka
t of
clea
carry out troubleshooting for overheating.
tion
reat
lean
filte
ing
ring
ntac
er li
Legend
cha
tion
lve
ed p
k
air b
air c
inje
l lev
fuel
urbo
, lea
e co
r va
ston
njec
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
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
D41E, P-6 20-263

1
TROUBLESHOOTING S-7
S-7 Exhaust smoke is black

(incomplete combustion) Causes
General causes why exhaust smoke is black
d)
ead
n)
eize
ctio
nd h
er s
at
ray
inje
e se
er a
lung
e sp
sive
valv
harg
• Excessive injection of fuel
ctiv
ck, p
renc
x ce s
rboc
and
de f e
p (ra
ent
erfe
( e
de r
alve
n tu
g
fler
e
p
lem
zle,
imin
ranc
, int
pum
n
f
e
u
of v
noz
u
i
er e
, cy l
e
p
ed m
rger
clea
on t
etw
ion
ion
lean
tion
tact
ring
Legend
cha
air b
e ct i
ject
ject
e
logg
v
con
njec
air c
l
urbo
r inj
a
ston
e in
e in
v
e of
d, c
e
i
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
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 D41E, P-6

1
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
General causes why oil consumption is excessive
arge
och
• Abnormal combustion of oil
Turb
al
d
• External leakage of oil
he a
n se
ace
stem
e
ping l cooler
• Wear of lubrication system
hos
surf
de r
oke
er
e sy
r lin
cylin
he r
), br
seal
plug
i
or o
reat
k
inde
d
end
uide
inta
n or
eal,
n
ain
e
or b
ilter
, cyl
e
wer
m, g
om
ar s
il pa
il dr
n
il pi
ing
i
oil f
b
ther
r
ring
in fr
Legend
t blo
n re
oole
t tur
(ste
mo
mo
mo
on r
m
brea
roke
ston
cked
al a
al a
oil c
e fro
e fro
e fro
e fro
lve
pist
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
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
D41E, P-6 20-265

1
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
bine
r tur
pipe
se
er
r ho
e
r lin
harg
ain
athe
inde
r dr
e
boc
lack
guid
, bre
arge
, cyl
t tur
is b
r
e
ther
oole
och
ring
valv
er
Legend
al a
oke
l filt
brea
turb
oil c
ston
e se
lve,
t sm
o i
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
Confirm recent repair history Exh

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 D41E, P-6

1
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
)
iston
njec
linka
el fil
p (p
ive i
g, fu
trol
p um
r
ger
cess
c o ve
l con
pipin
plun
ng
y
p (ex
eed
spra
f fue
head
timi
fuel
ump
ide f
pum
lder
nt o
tion
from
side
l ins
on p
le ho
Legend
stme
injec
tion
el in
age
a
jecti
e
injec
nozz
adju
oil s
fuel
of fu
leak
i n
ctive
ctive
ctive
ctive
ctive
ctive
age
rnal
Defe
Defe
Leak
Defe
Defe
Defe
Defe
Exte
Questions

More than for other machines of same
Condition of fuel model
consumption Gradually increased
Suddenly increased
Black
Exhaust smoke color
White
There is irregular combustion
Check items
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
D41E, P-6 20-267

1
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
Legend
by p
er h
r tra
oler
s in
ylind
rack
used
owe
il co
nal c
en o
en p
en c
s ca
Brok
Brok
Hole
Brok
Inter

Questions

Suddenly increased
Oil level
Gradually increased
Hard water is being used as cooling water
Engine oil level has risen, oil is cloudy white
Check items
Excessive air bubbles inside radiator, spurts back

Hydraulic oil, transmission oil is cloudy white
When hydraulic oil, transmission oil is drained, water is
found
shooting
Trouble-

Pressure-tightness test of cylinder head shows there is leakage
Replace
Replace
Replace
Replace
Replace
Remedy
20-268 D41E, P-6

1
S-12 Oil pressure caution lamp lights

up (Drop in oil pressure)
General causes why oil pressure lamp lights up
• Leakage, clogging, wear of lubricating system

• Defective oil pressure control
• 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 86 104 122˚F
-30 -20 -10 0 10 20 30 40 50˚C
SAE 30CE,CF-4 Causes
SAE 10WCE,CF-4
Engine oil
SAE 10W-30CE,CF-4
SAE 15W-40CE,CF-4
g
SAE 5W-40CE,CF-4
ipin
n
n
l pa
sor
l pa
lic p
ing
SAE 5W-30CE,CF-4
sen
e oi
e oi
alve
drau
braz
SAE 0W-30CE,CF-4 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
Legend
l pu
in o
lief
ion
il pi
il in
oil f
stra
l
arin
, cru
e re
e re
e oi
e oi
suct
uel
o
: Most probable causes (judging from Questions and Check items) 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
D41E, P-6 20-269

1
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
r)
mbe
ver
n cha
d co
eal
ustio
hea
nt s
p
omb
pum
e
side
m
ace
prec
quip
e
g in
ion
surf
-ring
leev
k
t
aske
ry e
ject
bloc
ipin
seal
er s
re, O
ad g
e in
a
p
g
i
der
hold
l
from
ittin
t
rear
osta
aux
d, he
r co
nsid
cylin
by p
Legend
zzle
oole
ged
r hea
erm
mp
fuel
art i
side
e no
e pu
ama
ade
linde
e th
oil c
p
: Most probable 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
: Items to confirm the cause. Defe
Crac
Wor
Lea
Brok
Bro

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 D41E, P-6

1
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
ge
ket
t op
lley
• Defective cooling circulation system
erat
gau
gas
ns
s no
n pu
emp
ture
or fi
ead
oler
fl Carry out troubleshooting for chassis.
doe
n fa
oil t
e
pera
diat
d, h
valv
il co
tat (
g
e
wor
ater
ittin
r
sion
d ra
hea
ump
tem
o
e
c
o
s
gw
r
o
ing,
ator
by p
essu
ken
Legend
she
mis
herm
der
ater
er p
olin
lipp
, bro
radi
, cru
cylin
ans
e pr
ade
ew
wat
t
o
s
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
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
D41E, P-6 20-271

1
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
• Abnormality due to defective parts
er s
ce
n
out o
der
rock
aran
• Abnormal combustion
lung
r
arge
ive
e
ylin
c
• Air sucked in from intake system
o ard
e cl e
cess
alve
eren
ck, p
renc
och
pum ozzle
g, c
m (v
ing b
sh
x
valv
f
p (ra
turb
erfe
n rin
r
p (e
inte
on n
ckla
yste
divid
, int
ing
t of
pum
een
isto
a
belt
ecti
b
lve s
ush
n
rger
fler (
train
etw
of p
e
j
ion
ion
n
n
m
ic va
ed b
Legend
n, fa
i
cha
just
air b
muf
d
ject
ject
ear
r
e
a
ynam
z
z
urbo
r ge
d fa
e ad
, sei
ve w
e in
side
, sei
e in
e of
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
Exc

Questions
Condition of abnormal Gradually occurred

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

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 D41E, P-6

1
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”.
n)
, etc.
ned
shio
ctio
General causes why vibration is excessive
lever
alig
per)
n cu
inje
mis
cker
dam
roke
sive
ring
• Defective parts (abnormal wear, breakage)
e, ro
n
aft (
xces
s, b
bea
ai
• Improper alignment
(valv
er tr
ash
t sh
bolt
ain
p (e
• Abnormal combustion
ystem
ackl
utpu
d, m
o
ting
pum
nd p
b
lve s
de o
g ro
n
hing
ion
a
i
r tra
o
ic va
Legend
gine
em
ctin
insi
ject
bus
gea
ynam
nne
ngin
f en
e in
part
r
d
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
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
D41E, P-6 20-273

1
TROUBLESHOOTING
TROUBLESHOOTING OF ELECTRICAL SYSTEM

(E MODE)
Table of failure modes and causes (electric system) ........................................................................ 20-302

Electrical circuit diagrams for each system ........................................................................................ 20-305
E-1 Starting motor is not cranked when starting switch is turned to ON .................................... 20-310
E-2 Engine does not start (Engine stop solenoid malfunctions) .................................................... 20-312
E-3 Lamps do not light up ................................................................................................................... 20-315
a) Head lamps ............................................................................................................................... 20-315
b) Rear lamps ................................................................................................................................ 20-316
E-4 Automatic preheating is not carried out when glow switch is turned to AUTO .................. 20-318
E-5 Wiper does not operate ................................................................................................................ 20-320
E-6 No washer fluid is sprayed out ................................................................................................... 20-324
E-7 Air conditioner has no effect ........................................................................................................ 30-326
a) No air comes out ...................................................................................................................... 20-326
b) Does not become cool ............................................................................................................. 20-330
E-8 Fan malfunctions ............................................................................................................................ 20-334
a) Forward fan speed is low ........................................................................................................ 20-334
b) Forward fan speed does not lower from maximum level
(when water temperature is below 85°C).............................................................................. 20-334
c) Fan does not revolve in reverse ............................................................................................. 20-336
D41E, P-6 20-301

1
TROUBLESHOOTING TABLE OF FAILURE MODES AND CAUSES
TABLE OF FAILURE MODES AND CAUSES

(ELECTRIC SYSTEM)
Wiper intermittent selector switch
Wiper intermittent selector relay

Engine stop solenoid
Engine stop timer
Engine stop relay
Glow plug switch

Wiring harness
Bimetal timer
Wiper switch
Battery relay
Wiper motor
Panel switch
Heater relay
Light switch
Battery
Light
Fuse
Failure mode
1 When starting switch is turned ON,

fi
fi
fi
fi
starting motor does not rotate
Engine does not start (Engine stop

fi
fi
fi
fi
2 solenoid malfunctions)
Lamps do not light up

fi
fi
fi
fi
fi
fi
fi
3 (Head lamp and rear lamp)
When glow plug switch is turned to

fi
fi
fi
fi
fi
fi
fi
4 AUTO position, engine is not heated
automatically
fi
fi
fi
fi
fi
5 Wiper does not operate
fi
6 Washer fluid does not spout out

fi
fi
fi
fi
7 Air conditioner does not work

fi
8 Fan reverse solenoid malfunctions
20-302 D41E, P-6

1
fi Intermittent relay
fi Washer motor
D41E, P-6
fi Washer nozzle
fi Washer piping
fi Air conditioner compressor

TROUBLESHOOTING
fi Air conditioner electromagnetic relay
fi Blower motor
fi Air conditioner switch
fi Fan reverse switch
fi Fan controller
fi Fan reverse solenoid
E-8
E-7
E-6
E-3
E-2
E-1
E-5
E-4
code E-OX.
Regular
regular trouble-
is detected, go to
troubleshooting
If any abnormality
of troubleshooting
shooting (YES/NO)
1
20-303
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM
ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM

WIPER RELATED SYSTEM DIAGRAM
D41E, P-6 20-305

1
CHASSIS RELATED SYSTEM DIAGRAM

(1/2)
20-306 D41E, P-6

1
D41E, P-6 20-307

1
(2/2)
20-308 D41E, P-6

1
TROUBLESHOOTING E-1
E-1. Starting motor is not cranked when starting switch is turned to ON
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
flCheck operation of limit switch before starting
• Turn starting troubleshooting.
(*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. harness between
YES starting switch
terminal BR and
(*1.) 8 battery relay (+)
(*1.) 1 normal?
Is there continuity
Are specific YES between starting • Between starting
gravity and switch BR and NO
switch terminals B
voltage of (*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
20-310 D41E, P-6

1
TROUBLESHOOTING E-1
Cause Remedy
Repair or
Defective starting motor
replace
Defective contact of
wiring harness between
Repair or
battery relay and starting
replace
motor, or defective
starting motor
Defective alternator safety

relay Replace
Defective safety limit
switch, or defective
contact or disconnection Repair or
in wiring harness replace
between starting motor
terminal S and starting
switch terminal C
Defective starting switch Replace
10 YES
Defective battery relay Replace
Is there continuity
between battery
terminal (–) and Defective contact of
frame ground? wiring harness between Repair or
battery relay (–) and replace
• Turn starting NO
frame ground
switch OFF. Defective contact, or
disconnection in wiring
Repair or
harness between starting
replace
switch terminal BR and
battery relay (+) terminal

(between B and BR)
Repair or
harness between battery
replace
(+) terminal and starting
switch terminal B
Charge or
Defective battery
replace
*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.
D41E, P-6 20-311

1
TROUBLESHOOTING E-2
E-2. Engine does not start (Engine stop solenoid malfunctions)

fl Carry out the following troubleshooting when the starting motor rotates normally.
a) When solenoid does not pull
3 YES
Is resistance
YES between CN60
(female) (C) and
GND normal?
• Max. 1 Ω NO
• Turn starting
switch OFF.
2 • Disconnect CN60. YES
Is voltage
YES between CN60
(A) and GND
normal?
• For about 10
seconds after YES
starting switch is
turned ON: 20 -
30 V 4
• About 10 6
Is voltage
seconds later: between CN53 Is voltage
Max. 1 V of relay and YES between CN24
NO GND normal (1) and GND
CN52? normal?
• 20 - 30 V
• Turn starting • 20 - 30 V
switch ON. • Turn starting
switch ON.
NO
1 5
Is resistance Is voltage
between CN60 between CN52 of
(male) (A) and (C)
normal and are NO relay and GND
they insulated normal?
from chassis
ground?
• 0.73 – 0.90 Ω
• Between CN60
(male) (A) -
chassis ground:
Min. 1 MΩ
• Turn starting
switch OFF. 12 YES
• Disconnect CN60. Is voltage
between CN112
and GND
NO normal?
• 20 - 30 V NO
• Turn starting
switch ON.
NO
20-312 D41E, P-6

1
TROUBLESHOOTING E-2
Cause Remedy
Defective engine stop

Replace
solenoid
Disconnection or
defective contact in wiring Repair or
harness between CN60 replace
(female) (C) - GND
Disconnection or
harness between CN53 - replace
CN60 (female) (C)
7 YES Defective engine stop

Replace
Is resistance relay
between CN24
(female) (2) and Disconnection or
CN66 (female) (4) defective contact in wiring
normal? harness between CN66 Repair or
• Max. 1 Ω NO (female) (4) - CN24 replace
(female) (2)
• Turn starting
switch OFF. Disconnection or
• Disconnect CN24 YES defective contact in wiring Repair or
and CN66. harness between CN66
(female) (3) - CN24 replace
(female) (1)
8
10 YES Defective engine stop
Is voltage Replace
Is resistance timer
between CN66 (3)
and GND normal? YES between CN66
(female) (2) and Disconnection or
9 GND normal? defective contact in wiring Repair or
• 20 - 30 V
• Turn starting • Max. 1 Ω NO harness between CN66 replace
Is voltage • Turn starting (female) (2) - GND
switch ON. between CN66 (1) switch ON. Disconnection or
NO and GND normal? • Disconnect CN66.
defective contact in wiring
11 YES Repair or
harness between CN114 -
• 20 - 30 V Is voltage CN32 (6) - CN58 (8) - CN66 replace
• Turn starting between CN114 (female) (1)
switch ON. NO and GND normal?
• 20 - 30 V NO (Between B - BR)
• Turn starting
switch ON. Disconnection or
harness between CN112 - replace
CN32 (9) - CN58 (7) - CN52

(Between B - ACC)
Defective engine stop Replace

solenoid
D41E, P-6 20-313

1
TROUBLESHOOTING E-2
b) When solenoid pulls but does not hold
Cause Remedy
2 YES Defective engine stop Replace

Is resistance solenoid
YES between CN60
1 (female) (C) and Disconnection or
GND normal? defective contact in wiring Repair or
Is resistance harness between CN60 replace
• Max. 1 Ω NO
between CN60 (B) (female) (C) - GND
• Turn starting switch OFF.
and GND normal? • Disconnect CN60. Disconnection or
Repair or
• 20 - 30 V harness between CN60
NO replace
• Turn starting (female) (B) - CN58 (male)
switch ON. (8) (up to branching point)
20-314 D41E, P-6

1
TROUBLESHOOTING E-3
E-3. Lamps do not light up

fl Carry out the following troubleshooting when the battery is normal.
fl Before starting the following troubleshooting, check that fuse FB1, No. 1, is normal.
a) Head lamp
Cause Remedy
Defective lamp that does

4 YES not light up or defective Repair or
Is voltage contact in its wiring replace
YES between CN5 or harness
3 CN6 and chassis Disconnection or defective
Is continuity ground normal? contact in wiring harness Repair or
YES between head • 20 - 30 V NO between CN5 (female) (1) replace
lamp switch L and • Turn starting switch ON. or CN6 (female) (1) - CN48
2 M as shown in
Table 1? • Turn head lamp (female) (3)
Is voltage switch ON.
YES between CN48 • Disconnect CN48. Defective head lamp
• Turn starting Replace
NO switch
(2) and chassis switch OFF.
1 ground normal? flIf rear lamp is normal, head lamp Disconnection or
switch may be checked by replacing it
When starting • 20 - 30 V with rear lamp switch. defective contact in wiring
switch is turned harness between CN48 Repair or
• Turn starting
OFF, does battery NO (female) (2) - fuse FB1, replace
switch ON.
relay make sound? No. 1
• Turn starting Start troubleshooting
switch ON, then from E-1, Step 7
OFF. NO
Table 1
E L M Continuity
OFF Made
ON Broken
E-3. a) Related electrical circuit diagram
D41E, P-6 20-315

1
TROUBLESHOOTING E-3
b) Rear lamp
Cause Remedy
Defective lamp that does

4 YES not light up or defective Repair or
Is voltage contact in its wiring replace
YES between CN1 harness
3 and chassis
Disconnection or defective
ground normal?
Is continuity contact in wiring harness Repair or
YES between rear • 20 - 30V NO between CN1 - CN47 replace
lamp switch L and
M as shown in • Turn starting switch ON.
2 Table 2? • Turn rear lamp switch
Is voltage ON.
YES between CN47 • Disconnect CN47. Defective rear lamp
NO switch
(2) and chassis switch OFF.
1 ground normal? flIf head lamp is
normal, rear lamp switch may be checked Disconnection or
When starting • 20 - 30V by replacing it with head lamp switch.
switch is turned defective contact in wiring Repair or
OFF, does battery • Turn starting harness between CN47 -
NO replace
relay make switch ON.
sound? fuse FB1, No. 1
• Turn starting Start troubleshooting

switch ON, then from E-1, Step 7
OFF. NO
Table 2
E L M Continuity
OFF Made
ON Broken
E-3. b) Related electrical circuit diagram
20-316 D41E, P-6

1
TROUBLESHOOTING E-4
E-4. Automatic preheating is not carried out when glow switch is turned
to AUTO
fl When the battery is normal.
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
(*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?
• Turn starting
switch ON →
OFF. NO
*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.
20-318 D41E, P-6

1
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 (1)
Defective bimetal timer Replace
Repair or
harness between starting
replace
switch terminal BR and
CN38 (2)
Start troubleshooting
from E-1 Item 7
D41E, P-6 20-319

1
TROUBLESHOOTING E-5
E-5. Wiper does not operate

fl Carry out the following troubleshooting when the engine starts.
fl Before starting the following troubleshooting, check that wiper fuses (4), (5), and (6) are normal.
fl If any wiper does not operate, check the wiring harness between CN85 fusible link and wiper
fuses.
a) When continuous operation is defective (The following shows the rear wiper system. For the
connector Nos. of the other wipers, see the list.)
YES
3 YES
1 Is resistance
When CN32 relay YES between CN37
is replaced with (female) (2) and
another relay, GND normal?
does condition
become normal?
• Max. 1 Ω NO
flFor connector • Turn starting
Nos. of other switch OFF.
relays, see list.
2 • Disconnect YES
Is voltage CN37.
between CN37
NO (1) and GND
normal? YES
• 20 - 30 V
• Turn starting 6
switch ON.
• Turn wiper 4 Is voltage YES
YES between CN32
switch ON. Is voltage
between CN32 (4) and GND
(5) and GND normal?
NO 7
normal?
• 20 - 30 V Is voltage
• 20 - 30 V • Turn starting between CN33 (6)
• Turn starting switch ON. NO and GND normal?
switch ON. • Turn wiper
• Turn wiper switch ON.
• 20 - 30 V
switch ON.
• Turn starting
5
switch ON.
Is voltage • Turn wiper NO
between CN32 (3) switch ON.
NO and GND normal?
• 20 - 30 V
• Turn starting
switch ON.
NO
20-320 D41E, P-6

1
TROUBLESHOOTING E-5
Cause Remedy
Defective CN32 relay

Replace
(Intermittent)
Defective wiper motor Replace
Disconnection or
(female) (2) - GND
Disconnection or
harness between CN37
(female) (5)
Disconnection or
(female) (6) - GND
Disconnection or
Repair or
(female) (6)
Defective CN33 relay

9 YES
(Wiper intermittent Replace
Is voltage selector)
YES
between CN33 (1)
and GND normal? Defective wiper
8
intermittent selector Replace
Is voltage • Max. 1 V NO switch
between CN33 (3) • Turn starting switch ON.
Disconnection or
and GND normal? • Turn wiper switch ON.
10 YES Repair or
replace
• 20 - 30 V Is voltage (female) (4) - CN33
• Turn starting between CN12 (4) (female) (3)
switch ON. NO and GND normal?
• Turn wiper 11 YES
Rear wiper Replace
switch ON. • 20 - 30 V Is voltage
• Turn starting between CN12
switch ON. NO (2), (3) and GND Disconnection or
• Turn wiper normal? defective contact in wiring Repair or
switch ON. NO harness between fuse (4) - replace
• 20 - 30V
• Turn starting CN12 (female) (2), (3)
switch ON.
Disconnection or
harness between fuse (4) - replace
CN32 (female) (3)
D41E, P-6 20-321

1
TROUBLESHOOTING E-5
List of combinations of wiper motors, switches, and relays

Wiper motor
REAR RIGHT FRONT LEFT
Wiper switch connector
No. CN12 CN13 CN14 CN15
Intermittent selector relay
connector No. CN33 CN31 CN29 CN27
Intermittent relay connec-
tor No. CN32 CN30 CN28 CN26
Wiper motor drive circuit CN37 CN17 CN23 CN24
terminal No. Pin (1) Pin (3) Pin (6) Pin (3)
Wiper motor 24-V power CN37 CN17 CN23 CN24
supply terminal No. Pin (3) Pin (4) Pin (3) Pin (4)
Wiper blade storage CN37 CN17 CN23 CN24
circuit terminal No. Pin (4) Pin (3) Pin (2) Pin (2)
Fuse No. (4) (6) (5) (6)
20-322 D41E, P-6

1
TROUBLESHOOTING E-5
b) When intermittent operation is defective (When continuous operation is normal)
fl The wiper stops about 5 seconds each time it completes a cycle of forward and reverse movement.
fl The following shows the rear wiper system. For the connector Nos. of the other wipers, see the
list.
Cause Remedy
YES Defective CN32 relay

Replace
(Intermittent)
1
Is voltage Disconnection or
between CN32 YES defective contact in wiring Repair or
(2) and GND harness between CN32 replace
2
normal? (female) (2) - CN33
Is voltage (female) (5)
• 20 - 30 V between CN33
• Turn starting NO (5) and GND 3 YES Defective CN33 relay
switch ON. normal? Replace
Is voltage (Intermittent selector)
• Turn wiper between CN33
switch ON. • 20 - 30 V
(1) and GND
• Intermittent • Turn starting NO normal?
selector switch switch ON.
ON. • Turn wiper • 20 - 30 V NO
switch ON. • Turn starting
• Intermittent switch ON.
• Turn wiper
selector switch switch ON.
ON. • Intermittent
selector switch
ON.
Disconnection or
YES Repair or
4 harness between CN11
replace
(female) (2) - CN33
Is voltage
(female) (1)
between CN11
(2) and GND 5 YES Defective intermittent
normal? Replace
Is voltage selector switch
• 20 - 30 V between CN11
• Turn starting
switch ON. NO (1) and GND Disconnection or
• Turn wiper normal? defective contact in wiring Repair or
switch ON. NO harness between fuse (4) - replace
• Intermittent • 20 - 30 V
CN11 (female) (1)
selector switch • Turn starting
ON. switch ON.
D41E, P-6 20-323

1
TROUBLESHOOTING E-6
E-6. No washer fluid is sprayed out

fl Carry out the following troubleshooting when the battery is normal.
fl Before starting the following troubleshooting, check that the wiper fuses are normal.
YES
1 YES
Is washer motor
5
running (Is
running sound of Does wiper of
motor heard)? YES washer which
does not spout
• Turn starting 4 water move?
switch ON.
• Turn washer YES Do other washers • Turn starting
switch (wiper operate switch ON.
switch) ON. normally? • Turn wiper NO
(*1.) 3 switch ON.
Is there continuity flWhen wiper is
YES between starting • Turn starting
normal
switch ON.
switch terminals
• Turn washer NO
(*1.) 2 B and BR?
switch ON.
When starting • Turn starting flWhen other wipers
switch is switch ON. are normal
operated, does
NO battery relay • Disconnect NO
make sound? terminal B.
• Turn starting
switch ON and
OFF. NO
*1. When the lamp (head lamp or rear lamp) circuit or the horn circuit is normal, this check may be
substituted by checking if the lamp lights up normally or the horn sounds normally.
20-324 D41E, P-6

1
TROUBLESHOOTING E-6
Cause Remedy
Lack of water, clogged

Repair or
nozzle, or defective water
replace
piping
8 YES
Defective washer motor Replace
YES Is ground wire of
7 washer motor
Is voltage connected?
YES between CN26 on
Repair or
cab side and Defective ground wire
chassis ground NO replace
6 normal? (*2.)
When defective • 20 - 30 V Disconnection or
washer (wiper)
switch is replaced • Turn starting defective contact in wiring Repair or
another one, does switch ON. NO harness between CN26 on replace
condition become
normal? • Turn washer cab side - CN11 on cab
switch ON. side
• Turn starting
switch ON. Defective washer (wiper)
Replace
• Turn washer NO switch
switch ON. (*2.)
flWhen other switches Disconnection or
are normal defective contact in wiring
harness between CN11 Repair or
(2), (3) on cab side - fuse replace
on cab side
Broken fusible link on cab
side, or disconnection or Repair or
harness between battery replace
relay - fuse box terminal B
on cab side
Defective battery relay Replace
*2. The left washer is used as an example in this troubleshooting. For the connector Nos. of other
washers corresponding to CN11 on the cab side, see the following.
Left washer Front washer Right washer Rear washer
Connector No. CN11 CN12 CN13 CN14
D41E, P-6 20-325

1
TROUBLESHOOTING E-7
E-7. Air conditioner has no effect

fl When the battery and battery relay are normal.
a) No air comes out YES
5
Is continuity
YES between CN44
(4) (female) and
4 CN33 (2) normal?
Is continuity
YES between blower • Max. 1 Ω
switch terminals as • Turn starting NO
shown in Table 1? switch OFF.
3
Is voltage
YES between CN44 • Turn starting
switch OFF.
(3) and chassis NO
• Disconnect
2 normal?
CN44.
Is resistance • 20 - 30V
(male) (1) and (3) switch ON. NO
1 normal?
Is voltage • 240 ± 40 Ω
between CN37 • Turn starting
(1) and chassis switch OFF. NO
ground normal? • Disconnect
CN37.
• 20 - 30V
• Turn starting
switch ON. NO
20-326 D41E, P-6

1
TROUBLESHOOTING E-7
Cause Remedy
7 YES
Go to A on next page
Is voltage
YES between CN37
6 (4) and chassis
Is voltage normal? Defective air conditioner
Replace
between CN37 • Turn starting NO relay
(2) and chassis switch ON.
ground normal? • Blower switch: Any position Defective contact, or
except OFF. disconnection in wiring Repair or
• 20 - 30V
• Turn starting NO harness between fuse replace
switch ON. No. 8 and CN37 (2)
and CN33
Defective blower switch Replace
and CN44 (3)
Defective air conditioner

Replace
relay
harness between fuse No. replace
8 and CN37 (1)
Table 1
Terminal
Position B LW LY L
OFF
LO
ME
HI
D41E, P-6 20-327

1
TROUBLESHOOTING E-7
12 YES
Is continuity
YES between CN39
11 (1) and CN44 (2)
Is continuity normal?
YES between CN39 . Max. 1 Ω NO
(3) and CN33 (2) . Turn starting switch OFF.
10
normal? . Disconnect CN39 and CN44.
Is resistance between
YES CN39 (male) (2) and • Max. 1 Ω
(1), or between (2) • Turn starting NO
9 and (3) normal? switch OFF.
• Between (2) and (3): • Disconnect CN39
YES Does blower 3 ± 0.3 Ω and CN33.
motor rotate? • Between (2) and (1): NO
8 1 ± 0.1 Ω
• Turn starting switch
Is voltage • Turn starting OFF.
between CN57 switch ON. • Disconnect CN39.
A
(1) and chassis • Blower switch: NO
normal? Any position
• 20 - 30V except OFF.
• Turn starting
switch ON. NO
• Blower switch:
Any position
except OFF.
20-328 D41E, P-6

1
TROUBLESHOOTING E-7
Cause Remedy
Go to b)
and CN44
and CN33
Defective blower resistor Replace
Defective blower motor Replace
and CN37
D41E, P-6 20-329

1
TROUBLESHOOTING E-7
b) Does not become cool
YES
5
Is continuity
YES between CN45 (2)
(female) and CN36
4 (3) (female) normal?
Is continuity
• Max. 1 Ω
YES between CN45
(male) (3) and (2)
switch OFF.
3 normal?
Is continuity • Max. 1 Ω
YES between CN45 • Turn air
(1) and CN44 (3) conditioner NO
2 normal? switch ON.
Is continuity • Max. 1 Ω • Disconnect CN45.
(male) (3) and (1) switch OFF. NO
1 normal?
Is voltage • Max. 1 Ω
between CN45 • Turn air
(3) and chassis conditioner NO
normal? switch ON.
• 20 - 30V • Disconnect CN45.
• Turn starting
switch ON. NO
20-330 D41E, P-6

1
TROUBLESHOOTING E-7
Cause Remedy
7 YES
Go to B on next page
Is continuity
YES between CN36
6 (1) and CN44 (3) Defective contact, or
Is resistance normal? disconnection in wiring Repair or
between magnet NO harness between CN36 (1) replace
• Max. 1 Ω
relay (3) and (1) and CN44 (3)
• Turn starting
normal?
switch OFF.
• 240 ± 40 Ω Defective magnet relay Replace
switch OFF.
and CN36

Replace
switch
and CN44 (3)

Replace
switch
harness between fuse replace
FB2, No. 3 and CN45 (3)
D41E, P-6 20-331

1
TROUBLESHOOTING E-7
12 YES
YES Is voltage
11 between CN14
Is voltage (1) and chassis
YES between CN43 normal?
(4) and chassis • 20 - 30V NO
10 normal? • Turn dual pressure switch ON.
Is voltage • 20 - 30V • Turn thermostat switch ON.
YES between CN43 • Turn dual (*1.)
(1) and chassis pressure switch NO
9 normal? ON.
Is voltage • Turn thermostat switch ON.
• 20 - 30V
YES between CN37 (*1.)
• Turn starting
(4) and chassis switch ON. NO
8 normal? • Blower switch: Any position except
Is voltage • 20 - 30V OFF.
between CN36 • Turn starting • Turn air conditioner switch ON.
B
(2) and chassis switch ON. NO
ground normal? • Blower switch: Any position except
OFF.
• 20 - 30V
• Turn air conditioner switch ON.
• Turn starting
switch ON. NO
*1. Dual switch ON-OFF switching pressure

Pressure in refrigerant circuit:
,./
OFF at 2.65 MPa {27 kg/cm2} (when increasing)

High pressure side
ON at 2.65 MPa {27 kg/cm2} (when decreasing)
,./
OFF at 0.21 MPa {2.1 kg/cm2} (when decreasing)

Low pressure side
ON at 0.23 MPa {2.35 kg/cm2} (when increasing)
fl Thermostat switch ON-OFF switching temperature

Evaporator discharge temperature
OFF at above 1°C (when increasing)
ON at below 4.5°C (when decreasing)
20-332 D41E, P-6

1
TROUBLESHOOTING E-7
Cause Remedy
Defective air conditioner Repair or

compressor replace
and CN14
Defective dual pressure

Replace
switch
and CN43
Defective magnet relay Replace
harness between fuse No. replace
8 and CN36
D41E, P-6 20-333

1
TROUBLESHOOTING E-8
E-8. Fan malfunctions

a) Forward fan speed is low
Cause Remedy
2 YES
Go to H-8, No. 1
Is current in
YES CN90 (3) or (4)
1 (Solenoid circuit)
normal? Defective operation of fan
Is voltage Replace
• Turn starting NO controller
between CN90
(2), (5) and GND switch ON.
normal? • When water temperature is
85 - 95 °C: 0 - 1 A Defective water
NO temperature sensor
switch ON.
• When water
temperature is 95 °C:
2.44 ± 0.1 V
• When water
temperature is 85 °C:
2.77 ± 0.1 V
b) Forward fan speed does not lower from maximum level (when water temperature is below 85°C)
fl Before carrying out troubleshooting, stop the engine and set the reverse switch in the FORWARD
position.
Cause Remedy
3 YES
Defective fan controller Replace
Is voltage
YES Disconnection or
between CN90 (1)
and (2) normal? defective contact in wiring Repair or
2 harness between fuse (7) - replace wiring
• Turn starting NO CN32 (1) - CN87 (8) - harness
controller - CN87 (11) -
YES Is current output switch ON.
from CN90 (3) or • 20 - 30 V CN32 (10) - CN90 (female)
(4)? YES
4 Defective fan controller Replace
• Turn starting
1 switch ON. Is voltage Disconnection or
Is resistance • When water between CN90 (1) defective contact in wiring Repair or
between CN99 temperature is NO and GND normal? 5 YES harness between CN87 replace wiring
(male) (1) and (2) below 85°C: Min. Is voltage harness
normal and are (male) (11) - CN32 (10) -
they insulated 800 mA • 20 - 30 V between CN87 CN90 (female) (1)
from chassis • CN90 (3) is
ground? NO (11) and GND
OUTPUT and (4) normal?
• Turn starting is RETURN. Defective controller Replace
switch OFF. • 20 - 30 V NO
• Between (1) and
(2): 7 ± 3 Ω (20°C)
• Between (1) and Defective fan solenoid Replace
chassis ground: NO
Min. 1 MΩ
• Disconnect
20-334 D41E, P-6

1
TROUBLESHOOTING E-8
fl Before starting the following troubleshooting, check that fuse FB2 (7) is normal.
c) Fan does not revolve in reverse
YES
YES
3 5
Is voltage Is voltage
YES between CN87 YES between CN87
(9) and GND (2) and GND
normal? normal?
• 20 - 30 V • 20 - 30 V NO
• Turn starting
4
• Turn starting
switch ON. Is voltage switch ON.
2 • Fan reverse between CN87 (6) • Fan reverse switch:
switch: NO and GND normal? REVERSE position
Is voltage REVERSE
YES between CN95 position
(1) and GND • 20 - 30 V
normal? • Turn starting
switch ON.
• 20 - 30 V
1 • Turn starting NO
switch ON.
Is resistance • Fan reverse switch:
between CN95
(male) (1) and (2) REVERSE position 8 YES
normal and are
then insulated Is resistance
from chassis between CN95
ground? (female) (2) and
NO
GND normal?
• Approx. 39 Ω
• Between CN95 • Max. 1 Ω NO
(male) (1) - • Turn starting
chassis ground: switch OFF.
Min. 1 MΩ • Disconnect CN95.
• Turn starting
switch OFF. NO
• Disconnect
CN95.
20-336 D41E, P-6

1
TROUBLESHOOTING E-8
Cause Remedy
Disconnection or
harness between CN87 Repair or
(male) (9) - CN31 (11) - replace
CN8 (10) - CN95 (female)
(1)
Defective controller Replace
Disconnection or
YES defective contact in wiring Repair or
6 replace
(female) (4) - CN87 (male)
(2)
Is voltage
between CN71 (4)
and GND normal? 7 YES Defective fan reverse Replace
switch
Is voltage
• 20 - 30 V between CN71 (3)
• Turn starting NO Disconnection or
and GND normal? defective contact in wiring Repair or
switch ON. harness between CN71
• Fan reverse switch: • 20 - 30 V NO (female) (3) - CN87 (male) replace
REVERSE position • Turn starting switch ON. (6) (up to branching point)
Disconnection or
harness between fuse FB2
(7) - CN3 (12) - CN87 replace
(male) (6)
Defective fan reverse

Replace
solenoid
Disconnection or
Repair or
replace
(female) (2) - CN8 (8) -
GND
Defective fan reverse

solenoid Replace
D41E, P-6 20-337

1
TROUBLESHOOTING E-8
20-338 D41E, P-6

1
TROUBLESHOOTING
TROUBLESHOOTING OF HYDRAULIC,
MECHANICAL SYSTEM
(H MODE)
Table of failure modes and causes (hydraulic, mechanical system) ............................................... 20-402
H-1 Brakes do not work .................................................................................................................... 20-404
a) When inching pedal is operated .......................................................................................... 20-404
b) When parking brake lever is at LOCK ................................................................................. 20-405
H-2 Machine does not turn (can travel in a straight line) ............................................................ 20-406
H-3 Overruns when turning .............................................................................................................. 20-407
H-4 Can turn in only one direction (when steering and directional lever is operated) ........... 20-408
H-5 Machine does not move off in any speed range ................................................................... 20-409
H-6 Excessive time lag ...................................................................................................................... 20-410
H-7 Machine can travel in only one direction (forward or reverse) ........................................... 20-410
H-8 Machine does not move (when engine is started and lever is shifted to 2nd or 3rd) ..... 20-411
H-9 Power train oil temperature rises too high ............................................................................. 20-412
H-10 Lacks drawbar pull, travel speed is slow ................................................................................ 20-413
H-11 Abnormal noise is generated from around tandem pump ................................................... 20-414
H-12 No work equipment moves ....................................................................................................... 20-415
H-13 Speed of all work equipment is slow or lacks power ........................................................... 20-415
H-14 Blade lift speed or tilt speed is slow or lacks power ............................................................ 20-416
H-15 Blade angle speed is slow or lacks power .............................................................................. 20-417
H-16 Hydraulic drift of blade lift, blade tilt is excessive ................................................................. 20-418
H-17 Hydraulic drift of blade angle is excessive ............................................................................. 20-418
H-18 Fan speed is low ......................................................................................................................... 20-419
D41E, P-6 20-401

1

(HYDRAULIC, MECHANICAL SYSTEM)
Hydraulic system
Parts causing failure
Power train
Transmission valve
Speed, directional valve
Parking brake cylinder

Parking brake valve
Power train pump
Modulating valve
Inching valve
Priority valve
Clutch piston
Brake piston
Brake valve
PPC valve
Failure mode
1 Brakes do not work (*1) fi fi fi fi

2 Machine does not turn (can travel in a straight line) fi fi fi fi
3 Overruns when turning fi fi fi fi
Can turn in only one direction (when steering and
4 directional lever is operated) fi
5 Machine does not move off in any speed range fi fi fi fi fi fi fi fi
6 Excessive time lag fi fi fi fi
7 Machine can travel in only one direction (forward or reverse) fi fi
Machine does not move (when engine is started and lever
8 is shifted to 2nd or 3rd) fi fi fi
9 Power train oil temperature rises too high fi fi fi fi fi fi
10 Lacks drawbar pull, travel speed is slow fi fi fi fi fi fi fi
11 Abnormal noise is generated from around hydraulic pump fi
12 No work equipment moves
13 Speed of all work equipment is slow
14 Blade lift speed or tilt speed is slow or lacks power
15 Blade angle speed is slow or lacks power
16 Hydraulic drift of blade lift or tilt is excessive
17 Hydraulic drift of blade angle is excessive
18 Fan rotates abnormally
*1. When the brake pedal or inching pedal is actuated.
20-402 D41E, P-6

1
fi
fi
Hydraulic pump
fi fi
Strainer
D41E, P-6
Unload valve
fi fi
fi fi
Main relief valve
Valves
Safety valve (angle only)
TROUBLESHOOTING
fi fi
fi
fi fi
fi
Work equipment
Spool
fi
fi
fi
fi
Hydraulic cylinder
Fan pump
Hydraulic system
Fan motor
Fan
Relief valve
fi fi fi fi
Reverse solenoid valve, Forward/Reverse selector valve
fi
fi
fi
fi
fi
fi
fi
fi
fi
fi
fi
Linkage
Steering clutch (disc, plate, etc.)
fi
fi fi
fi fi
fi fi
Brake clutch (disc, plate, etc.)
fi fi fi
fi fi fi
fi
fi fi fi
Internal parts of transmission
fi fi fi fi
Engine
Cooling system
Mechanical system
fi
fi
fi
fi fi
Loose piping clamps, air in circuit, oil leakage
go to
H-fiX
H- 1
H-11
H- 9
H- 8
H- 6
H- 4
H- 3
H-17
H-15
H-14
H-13
H-12
H-10
H- 7
H- 5
H- 2
H-18
H-16
YES/NO Table
Troubleshooting
Troubleshooting
For abnormalities,
1
20-403
TROUBLESHOOTING H-1
H-1. Brakes do not work

fl When turning is normal.
(If turning is abnormal, carry out troubleshooting from H-2 – H-4 according to the symptoms.)
fl Check the oil level in the power train before carrying out troubleshooting.
a) When inching pedal is operated

fl Carry out troubleshooting with the parking brake lever at RELEASE.
Cause Remedy
YES Defective brake piston or Repair or

2 brake lining replace
YES Is brake oil

pressure normal? 3 YES Defective parking brake Repair or
Is adjustment of valve replace
fl See Table 1. parking brake
1
NO lever linkage
normal? Defective adjustment of
Is inching oil Adjust
flSee TESTING NO parking brake linkage
pressure normal?
AND
ADJUSTING.
fl See Table 1. 4 YES Defective operation of Repair or
brake valve replace
Is adjustment of
inching pedal
NO linkage normal?
Defective adjustment of
Adjust
NO inching pedal linkage
flSee TESTING
AND
ADJUSTING.
Table 1
Oil pressure
Conditions MPa {kg/cm2}
Inching pedal full stroke Engine at full throttle Min. 2.2 {22}
Brake pedal full stroke Engine at full throttle Min. 2.2 {22}
fl Set pressure: 2.66 ± 0.1 MPa {27.1 ± 1 kg/cm2}
20-404 D41E, P-6

1
TROUBLESHOOTING H-1
b) When parking brake lever is at LOCK
Cause Remedy
YES Defective adjustment of

Adjust
brake linkage
1 3 YES Defective operation of

Correct
Does parking Is movement smooth
brake linkage
brake cylinder YES when parking brake
rod move cylinder rod is
smoothly? 2 disconnected?
Defective parking brake
Replace
fl See Table 1 Is brake cylinder fl See Table 1 NO cylinder
actuation oil
NO pressure
normal? 4 YES Defective actuation of Correct or
fl See Table 1 Is adjustment of parking brake valve replace
parking brake
NO lever linkage Defective adjustment of
normal?
parking brake lever Adjust
fl See TESTING NO linkage
AND
ADJUSTING.
Table 1
Parking brake Actuation oil pressure
Parking brake lever cylinder rod MPa {kg/cm2}
Up (RELEASE) Extended Min. 2.3 {23}
Down (LOCK) Retracted 0 {0}
fl At 2.3 MPa {23 kg/cm2}, the spring is fully compressed.
D41E, P-6 20-405

1
TROUBLESHOOTING H-2
H-2. Machine does not turn (can travel in a straight line)

Cause Remedy
3 YES Defective brake lining or

Repair
plate
YES Is brake piston
2 moving?
Defective brake piston Replace

YES Is brake oil NO
pressure normal?
fl See Table 1. Defective PPC valve Replace

1
NO
Is clutch
disengaged? 5 YES
Defective clutch (seized) Repair
(*1.) YES Is clutch piston
4 moving?
Is clutch and Defective clutch piston Replace

brake oil NO
NO pressure normal?
fl See Table 1. Defective PPC valve Replace

NO
*1. Travel in F1 (R1) with the engine at low idling, and operate the steering joystick slowly to the left
or right. The machine must turn slowly.
Table 1
Hydraulic pressure
MPa {kg/cm2}
Conditions
Clutch Brake
Steering and directional • Engine at Min 3.0 {30.5}
high idling (left, right) 0 (left, right)
lever not operated
Operated • Engine at Right: Min. 3.0 {30.5} Right: 0
Steering and to left high idling Left: 0 Left: Min. 3.0 {30.5}
directional lever
operated Operated • Engine at Right: 0 Right: Min. 3.0 {30.5}
to right high idling Left: Min. 3.0 {30.5} Left: 0
20-406 D41E, P-6

1
TROUBLESHOOTING H-3
H-3. Overruns when turning
Cause Remedy
1 YES
Go to H-2 Item 2
Is clutch
disengaged?
Go to H-2 Item 4
(*1.) NO
*1. Travel in F1 (R1) with the engine at low idling, and operate the steering joystick slowly to the left
or right. The machine must turn slowly.
D41E, P-6 20-407

1
TROUBLESHOOTING H-4
H-4. Can turn in only one direction (when steering and directional lever
is operated)
Cause Remedy
3 YES
Defective disc or plate Repair
YES Is clearance
between piston
2 and cam normal?
Defective adjustment Adjust
YES Do clutch and fl See TESTING NO
brake pistons
move smoothly? AND
ADJUSTING.
1 Defective operation of
Replace
NO piston
Is clutch and
brake oil
pressure normal? 4 YES
Defective PPC valve Replace
fl See Table 1. Is adjustment of
PPC valve linkage
NO normal?
Defective adjustment of Adjust
fl See TESTING NO linkage
AND
ADJUSTING.
Table 1
Hydraulic pressure
MPa {kg/cm2}
Conditions
Clutch Brake
Steering and directional • Engine at Min 3.0 {30.5}
high idling (left, right) 0 (left, right)
lever not operated
directional lever
20-408 D41E, P-6

1
TROUBLESHOOTING H-5
H-5. Machine does not move off in any speed range

Cause Remedy
YES Defective transmission or

3 Repair
bevel gear shaft
When directional
YES lever is moved to F or
R, does oil pressure
drop momentarily 5 YES Defective actuation of Correct or
2 and then rise again? modulating valve replace
Is adjustment of
• Engine at full
gear shift lever
YES Is parking brake throttle NO linkage correct?
released? • Move Defective adjustment of
directional Adjust
flSee TESTING NO linkage
lever to F or R.
1 fl See Table 2. • Min. 2.6 MPa AND
{26 kg/cm2} ADJUSTING.
Is clutch, brake
Go to H-1. b)
oil pressure NO
normal?
fl See Table 1. 4 YES Defective power train

Replace
pump
Is PPC valve
NO linkage normal?
Defective adjustment of Adjust
flSee TESTING NO PPC valve linkage
AND
ADJUSTING.
Table 1
Hydraulic pressure
MPa {kg/cm2}
Conditions
Clutch Brake
High Min 3.0 {30.5}
idling (left, right) 0 (left, right)
Steering and directional • Engine
lever not operated Low Min 3.0 {30.5}
idling (left, right) 0 (left, right)
directional lever
Table 2
Parking brake Actuation oil pressure
Parking brake lever cylinder rod MPa {kg/cm2}
Up (RELEASE) Extended
Down (LOCK) Retracted 0 {0}
D41E, P-6 20-409

1
TROUBLESHOOTING H-6, 7
H-6. Excessive time lag

Cause Remedy
YES Defective operation of Repair or

3 transmission valve (spool) replace
YES Is modulating oil

pressure normal? 4 YES Defective power train
Replace
2 pump
Does modulating
• Oil pressure: valve move
YES Is adjustment of Min. 2.6 MPa NO smoothly?
gear shift lever {26 kg/cm2} Defective operation of
linkage normal? • Engine at full Clean or replace
1 NO modulating valve
throttle
flSee TESTING
Is brake AND
dragging? ADJUSTING. Defective adjustment of
Adjust
NO linkage
(*1.)
Go to H-2
NO
*1. Stop the machine on level ground, run the engine at low idling, then shift to F1 and check if the
machine moves (travels).
H-7. Machine can travel in only one direction (forward or reverse)

fl Conditions: Modulating oil pressure is normal (Min. 2.6 MPa {26 kg/cm2})
Cause Remedy
2 YES Defective inside Repair or

When directional transmission replace
YES lever is moved to F or
R, does oil pressure
1 drop momentarily
and then rise again? Defective actuation of Correct or
Is adjustment of directional spool replace
• Engine at full NO
gear shift lever
throttle
linkage normal?
• Move directional lever to F or R.
• Min. 2.6 MPa {26 kg/cm2} Defective adjustment of
flSee TESTING Adjust
NO linkage
AND
ADJUSTING.
20-410 D41E, P-6

1
TROUBLESHOOTING H-8
H-8. Machine does not move (when engine is started and lever is shifted
to 2nd or 3rd)
fl When 1st is normal for both FORWARD and REVERSE.
Cause Remedy
YES Defective clutch for speed

Repair or
range with defective oil
1 replace
pressure
When gear shift lever
is moved to 2nd or
3rd, does oil pressure
drop momentarily 2 YES Defective actuation of Repair or
and then rise again? gear shift valve spool replace
• Engine at full Is gear shift lever
throttle NO linkage normal?
• Min. 2.6 MPa {26 Defective adjustment of
Adjust
kg/cm2} flSee TESTING NO gear shift lever linkage
• Move gear shift AND
lever to 2nd or ADJUSTING.
3rd.
D41E, P-6 20-411

1
TROUBLESHOOTING H-9
H-9. Power train oil temperature rises too high

Cause Remedy
4 YES Defective cooling system

(See Engine Volume)
YES
Is travel speed
normal?
3 Slipping clutch Repair

fl See MAINTENANCE NO
STANDARD.
YES Is modulating oil (When engine
pressure normal? speed is normal.) Drop in performance of
5 YES power train pump or air Repair or
2 sucked in replace
Does modulating
• Oil pressure: valve move
YES Is power train oil Min. 2.6 MPa NO smoothly?
temperature {26 kg/cm2} Defective actuation of Correct or
sensor normal? • Engine at full
1 NO modulating valve replace
throttle
• Remove oil
Is brake temperature
sensor. Defective oil temperature
dragging? Replace
• Check resistance sensor
NO
value.
(*1.) fl See Table 1
Go to H-2
NO
Table 1
Oil When normal
temperature
l l
l l
l l
l l
20-412 D41E, P-6

1
TROUBLESHOOTING H-10
H-10. Lacks drawbar pull, travel speed is slow

Cause Remedy
4 YES
Slipping steering clutch Repair
When turning,
YES does sprocket on
opposite side stop
3 or slow down? Slipping transmission Repair or
NO clutch replace
YES Is clutch oil
pressure normal?
5 YES
Defective PPC valve Replace
• Engine at full
2 throttle Is PPC valve
• Min. 3.0 MPa NO linkage normal?
YES Is modulating {30.5 kg/cm2} Defective adjustment of
relief oil pressure Adjust
normal? flSee TESTING NO PPC valve linkage
AND
• Engine at full ADJUSTING.
1
throttle 6 YES Drop in performance of
Replace
• Min. 2.6 MPa {26 power train pump
Is brake Does modulating
kg/cm2}
dragging? relief valve move
NO smoothly?
Defective actuation of Correct or
(*1.) NO modulating relief valve replace
Go to H-2
NO
D41E, P-6 20-413

1
H-11. Abnormal noise is generated from around tandem pump

fl Check the oil level in the hydraulic tank before carrying out troubleshooting.
Cause Remedy
YES
Defective seal Tighten
2 . Loose piping clamp
Is air being . Damaged O-ring
YES sucked into
YES
pump suction 3 Clogged strainer Clean
circuit?
Is strainer
1 clogged?
NO 4 YES
Defective pump Replace
Is correct oil Are metal
being used? particles found
NO when hydraulic Operate for a time and Inspect again
oil is drained?
watch for change in (according to
NO symptoms change in
symptoms)
Improper oil being used Replace

NO
20-414 D41E, P-6

1
H-12. No work equipment moves

Cause Remedy
2 YES Defective main relief Adjust

Does condition valve
YES become normal
when main relief
1 valve is cleaned or
When pressure replaced?
Defective unload valve Replace
measurement plug • Engine at full NO
is removed and
throttle
engine is cranked,
does oil come out?
Defective hydraulic pump Repair or
• Crank with or defective PTO replace
starting motor. NO
H-13. Speed of all work equipment is slow or lacks power

Cause Rmedy
YES Drop in performance of Replace

1 hydraulic pump
Is relief pressure
at end of hydraulic
cylinder stroke 2 YES Defective main relief Adjust or
normal? Does condition valve replace
become normal
• Engine at full when main relief
throttle NO valve is cleaned or
• Min. 17.7 MPa replaced?
Defective unload valve Replace
{180 kg/cm2} NO
D41E, P-6 20-415

1
H-14. Blade lift speed or tilt speed is slow or lacks power

fl Check if the blade has been modified.
fl When the angle cylinder is normal.
Cause Remedy
3 YES Defective actuation of

Is relief pressure control valve spool Replace
YES (pump discharge
pressure) at end of
2 hydraulic cylinder
stroke normal? Excessive oil leakage
Repair
YES Is work • Hydraulic oil NO from hydraulic cylinder
equipment lever
1 pressure: Min.
linkage normal?
17.7 MPa {180 kg/cm2}
• Engine at full throttle Defective adjustment of
Does cylinder
flSee TESTING work equipment lever Adjust
extend and NO
AND linkage
retract smoothly?
ADJUSTING.
Air in circuit Bleed air

NO
20-416 D41E, P-6

1
H-15. Blade angle speed is slow or lacks power

fl Check if the blade has been modified.
fl When the lift and tilt cylinders are normal.
Cause Remedy
YES Defective actuation of

Replace
3 control valve spool
Is relief pressure
YES (pump discharge
pressure) at end of
hydraulic cylinder 4 YES Replace
Defective safety valve
stroke normal?
2 Is leakage from
• Engine at full hydraulic
NO cylinder normal?
YES Is work throttle
Excessive leakage from
equipment lever • Oil pressure: Repair
linkage normal? Min. 17.7 MPa • Engine at full throttle NO hydraulic cylinder
1 {180 kg/cm2} • Max. 8 cc/min.
flSee TESTING flSee TESTING AND
Does cylinder ADJUSTING. Defective adjustment of
AND
extend and work equipment lever Adjust
ADJUSTING. NO
retract smoothly? linkage
Air in circuit Bleed air

NO
D41E, P-6 20-417

1
H-16. Hydraulic drift of blade lift, blade tilt is excessive
Cause Remedy
1 YES Defective oil-tightness of

Replace
control valve spool
Is leakage from
hydraulic
cylinder normal? Excessive leakage inside
cylinder Replace
• Engine stopped NO • Defective piston seal
• Max. 8 cc/min
flSee TESTING AND
ADJUSTING.
H-17. Hydraulic drift of blade angle is excessive
Cause Remedy
2 YES
Defective safety valve Replace
Does condition
YES become normal
1 when safety valve
is replaced? Defective oil-tightness of
Is leakage from control valve spool Replace
NO
hydraulic
cylinder normal?
Excessive leakage inside
• Engine stopped cylinder Replace
• Max. 8 cc/min. NO • Defective piston seal
flSee TESTING
AND ADJUSTING.
20-418 D41E, P-6

1
H-18. Fan speed is low

fl Carry out the following troubleshooting after checking that the electric system is normal.
Cause Remedy
1 YES Clogging or defective

Clean
When relief valve operation of relief valve
is disassembled
and cleaned,
does condition • Lowering of fan pump
become normal? performance
Replace
• Fan speed NO • Lowering of fan motor
: 2000 +200 rpm performance
–100
+4.9
• Circuit oil pressure: 18.6 –2.9 MPa {190 +50 2
–30 kg/cm }
• Run engine at full throttle.
• Oil temperature: 80°C
• Disconnect connector CN99.
D41E, P-6 20-419

1
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 ..................... 20-505
M-2 When starting switch is turned to ON, all monitor panel lamps light up
and do not go out ......................................................................................................................... 20-505
M-3 Preheating display ( ) is abnormal .................................................................................... 20-506
SAP00526
a) Preheating monitor does not light up ................................................................................. 20-506

b) Preheating monitor stays lighted up ................................................................................... 20-506
M-4 CAUTION items light up or flash ................................................................................................ 20-508
a) ( SAP00522
) (charge) lights up or flashes .................................................................................. 20-508
b) When starting switch is turned to ON and engine is started,
( ) (engine oil pressure) lights up or flashes ........................................................... 20-509
c) ( ) (coolant temperature) flashes ................................................................................ 20-510
SAP00527
d) ( ) (power train oil temperature) flashes ................................................................... 20-511

M-5 Buzzer is abnormal ....................................................................................................................... 20-512
a) Caution item flashes but buzzer does not sound .............................................................. 20-512
b) Monitor display is normal, but buzzer sounds ................................................................... 20-512
M-6 Warning lamp is abnormal .......................................................................................................... 20-513
a) Caution item is flashing but lamp does not flash ............................................................. 20-513
b) Monitor display is normal but lamp flashes ...................................................................... 20-513
M-7 Gauge is abnormal ....................................................................................................................... 20-514
a) Abnormality in engine coolant temperature gauge .......................................................... 20-514
b) Abnormality in power train oil temperature gauge ........................................................... 20-515
c) Abnormality in fuel level gauge ........................................................................................... 20-516
M-8 Service meter does not move after engine is started ............................................................. 20-517
M-9 Monitor panel lighting does not light up (front lamps are normal) ...................................... 20-518
D41E, P-6 20-501

1

(MACHINE MONITOR SYSTEM)
Sensors Troubleshooting
Parts causing failure
For
abnormali-
ties, go to
Trouble-
shooting
YES/NO
Table M-fiX
Engine coolant temperature

Power train oil temperature
Starting motor system
Central alarm buzzer

Engine oil pressure
Preheating system
Alternator system
Monitor panel
Power source
Fuel level
Failure mode
No display is given on monitor panel when fi fi

1 starting switch is turned to ON M-1
When starting switch is turned to ON, all

2 monitor panel lamps light up and do not go out fi M-2
3 Preheating display is abnormal fi fi M-3
4 CAUTION items light up or flash fi fi fi fi fi M-4
5 Buzzer is abnormal fi fi M-5
6 Warning lamp is abnormal fi M-6
7 Gauge is abnormal fi fi fi fi M-7
8
Service meter does not move after engine is
started
fi fi M-8
Monitor panel lighting does not light up (front

9 lamps are normal) fi M-9
20-502 D41E, P-6

1
ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM

MACHINE MONITOR RELATED SYSTEM DIAGRAM
20-504 D41E, P-6

1
TROUBLESHOOTING M-1, M-2
M-1. No display is given on monitor panel when starting switch is turned

to ON
(If it is blown, check for a short circuit in the wiring harness between CN49(1) – CN31(1) – fuse
FB1, No. 2.)
Cause Remedy
2 YES
YES Does problem

1 appear again?
Is voltage Good (problem is removed)

between CN49 • Turn starting NO
(female) (1) and switch ON.
(2) normal? disconnection in wiring
Repair
• 20 – 30V harness between fuse FB1,
NO or replace
• Turn starting No. 2 – CN31 (1), (2) – CN49
switch ON. (1) – (2) – chassis ground
• Disconnect CN49 (female)
and connect T-adapter.
M-2. When starting switch is turned to ON, all monitor panel lamps light
up and do not go out
Cause Remedy
Defective motor Replace
M-1, M-2 Related electrical circuit diagram
D41E, P-6 20-505

1
TROUBLESHOOTING M-3
M-3. Preheating display is abnormal

SAP00526

(If it is blown, check for a short circuit in the wiring harness between grid heater relay – CN58(12)
– CN32(7) – starting switch terminal R1, terminal B – CN32(5) – fuse, or between battery relay –
CN32(6),(7) – CN38(8), 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)
• Turn starting switch ON.
a) Preheating monitor does not light up

Cause Remedy
YES
1
Disconnection in wiring
Is voltage 3 YES harness between CN49 (6) Repair
between CN49 – CN31 (5) – CN58 (11) – 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 (5) –
1 YES Repair
CN58 (11) – heater relay,
or replace
Is voltage or between starting
between CN49 switch R1 – CN32 (7) –
(6) and chassis CN58 (12) – heater relay
normal?
• 4 – 30V NO
20-506 D41E, P-6

1
TROUBLESHOOTING M-3
M-3. a), b) Related electrical circuit diagram
D41E, P-6 20-507

1
TROUBLESHOOTING M-4
M-4. CAUTION items light up or flash

a) (charge) lights up or flashes

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

(*A) 2
Is voltage disconnection in wiring
YES between CN49 harness between CN49 (4) –
(4) and chassis 3 YES CN31 (3) – CN58 (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
Does engine oil ground normal?
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. (*B) 4 YES
When cranking, is
voltage between
NO CN49 (5) and chassis Defective contact, or
ground normal? disconnection in wiring Repair
harness between CN49 (5) or replace
• 10 – 30V NO – CN31 (4) – CN32 (8) –
• Turn starting starting switcn terminal C
switch ON.
(2) When it flashes

Start troubleshooting from the items marked * 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}
20-508 D41E, P-6

1
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) When it lights up Cause Remedy
1 YES Start troubleshooting

from (*A) in M-4. a)
Does charge
lamp also light
up?
Start troubleshooting
NO from (*B) 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,
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) – CN31
Is there continuity (7) – CN58 (1) – engine oil or replace
• Remove terminal between CN49 pressure 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
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}
D41E, P-6 20-509

1
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 CN49 (2) Wiring harness between
Is indicator of
coolant tempera- CN15. NO and CN50 (1) CN49 (2) – CN31 (2) –
• Run engine at normal? CN58 (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.
M-4. c) Related electrical circuit diagram
20-510 D41E, P-6

1
TROUBLESHOOTING M-4
d) (power train oil temperature) flashes
Cause Remedy
Carry out
sensor check
YES Defective power train oil according to
2 temperature sensor STANDARD
VALUE TABLE,
YES Does flashing go replace
out when CN28
3 YES
is disconnected? Defective monitor panel Replace
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 (9) –
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.
• Run engine at • Disconnect CN28.
half throttle or Defective monitor panel Replace
above. NO
M-4. d) Related electrical circuit diagram
D41E, P-6 20-511

1
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 FB 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
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
20-512 D41E, P-6

1
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
D41E, P-6 20-513

1
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.
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 – CN58 (3) – CN31 (2) – or replace
• Connect short CN49 (2), or between CN15
connector to (2) – CN58 (2) – CN31 (8) –
CN15 (female). CN50 (1) – chassis ground
• Turn starting
switch ON.
M-7. a) Related electrical circuit diagram
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
20-514 D41E, P-6

1
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 (9) – CN50 (2), or
• Connect short between CN28 (2) and
connector to chassis ground
CN28.
• Turn starting
switch ON.
M-7. b) Related electrical circuit diagram
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
D41E, P-6 20-515

1
TROUBLESHOOTING M-7
c) Abnormality in fuel level gauge

Cause Remedy
(1) Fuel level is always shown as FULL
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
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 (10) – 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
M-7. c) Related electrical circuit diagram
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
20-516 D41E, P-6

1
TROUBLESHOOTING M-8
M-8. Service meter does not move after engine is started

Cause Remedy
1 YES
Go to M-4. a).
Does charge
abnormality
display flash?
• Start engine. NO
D41E, P-6 20-517

1
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
ground normal? disconnection in wiring
Repair
harness between CN49 (7)
NO or replace
• 20 – 30V – CN31 (6) – CN32 (3) –
• Turn starting switch ON. CN48 (3)
• Turn front lamp switch ON.
M-9. Related electrical circuit diagram
20-518 D41E, P-6

1
30 DISASSEMBLY AND ASSEMBLY
Method of using manual ............................ 30- 3 TRANSMISSION

Precautions when carrying out Disassembly ............................................. 30-47
operation ................................................... 30- 4 Assembly .................................................. 30-58
Special tool list ............................................ 30- 6 STEERING CASE
Sketches of special tools ............................ 30-12
Disassembly ............................................. 30-70
FUEL INJECTION PUMP Assembly .................................................. 30-76
Removal .................................................... 30-14
FINAL DRIVE
Installation ................................................ 30-16
Removal .................................................... 30-85
ENGINE HOOD Installation ................................................ 30-85
Removal .................................................... 30-18 Disassembly ............................................. 30-86
Installation ................................................ 30-19 Assembly .................................................. 30-90
CYLINDER HEAD IDLER
Removal .................................................... 30-20 Removal .................................................... 30-95
Installation ................................................ 30-23 Installation ................................................ 30-95
FUEL TANK RECOIL SPRING
RADIATOR, OIL COOLER IDLER
FAN DRIVE PUMP TRACK ROLLER
Removal .................................................... 30-28 Disassembly ........................................... 30-102
Installation ................................................ 30-28 Assembly ................................................ 30-104
FAN MOTOR CARRIER ROLLER
Removal .................................................... 30-29 Disassembly ........................................... 30-106
Installation ................................................ 30-29 Assembly ................................................ 30-107
ENGINE TRACK SHOE
Removal .................................................... 30-30 Removal .................................................. 30-109
Installation ................................................ 30-33 Installation .............................................. 30-110
Overall disassembly .............................. 30-111
RADIATOR, RADIATOR GUARD Overall assembly ................................... 30-116
Removal .................................................... 30-34
Installation ................................................ 30-36 Press-fitting jig dimension table
for link press .......................................... 30-130
DAMPER
ONE LINK
Removal .................................................... 30-37
Field disassembly .................................. 30-131
Installation ................................................ 30-38 Field assembly ....................................... 30-133
TRANSMISSION MAIN CONTROL VALVE
Removal .................................................... 30-40 Assembly ................................................ 30-140
Installation ................................................ 30-43
HYDRAULIC CYLINDER
PTO Disassembly ........................................... 30-146
Disassembly ............................................. 30-44 Assembly ................................................ 30-148
Assembly .................................................. 30-45
D41E, P-6 30-1

1
DISASSEMBLY AND ASSEMBLY RADIATEUR
WORK EQUIPMENT
Removal .................................................. 30-150
Installation .............................................. 30-151
Disassembly ........................................... 30-152
Assembly ................................................ 30-155
HYDRAULIC TANK
Removal .................................................. 30-158
Installation .............................................. 30-158
ROPS ROOF, GUARD
Removal .................................................. 30-159
Installation .............................................. 30-159
ROPS
Removal .................................................. 30-160
Installation .............................................. 30-160
OPERATOR'S CAB
Removal .................................................. 30-161
Installation .............................................. 30-163
FLOOR FRAME
Removal .................................................. 30-167
Installation .............................................. 30-171
OPERATOR'S CAB GLASS
(STUCK GLASS)
Removal .................................................. 30-173
Installation .............................................. 30-174
30-2 D41E, P-6

1
(2)
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
METHOD OF USING MANUAL

1. When removing or installing unit assemblies
1 When removing or installing a unit assembly, the order of work and techniques used are given
for the removal operation; the order of work for the installation operation is not given.
2 Any special techniques applying only to the installation procedure are marked 1, and the
same mark is placed after the relevant step in the removal procedure to indicate which step in
the installation procedure it applies to.
(Example)
REMOVAL OF ™™™™ ASSEMBLY ....... Title of operation

¤. .............................................................. Precautions related to safety when carrying out the operation
1. × × × × (1) ............................................. Step in operation
fl ........................................................ Technique or important point to remember when
removing × × × × (1).
2. (2) ........................................... 1..........indicates that a technique is listed for use
during installation
3. assembly (3)
6.............................................................See Lubricant and Coolant Table
INSTALLATION OF ™™™™ASSEMBLY .. Title of operation

• Carry out installation in the reverse order to removal.
1...............................................................Technique used during installation
fl ............................................................ Technique or important point to remember when
installing (2).
• Adding water, oil ..................................Step in operation
fl ............................................................ Point to remember when adding water or oil
5..........................................................Quantity when filling with oil and water
2. General precautions when carrying out installation or removal (disassembly or assembly) of units
are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow
these precautions when carrying out the operation.
3. Listing of special tools

1 For details of the descriptions, part number, and quantity of any tools (A1, etc.) that appear in
the operation procedure, see the SPECIAL TOOLS LIST given in this manual.
D41E, P-6 30-3

1
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
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 Plug (Nut side) Nut (Elbow side)

02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
3) 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
30-4 D41E, P-6

1
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
4) 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
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,
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.
D41E, P-6 30-5

1
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
3 795-799-1390 Remover 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
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 D41E, P-6

1
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

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 (*) are used with
the track shoe assembly still
1 791-630-3530 Pusher 1
installed to the chassis when
791-635-3120 Support (*) 1 removing or press fitting the
Track shoe
R link pin.
assembly 791-635-3130 Nut (*) 1
791-635-3140 Screw (*) 1
791-635-3150 Hook (*) 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
D41E, P-6 30-7

1
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
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 D41E, P-6

1
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 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
D41E, P-6 30-9

1
remodel
Sketch
Qty
New/
799-703-1200 Service tool kit 1
799-703-1100 Vacuum pump (100V) 1
installation
Removal,
Air conditioner Charging air conditioner
X 799-703-1111 Vacuum pump (220V) 1
unit with gas
799-703-1121 Vacuum pump (240V) 1
799-703-1400 Gas leak detector 1
Operator's cab
Litter Installation of window
glass (Stuck X1 793-498-1210 2
(Suction cup) glass
glass)
30-10 D41E, P-6

1
(3)
D41E, P-6 30-11

1
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these
sketches.
J1-2
)1 )2
16
9
62
140 2-36 DRILLS

30 16 30 80
32
21.4±0.25
57
67
150
55 30
9
40
23
20
145
137.9±0.25 22 2-18 DRILLS CDD00504
HEAT TRETMENT MATERIAL

180
--- SEE DWG
02 PLATE SS400P 1 0.99 t16 PART NAME QTY

BRACKET 1
01 PLATE SS400P 1 2.14 t16
MASS 791T-427-1150
SYM. PART NAME MATERIAL QTY/SET (kg) REMARKES
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 D41E, P-6

1
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
L1-1
L2-1
D41E, P-6 30-13

1
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
REMOVAL OF FUEL INJECTION

PUMP ASSEMBLY
¤ Disconnect the cable from the negative (–) ter-
minal of the battery.
1. Open the engine side cover and remove the

lower side cover.

1) Disconnect connector (1) and remove cover
(2).
2) Loosen 2 each of compressor mounting
bolts (3) and (4).
3) Loosen locknut (5), turn adjustment bolt (6)
counterclockwise, and loosen and remove
the V-belt.
4) Remove 4 compressor mounting bolts (7),
compressor (8), and hose clamp and shift
the hose to the rear.
fl This work is necessary since the com-
pressor cannot be removed together
with bracket (9) which will be removed
next.
5) Remove bracket (9).
6) Remove bracket (10).
3. Disconnect fuel control rod (11). 1
4. Remove engine oil level gauge (12) together

with the bracket.
5. Remove clamp bolt (13).
6. Disconnect rod (14) and connector (15) and re-

move engine stop solenoid (16). 2
30-14 D41E, P-6

1
7. Remove clamp (17) and disconnect fuel inlet

tube (18). 3
8. Remove lubrication tube (19).
9. Disconnect fuel return hose (20).
10. Disconnect boost compensator hose (21).

11. Remove clamps (22) and (23) and disconnect 6
high-pressure injection pipes (24).
12. Remove bracket (25).

13. Using tool A1, rotate the engine forward and
push No. 1 cylinder top dead center positioning
pin (26) into the gear.
fl Pressing the pin against the gear, rotate the
engine slowly.
D41E, P-6 30-15

1
14. Remove the cover, nut (27), and washer.

fl Take care not to drop the washer inside the
case.
15. Remove 4 mounting nuts (29) of injection pump

assembly (28).
16. Using tool A2, push out and remove the injec-
tion pump assembly. 4
INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY
• Carry out installation in the reverse order to
removal.
1
fl Adjust the linkage. For details, see TEST-
ING AND ADJUSTING, Adjusting fuel con-
trol linkage.
2
fl Adjust the linkage. For details, see TEST-
ING AND ADJUSTING, Adjusting engine
stop solenoid linkage.
3
3 Sleeve nut of high-pressure injection
pipe: 29.4 Nm {3.0 kgm}
30-16 D41E, P-6

1
4
• Install the fuel injection pump assembly ac-
cording to the following procedure.
1) Check that the No. 1 cylinder is at the top
dead center.
fl See removal step 13.
2) Remove fuel injection pump plug (30) and
check that timing ping (31) is meshed with
timing pointer (32) in the injection pump.
3) If timing pin (31) is not meshed (If the pin is

directed to the opposite side), rotate the
camshaft slowly to fit the groove of timing
pin (31) to pointer (32) and tighten plug (30)
temporarily.
4) Matching the camshaft of the pump to the
pump drive gear, install injection pump as-
sembly (28).
fl Tighten mounting nut (29) temporarily.
3 Nut: 11.8 Nm {1.2 kgm}
fl After tightening the nut temporarily, pull
out the timing pin (from both engine
side and injection pump side).
5) Tighten nut (27).
3 Nut: 162.0 Nm {16.5 kgm}
fl After tightening the nut, check that the
timing pin can be inserted.
6) Matching stamped line (33) of the injection
pump body to stamped line (34) of the tim-
ing gear case, tighten nut (29).
3 Nut: 42.2 Nm {4.3 kgm}
7) Remove plug (30) and set timing pin (31) in
the plug (direct it to the opposite side) and
install the plug to the injection pump.
3 Nut: 14.7 Nm {1.5 kgm}
8) Pull out the positioning pin which was set
in step 5).
9) Carry out the rest of installation in the re-
verse order to removal.
D41E, P-6 30-17

1
DISASSEMBLY AND ASSEMBLY ENGINE HOOD
REMOVAL OF ENGINE HOOD

ASSEMBLY

1. Open the engine side cover.

2. Remove 2 each of the mounting bolts of oil
filler bracket (1) and washer tank bracket (2).
3. Disconnect clamp stay (3), (4).
4. Remove mounting bolt (5) on the left side of

washer tank bracket (2).
fl Lower the tank onto the engine.
5. Disconnect connector (6) and remove the clamp
bolt under the connector.
fl The clamp bolt is seen if the connector is
removed from the holder.
6. Loosen clamp (8) of air duct (7) and disconnect

the duct.
7. Remove mounting bolt (9) on the rear side of
the engine hood.
8. Remove the 2 mounting bolts on the front side
of the engine hood.
30-18 D41E, P-6

1
DISASSEMBLY AND ASSEMBLY ENGINE HOOD
9. Lift off engine hood assembly (10) with nylon

slings.
fl Check that the air duct is not removed.
4 Engine hood assembly: 110 kg
INSTALLATION OF ENGINE
HOOD ASSEMBLY

removal.
D41E, P-6 30-19

1
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
REMOVAL OF CYLINDER HEAD

ASSEMBLY

1. Drain the cooling water.

2. Remove the engine hood assembly. For details,
see REMOVAL OF ENGINE HOOD ASSEMBLY.
3. Remove both side covers under the engine.
4. Remove heat insulation cover (1) and muffler
(2).
5. Remove air intake hose (3) and air cleaner as-
sembly (4). 1
6. Remove the hose clamp and evaporator (5).
7. Remove the wiring harness, hose clamp, and

plate (6).
8. Loosen and remove alternator belt (7) from the

alternator pulley and disconnect bracket (9) of
alternator (8).
9. Disconnect overflow hose and remove reser-

voir tank (10).
10. Disconnect tube (11) and remove filter (12).
Remove clamp (13) of tube (11), too.
30-20 D41E, P-6

1
11. Remove radiator outlet hose (14), oil filler hose

(15), and stays (16) and (17).
12. Remove frame (18).

1) Disconnect connectors (19) and (20) and re-
move cover (21).
2) Loosen 2 each of compressor mounting
bolts (22) and (23).
3) Loosen locknut (24) and turn adjustment bolt
(25) to loosen and remove V-belt (26).
4) Remove compressor mounting bolts (22)
and (23), air conditioner compressor (27),
and hose clamp.
14. Disconnect wiring harness terminal (28) and

remove heater relay (29) and bracket (30).
D41E, P-6 30-21

1
15. Disconnect turbocharger inlet hose (31) and

outlet tube (32). 2
16. Loosen the band of air boost hose (33) and lift
off turbocharger exhaust manifold assembly
(34). 3
17. Remove rain trap tube (35) and aftercooler pipes
(36) and (37).
18. Remove air boost connector (38).
19. Remove breather hose (39).
20. Remove ground wiring harness (40).
21. Remove 6 high-pressure injection pipes (41)

and spill hose (42). 45
22. Remove nozzle holder (43). 6
23. Remove head cover (44). 7
24. Remove rocker arm assembly (45). 8

fl Loosen the locknut, and then loosen the
adjustment screw by 2 – 3 turns.
25. Remove push rod (46).

fl Before removing the cylinder head assem-
bly, check that the all wiring harnesses,
hoses, clamps, etc. have been removed.
26. Lift off cylinder head assembly (47). 9
4 Cylinder head assembly: 55 kg
30-22 D41E, P-6

1
INSTALLATION OF CYLINDER
HEAD ASSEMBLY

removal.
1
3 Turbocharger air boost hose clamp:
8.8 ± 0.5 Nm {90 ± 5 kgcm}
2
3 Sleeve nut of turbocharger inlet hose:
35 ± 5 Nm {3.6 ± 0.5 kgm}
3 Mounting bolt of turbocharger outlet tube:
24 ± 4 Nm {2.45 ± 0.41 kgm}
3 !2 i r q t o
fl Tighten the bolts in the order of 1 - B as
shown at right.
3 Mounting bolt of exhaust manifold:
43.2 Nm {4.4 kgm}
4
3 Delivery tube sleeve nut of high-pres-
sure injection pipe: !1 u e w y !0
24 ± 4 Nm {2.45 ± 0.41 kgm}
CED00039
5
3 Joint bolt: 8.1 Nm {82 kgcm}
6
3 Locknut: 60 ± 5 Nm {6.1 ± 0.51 kgm}
7
3 Mounting bolt of head cover:
24 ± 4 Nm {2.45 ± 0.41 kgm}
8
fl Clean the oil holes of the mounting bolts.
fl Check that the ball of the adjustment screw
is fitted to the socket of the push rod.
fl Adjust the valve clearance. For details, see
TESTING AND ADJUSTING, Adjusting valve
clearance.
3 Locknut: 24 ± 4 Nm {2.45 ± 0.41 kgm}
D41E, P-6 30-23

1
9
fl Check that there is not dirt and foreign mat-
ter on the mounting face of the cylinder
head and in the cylinders.
fl Apply molybdenum disulfide (LM-P) all over

the threads and seats of the bolts.
fl Tighten the cylinder head bolts in the fol-

lowing order.
2 Mounting bolt:
Anti-friction compound (LM-P)
3 Cylinder head mounting bolts:
1st time: Tighten to 90 ± 5 Nm {9.18 ± 0.51
kgm} in the order of [1] – [26].
Long bolts: Tighten to 120 ± 5 Nm {12.24 ± 0.51
kgm} in the order of [3], [6], [11],
[14], [19], and [22].
Tighten bolt [5] to 120 ± 5 Nm
{12.24 ± 0.51 kgm} while tightening
the other bolts in the order.
2nd time: 1) When using tool A3
• Using angle tightening wrench
(Tool A3), tighten to 90 ± 5 de-
grees in the order of [1] – [26].
2) When not using tool A3
• Make marks to the bolts and head
with a marker, etc. and tighten to
90 ± 5 degrees.
fl If the cylinder head mounting bolts are

longer than the limit, do not reuse them A3
but replace them.
Limit: Small bolt: 71.5 mm
Medium bolt: 122.1 mm
Large bolt: 182.9 mm
• Refilling with water

Add water to the specified level. Run the en-
gine to circulate the water through the system. CED00041
Then, check the water level again.
30-24 D41E, P-6

1
DISASSEMBLY AND ASSEMBLY FUEL TANK
REMOVAL OF FUEL TANK

ASSEMBLY
1 2
1. Remove connector (1) and ground connection
(2).
CED00049
2. Remove clamp (3).
3. Pull out right side rear lamp wiring.
CED00050
4. Remove fuel return hoses (4).
5. Remove hose clamp (5).
5 CED00051
6. Close fuel supply valve, and disconnect fuel

supply hose (6).
CED00052
D41E, P-6 30-25

1
DISASSEMBLY AND ASSEMBLY FUEL TANK
7. Disconnect backup buzzer wiring harness (7),

and remove from clamp.
CED00053
8. Remove 4 mounting bolts.
9. Lift off fuel tank assembly (8). 8
4 Fuel tank assembly: 110 kg (dry weight)
CED00054
INSTALLATION OF FUEL TANK

ASSEMBLY
removal.
30-26 D41E, P-6

1
DISASSEMBLY AND ASSEMBLY RADIATOR AND OIL COOLER
REMOVAL OF RADIATOR
AND OIL COOLER
ASSEMBLY
1. Remove the radiator and radiator guard as-

sembly. For details, see REMOVAL OF RA-
DIATOR AND RADIATOR GUARD ASSEMBLY.
2. Remove the clamp of hose (1) and hydraulic

oil cooler assembly (2).
3. Remove the clamps of wiring (3) and washer

hose (4).
4. Remove both lower mounting bolts (5).
5. Remove upper mounting bolts (6).
6. Lift off radiator and oil cooler assembly (7).
4 Radiator and oil cooler assembly:

76 kg
INSTALLATION OF
RADIATOR AND OIL COOLER
ASSEMBLY

removal.
D41E, P-6 30-27

1
DISASSEMBLY AND ASSEMBLY FAN DRIVE PUMP
REMOVAL OF FAN DRIVE

PUMP ASSEMBLY
1. Drain the oil from the hydraulic tank.
2. Open the engine side cover and remove the

lower side cover.
3. Disconnect pump outlet hose (1) and inlet

hose (2).
4. Remove 2 mounting bolts (3) and pump as-

sembly (4).
INSTALLATION OF FAN
DRIVE PUMP ASSEMBLY

removal.
• Refilling with oil (Hydraulic tank)

Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.
30-28 D41E, P-6

1
DISASSEMBLY AND ASSEMBLY FAN MOTOR
REMOVAL OF FAN MOTOR

ASSEMBLY
1. Open grille (1) and remove covers (2) and

(3).
2. Disconnect tubes (4) and (5) and remove

clamps (6), (7), and (8) and pull them out
forward.
fl Fit plugs to both tubes and elbows.
3. Disconnect drain hose (9) and remove clamp
(10).
fl Fit plugs to both tube and elbow.
4. Disconnect connectors (11) and (12) and re-
move the clamp.
5. Sling fan motor assembly (13) and remove

the mounting bolts and fan motor assembly.
fl Turning the fan motor assembly, pull it

out.
4 Fan motor assembly: 31 kg
INSTALLATION OF FAN
MOTOR ASSEMBLY

removal.
D41E, P-6 30-29

1
DISASSEMBLY AND ASSEMBLY ENGINE
REMOVAL OF ENGINE
ASSEMBLY
¤ Disconnect the cable from the negative (–)

terminal of the battery.
¤ Bleed refrigerant gas from air conditioner.
2. Remove the engine hood assembly. For de-
tails, see REMOVAL OF ENGINE HOOD AS-
SEMBLY.
3. Remove the radiator and radiator guard as-
sembly. For details, see REMOVAL OF RA-
DIATOR AND RADIATOR GUARD ASSEMBLY.
4. Remove heat insulation panel (1) and muf-
fler (2).
5. Remove air intake hose (3) and air cleaner
assembly (4).
6. Disconnect air conditioner hoses (6) and (7).
1
fl Loosen the sleeve nuts of the hoses a
little first to release the all air conditioner
gas (R134a), and then disconnect the
hoses.
fl Install covers so that dirt, water, etc. will
not enter the hoses.
7. Remove the upper, lower, right, and left cov-
ers on the side of the transmission.
8. Disconnect air conditioner hose (8).
fl Install a cover so that dirt, water, etc.
will not enter the hose.
9. Remove clamp (9) of the air conditioner hose

and evaporator (10).
10. Disconnect main wiring harness (11) from

the battery relay and remove clamp (12) and
bracket (13).
11. Disconnect connector (14) (CN58) and re-
move clamp (15).
12. Disconnect ground harness (16).
30-30 D41E, P-6

1
(3)
13. Remove overflow hose (17) and reservoir

tank (18).
14. Disconnect spill hose (19).
15. Remove cover (20).
16. Disconnect heater hose (21).
17. Disconnect (22) (CN66) and remove clamp

(23).
18. Remove relay (24).
19. Disconnect fuel control rod (25) and decelerator
cable (26). 2
20. Disconnect fuel supply hose (27).
fl Close the valve under the fuel tank.
21. Disconnect outlet hose (28) and inlet hose

(29) of the fan drive pump.
22. Disconnect fuel return hose (30).
23. Remove the cover under the transmission

and disconnect drive shaft (31). 3
D41E, P-6 30-31

1
24. Remove front (32) and rear (33) engine

mounting bolts on both sides.
fl Before removing the engine assembly, check

that the all clamps have been removed.
25. Sling engine assembly (34) and pull it out

forward to remove it.
4 Engine assembly: 580 kg
30-32 D41E, P-6

1
INSTALLATION OF ENGINE
ASSEMBLY

removal.
1
fl Install each hose without twisting it.
fl When installing the hoses of the air con-
ditioner circuit, take care that dirt, dust,
water, etc. will not enter them.
fl Before connecting each air conditioner
hose, check that the O-ring is fitted to it.
Apply sufficient amount of compressor
oil (DENSO: ND-OIL8, ZEXCEL: ZXL100PG)
to the O-ring.
Tighten the air conditioner gas pip-
ing to the following torque.
Thread side Tightening torque (Nm {kgm})
16 x 1.5 11.8 – 14.7 {1.2 – 1.5}
22 x 1.5 19.6 – 24.5 {2.0 – 2.5}
24 x 1.5 29.4 – 34.3 {3.0 – 3.5}
• Charging air conditioner with refrigerant gas

Using tool Y, charge the air conditioner cir-
cuit with refrigerant (R134a).
2
• Adjust the linkage. For details, see TESTING
AND ADJUSTING, Adjusting fuel control link-
age and Adjusting decelerator linkage.
3
2 Drive shaft mounting bolt:
Adhesive (LT-2)

Add water through the water filler to the
specified level. Run the engine to circulate
the water through the system. Then, check
the water level again.
• Refilling with oil (Hydraulic tank and power

train case)
again.
D41E, P-6 30-33

1
(3)
DISASSEMBLY AND ASSEMBLY RADIATOR AND RADIATOR GUARD
REMOVAL OF RADIATOR
AND RADIATOR GUARD
ASSEMBLY
1. Drain the cooling water.

3. Remove the engine hood assembly. For de-
tails, see REMOVAL OF ENGINE HOOD AS-
SEMBLY.
4. Remove both side covers under the engine.
5. Disconnect 4 washer hoses (1) and remove
washer tank (2).
6. Disconnect clamp stay (3).
7. Disconnect connector (4) and 4 washer hoses

and remove clamp bolts (6) and (7).
8. Disconnect oil cooler hose (8) and remove

alternator belt cover (9).
9. Disconnect overflow hose (10) and radiator
inlet hose (11). 1
10. Open grille (12) and remove covers (13) and

(14).
30-34 D41E, P-6

1
11. Disconnect hoses (15), (16), and (17) and re-

move clamps (18), (19), and (20) and push
the hoses toward the underguard.
12. Remove cover under the radiator.
13. Disconnect transmission oil cooler hoses (22)

and (23).
fl Fit plugs both tubes and elbows.
14. Loosen the clamp of radiator outlet hose (24).
1
15. Sling the radiator and radiator guard assem-

bly temporarily and remove 2 each of front
mounting bolts (25) and 2 each of rear
mounting bolts (26) on both sides.
16. Pulling out the radiator outlet hose from the

radiator side, remove radiator and radiator
guard assembly (27).
fl Take care not damage the hoses and
wiring harnesses which are removed to-
gether with the radiator and radiator
guard assembly.
4 Radiator and radiator guard assembly:

325 kg
D41E, P-6 30-35

1
INSTALLATION OF
RADIATOR AND RADIATOR
GUARD ASSEMBLY

removal.
1
• Radiator inlet and outlet hose clamps:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

Add water through the water filler to the
specified level. Run the engine to circulate
the water through the system. Then, check
the water level again.
• Refilling with oil (Hydraulic tank and power
train case)
again.
30-36 D41E, P-6

1
DISASSEMBLY AND ASSEMBLY DAMPER
REMOVAL OF DAMPER
ASSEMBLY
1. Remove undercover.
1
2. Drain oil from damper chamber.
6 Damper chamber: 1.1 ¬
3. Remove center floor plate.
4. Remove deceleration pedal and disconnect de-

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

turnbuckle. 2
3 2
CED00060
6. Disconnect drive shaft (4) at damper end.
7. Remove coupling.
4
CED00061
8. Using guide bolts 1 and forcing screws 2, re-

move cover assembly (5).
q q
w
5 w CED00062
D41E, P-6 30-37

1
9. Disassembly of cover assembly

1) Remove snap ring (7) from cover (6).
2) Support cover with block 1 and remove
shaft (8). 8
7
3) Remove oil seal (9) and snap ring (10) from 11
cover (6), then remove bearing (11).
10
6
q 9
CED00493
10. Remove damper assembly (12).
12
CED00063
INSTALLATION OF DAMPER 8
10
ASSEMBLY 6 9
1. Install damper assembly (12).
3 Damper assembly:
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
11
2. Assembly of cover assembly
1) Support cover (6) with block 2, use push w 7
tool to install bearing (11), and install snap
ring (10).
CED00549
2) Install oil seal (9).
3) Install shaft (8), then install snap ring (7).
3. Install cover assembly.
4. Install coupling. 4
5. Install drive shaft (4).

66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
CED00061
30-38 D41E, P-6

1
6. Install brake rod (2) and inching rod (3).

fl Adjust the inching rod.
For details, see ADJUSTING INCHING ROD.
fl Adjust the linkage of the parking brake.
For details, see ADJUSTING BRAKE ROD.
3 2
CED00060
7. Install deceleration cable (1) and deceleration

pedal.
fl Adjust the deceleration pedal. 1
For details, see ADJUSTING DECELERATION
PEDAL.
8. Install center floor plate.
9. Add oil to damper chamber.
5 Damper chamber: 1.1 ¬ (SAE30CD)

CDD00080
3 Plug: 68.6 ± 9.8 Nm {7 ± 1 kgm}
10. Install undercover.
D41E, P-6 30-39

1
DISASSEMBLY AND ASSEMBLY TRANSMISSION
REMOVAL OF TRANSMISSION
ASSEMBLY
1. Remove floor frame assembly.
For details, see REMOVAL OF FLOOR FRAME
ASSEMBLY.
2. Drain oil from the following.

1) Hydraulic tank: Approx. 37 ¬
2) Transmission oil pan: Approx. 22.5 ¬
3) Steering case: Approx. 80 ¬
3. Disconnect safety lock (parking brake) cable (1)

at brake valve end. 1 7 8
9 4
fl After disconnecting cable (1), loosen locknut 1
(2) and move the cable towards the frame.
4. Remove spring (3), and disconnect hoses (4),

(5), (6), (7), and (8).
2
5. Remove brake valve and block assembly (9).
3 6
5
CED00144
6. Tighten spring of parking brake cylinder (10)

with nut (11), extend mounting rod approx. 40
mm, and make enough play to remove mount-
ing pin (12).
11
fl Release the parking brake.
Procedure for releasing parking brake.
12
10
CED00145
7. Disconnect hoses (13), and remove priority valve

(14).
13
14
CED00146
30-40 D41E, P-6

1
8. Pull out pin (15) and remove mounting bolts,

then remove parking brake cylinder assembly 18
(16). 16 15
9. Disconnect rod (17), and remove bracket (18).
17 CED00147
10. Pull out pin (19), then remove bracket (20) to-
gether with cable, and move towards left side 21
20
of chassis.
11. Remove pins (21) and (22), then remove lever 22

(23).
23 19
CED00148
12. Disconnect transmission oil cooler hoses (24).
13. Disconnect pump outlet hoses (25). 25

26
14. Remove drive shaft (26). 2
24
CED00149
15. Remove steering case dipstick tube (27), then

remove suction tube (28).
16. Remove transmission dipstick tube (29).

27
29
28
CED00150
D41E, P-6 30-41

1
17. Sling transmission assembly (30), remove cover

under chassis, then remove 5 mounting bolts
(31) and 6 mounting bolts (32) at bottom of
transmission assembly.
31
CED00151
32
CED00152
18. Remove mounting bolts at top of transmission

assembly, then use forcing screws and lift off 30
transmission assembly (30).
4 Transmission assembly: 295 kg
CED00153
30-42 D41E, P-6

1
INSTALLATION OF
TRANSMISSION ASSEMBLY
removal.
1
• Adjust the parking brake.
Adjusting parking brake linkage.
2
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
• Refilling with oil

Add oil through oil filler to the specified level to
the following.
• Hydraulic tank: Approx. 37 ¬
• Transmission oil pan: Approx. 22.5 ¬
• Steering case: Approx. 80 ¬
fl Run the engine to circulate the oil through
the system. Then check the oil level again.
D41E, P-6 30-43

1
DISASSEMBLY AND ASSEMBLY PTO
DISASSEMBLY OF PTO
ASSEMBLY
1. Remove PTO and transmission case assembly. 1 q
For details, see Steps 1 – 10 of DISASSEMBLY
OF TRANSMISSION ASSEMBLY.
2. Cage assembly
1) Using forcing screws 1, remove cage as-
sembly (1).
2) Disassembly of cage assembly
i) Remove snap ring (2). 2
CED00345 CED00346
ii) Using push tool, pull out gear (3) from

inner race of bearing (4).
iii) Remove snap ring (5). 5
3
CED00347 CED00348
iv) Remove bearing (4) from cage (6).
3. Drive gear
1) Using push tool, remove drive gear (7).
2) Using push tool, remove bearing (8).

8
CED00351
30-44 D41E, P-6

1
ASSEMBLY OF PTO
ASSEMBLY
1. Drive gear
1) Using push tool, install bearing (8) to case. 8
CED00352
2) Support bearing (8) and install drive gear

(7).
3) Assembly of cage assembly

i) Using push tool, install bearing (4) to
cage (6).
ii) Install snap ring (5).
iii) Support bearing (4), and install gear (3)

to bearing (4).
iv) Install snap ring (2).
D41E, P-6 30-45

1
4) Install cage assembly (1) to case.

1
CED00356
30-46 D41E, P-6

1
DISASSEMBLY OF
fl After removing the discs and plates, keep them
in a flat place to prevent deformation.
fl When the transmission assembly has been in-
stalled, the backlash and tooth contact is not
adjusted, so before disassembly, accurately
measure dimension a between the end face of
the rear housing and the end face of the bevel
gear.
1. Tandem pump assembly 2

1) Remove tubes (1) and (2).
2) Remove tandem pump assembly (3).
3
1
CED00265
2. Inching valve bracket assembly

Remove bracket assembly (4).
4
CED00266
3. Transmission inlet hose

Remove hose (5). 5
4. Oil temperature sensor

Remove oil temperature sensor (6). 6
5. Modulating valve assembly

1) Remove tube (7).
2) Remove modulating valve assembly (8). 7
8 CED00267
D41E, P-6 30-47

1
6. Shift valve assembly

Remove shift valve assembly (9).
CED00268
7. Sleeve
Using eyebolts 1, remove sleeve (10).
q
10
CED00269
8. Strainer
1) Remove cover (11), then remove spring and 11 12
strainer assembly (13).
2) Remove strainer case (12). 13
CED00270
9. Coupling
1) Remove bolt (14), then remove holder (15). 14 16
2) Remove coupling (16).
17
3) Remove spacer (17).
15
CED00271 CED00272
30-48 D41E, P-6

1
10. PTO, transmission case assembly

1) Remove housing lock bolts (18) (left and
right: 2 each).
2) Remove 3 transmission case mounting bolts
(19).
18
19
CED00273
3) Using eyebolts 2 and shackle 3, lift at 3

points, and remove PTO and transmission
case assembly (20). e
w
20
CED00274
11. Tie bolt

Remove tie bolt (21).
fl When the tie bolt is removed, the piston 22 21
return spring will come out easily, so be
careful not to lose it.
12. No. 1 housing, No. 1 carrier assembly

Raise No. 1 housing, No. 1 carrier assembly
(22) from No. 2 housing, and remove.
fl Be careful not to get your fingers caught.
• Disassembly of No. 1 housing, No. 1 carrier CED00275

assembly
1) No. 2 sun gear
i) Remove snap ring (23).
ii) Remove No. 2 sun gear (24).
24
iii) Remove snap ring (25). 23
2) No. 1 carrier sun gear 27

25
ii) Remove No. 1 carrier sun gear (27).
26
CED00276 CED00277
D41E, P-6 30-49

1
3) Input shaft
ii) Push out from No. 2 sun gear end, and
remove input shaft (29).
iii) Remove snap ring (30).

iv) Remove snap ring (31), then remove 32
bearing (32) from input shaft (29).
30
29
31
CED00279
4) No. 1 carrier assembly

ii) Remove No. 1 carrier assembly (34) from
No. 1 housing (35).
iii) Remove collar (36).
5) Disassembly of No. 1 carrier assembly

42
i) Knock pin (37) into shaft (38).
ii) Knock out shaft (38), then remove thrust 38
washers (39), gear (40), and bearings (41)
from carrier (42). 39
40
41
39
37
CDD00281
30-50 D41E, P-6

1
6) Remove snap ring (43), then remove bear-

ing (44).
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
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).
16. No. 2 (F) clutch springs, disc, plates

D41E-6 Serial No. B40351 – B40357 CED00284
D41E-6 Serial No. B40366 – B40375
D41E-6 Serial No. B40421 – B40425
D41P-6 Serial No. B40340 – B40341
D41P-6 Serial No. B40345 – B40350
D41P-6 Serial No. B40358 – B40365 49
D41P-6 Serial No. B40379 53
D41P-6 Serial No. B40381 – B40382
D41P-6 Serial No. B40387 – B40388
D41P-6 Serial No. B40398 – B40399
D41P-6 Serial No. B40406 – B40407 50
D41P-6 Serial No. B40412
D41P-6 Serial No. B40430 – B40433 54
D41P-6 Serial No. B40435 – B40436
1) Remove washer (53), springs (54) and (55),
45
and guide (48).
2) Remove disc (49) and plates (45) and (50). CED00285
D41E, P-6 30-51

1
(3)
D41E-6 Serial No. B40392 – B40397

D41E-6 Serial No. B40420
D41E-6 Serial No. B40426 – B40429
D41E-6 Serial No. B40449 and up
D41P-6 Serial No. B40339 and up
D41P-6 Serial No. B40342 – B40344
D41P-6 Serial No. B40376 – B40378
D41P-6 Serial No. B40383 – B40386
D41P-6 Serial No. B40389 – B40391
D41P-6 Serial No. B40400 – B40405
D41P-6 Serial No. B40408 – B40411
D41P-6 Serial No. B40413 – B40419
D41P-6 Serial No. B40437 – B40444
1) Remove springs (54) and guide (48) and
springs (55).
2) Remove disc (49) and plates (45) and (50).
56
17. No. 1 carrier ring gear 57
1) Remove snap ring (56).
2) Remove No. 1 carrier ring gear (57).
18. No. 2 clutch ring gear

Remove No. 2 clutch ring gear (58).
58
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
30-52 D41E, P-6

1
(3)
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
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
D41E, P-6 30-53

1
(3)
iv) Remove snap ring (73), then remove

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

Remove No. 4 housing (76). 76
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
30-54 D41E, P-6

1
(3)
29. No. 3 carrier sun gear

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
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
specified dimension.
fl Dimension b: Distance from tip of
shaft to tip of cover
fl Dimension c: Distance from tip of
inner race to stepped
portion of shaft
iv) Remove collar (124) and spacer (86).
D41E, P-6 30-55

1
(3)
v) Using press, remove output shaft (87)

from cage (88).
vi) Remove spacer (86A) and inner race (90)
from output shaft (87).
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
with tags, and keep in a safe place. 121
viii)Remove oil seal (93) from cover (92). 93
91
CED00306 CDD00307
ix) Using push tool, push out outer race

(63), and remove bearing (94) and spacer
(120) from cage (88).
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
30-56 D41E, P-6

1
(3)
• 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
64 CED00311
4) Remove piston (105).

5) Remove snap ring (102), then remove collar
(101), bearing (103), and cage (104) from
housing (97).
fl Be careful not to lose ball (115).
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
D41E, P-6 30-57

1
(3)
8) No. 4 clutch carrier assembly 111

ii) Pull out shaft (111), and remove thrust 112
washers (112), gear (113), and bearing 114
(114).
113
112
110
CDD00314
30-57-1 D41E, P-6

(3)
ASSEMBLY OF
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),

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
30-58 D41E, P-6

1
(2)
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
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:
Thread tightener (LT-2)
Mounting bolt:
31.9 ± 2.5 Nm {3.25 ± 0.25 kgm}
CED00310
D41E, P-6 30-59

1
(2)
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).
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
30-60 D41E, P-6

1
(2)
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.
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.
D41E, P-6 30-61

1
(2)
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
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
30-62 D41E, P-6

1
(2)

Set No. 3 clutch ring gear (75) in position, and 74
install snap ring (74). 75
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
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
D41E, P-6 30-63

1
(2)
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
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
30-64 D41E, P-6

1
(2)
17. No. 1 carrier ring gear

1) Install No. 1 carrier ring gear (57) to No. 3
carrier.
2) Install snap ring (56). 56
18. No. 2 (F) clutch plates, discs, springs 57

D41E-6 Serial No. B40351 – B40357
D41E-6 Serial No. B40366 – B40375
D41E-6 Serial No. B40421 – B40425
D41P-6 Serial No. B40340 – B40341
D41P-6 Serial No. B40345 – B40350
D41P-6 Serial No. B40358 – B40365
D41P-6 Serial No. B40381 – B40382
D41P-6 Serial No. B40387 – B40388
D41P-6 Serial No. B40398 – B40399 CED00335
D41P-6 Serial No. B40406 – B40407
D41P-6 Serial No. B40430 – B40433
D41P-6 Serial No. B40435 – B40436
1) Install plate (45), discs (49), and plates (50). 49
fl Discs: 5, plates (50): 5, plate (45): 1
2) Install springs (55) and (54), guide (48), and 54
53
washer (53).
fl Free length of spring (large): 22.93 mm
(small): 18.65 mm 48 50
55 45
D41E-6 Serial No. B40392 – B40397 CED00336
D41E-6 Serial No. B40420
D41E-6 Serial No. B40426 – B40429
D41E-6 Serial No. B40449 and up
D41P-6 Serial No. B40342 – B40344
D41P-6 Serial No. B40376 – B40378
D41P-6 Serial No. B40383 – B40386
D41P-6 Serial No. B40389 – B40391
D41P-6 Serial No. B40400 – B40405
D41P-6 Serial No. B40408 – B40411
D41P-6 Serial No. B40413 – B40419
D41P-6 Serial No. B40437 – B40444
1) Install plate (45), discs (49), and plates (50).
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.) 52 51
19. No. 2 housing

Install No. 2 housing (52).

Install No. 1 clutch ring gear (51).
CED00337
outside circumference facing up.
D41E, P-6 30-65

1
(3)
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
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).
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"
30-66 D41E, P-6

1
(3)
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
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
D41E, P-6 30-67

1
(3)
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
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
30-68 D41E, P-6

1
(3)
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
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
D41E, P-6 30-69

1
(3)
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).
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
30-69-1 D41E, P-6

(3)
DISASSEMBLY AND ASSEMBLY STEERING CASE
DISASSEMBLY OF STEERING
CASE ASSEMBLY
1. Final drive assembly (left, right)
Remove final drive assembly.
For details, see REMOVAL OF FINAL DRIVE AS-
SEMBLY.
2. Floor frame assembly

Remove floor frame assembly.
For details, see REMOVAL OF FLOOR FRAME
ASSEMBLY.
3. Fuel tank assembly

Remove fuel tank assembly.
For details, see REMOVAL OF FUEL TANK AS-
SEMBLY.
4. Draining oil
1) Drain oil from steering case.
6 Steering case: Approx. 80 ¬
2) Drain oil from hydraulic tank.
6 Hydraulic tank: Approx. 37 ¬
5. Transmission assembly
Remove transmission assembly.
For details, see REMOVAL OF TRANSMISSION
ASSEMBLY.
5
6. Piping, spring
1) Disconnect piping (1), (2), (3), and (4). 5 2 3
2) Remove springs (5).
1
CED00382
7. Breather hose, suction tube

1) Remove breather hose (6).
2) Remove hydraulic oil suction tube (7).
7 6
CED00383
30-70 D41E, P-6

1
8. Brake, clutch lever

Remove brake levers (8) and clutch levers (9). 9 9
fl Make match marks at the shaft end before
removing.
8
8
CED00384
9. Cover assembly
1) Remove mounting bolts. 10
2) Using eyebolts 1, raise cover assembly (10)
horizontally and remove.
fl If the oil seal is to be used again, be
careful not to damage it.
q
CED00385
3) Remove steering piston assembly (11) from

cover assembly (10). 10
11 11
CED00386
4) Remove bearings (13) from cover assembly

(10).
12 10 12
5) Remove oil seals (12) from cover assembly
(10).
13 13
CED00387
D41E, P-6 30-71

1
10. Shaft, cam case assembly

1) Remove washers (14). 15 15
2) Pull out clutch shafts (15) and brake shafts
14 14
(16).
fl Your hands will slip, so be careful when 17
removing. 17
3) Remove clutch cam case assembly (17) and
16 16
brake cam case assembly (18).
14 14
18 18
CED00388
4) Remove washers (14).
14 14
CED00389
5) Remove bearings (22) from clutch cam case

(17).
fl Remove the brake cam case in the same 22 22
way.
17
CED00390
11. Clutch, brake disc

1) Remove mounting bolts of shaft assembly
(19).
21
2) Support clutch disc (20) and brake disc (21) 19
and pull out shaft assembly (19).
fl Remove on the opposite side in the same
way.
19 20
CED00391 CED00392
30-72 D41E, P-6

1
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
shaft (24) from cover (27).
fl The shape of the cover is different
depending on Serial Numbers.
ii) Remove snap ring (25), then remove

bearing (26) from shaft (24).
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
D41E, P-6 30-73

1
13. Carrier, bevel gear assembly

30 30
1) Sling carrier and bevel gear assembly (30). 31
2) Remove mounting bolts, then remove cage
and sun gear assembly (31).
fl Check the number and thickness of 32
shims (32), and keep in a safe place.
32
31
CED00397 CED00398
3) Lift off carrier and bevel gear assembly (30). 30
CED00399
4) Disassembly of cage, sun gear assembly

i) Remove snap ring (33), then remove sun
gear (34) from cage (35).
ii) Remove snap ring (36), then remove
bearing (37) from sun gear (34).
iii) Remove snap ring (38), then remove

bearing (39) from cage. 41 42
iv) Remove snap ring (40), then remove
bearing (41).
v) Remove bearing (42).
40
39 38
CED00402
30-74 D41E, P-6

1
Disassembly of carrier, bevel gear assem-

bly 43 44
i) Remove mounting bolts, then remove
plate (43).
ii) Remove carrier assembly (44).
CED00403 CED00404
iii) Remove carrier assembly (44) on oppo-

site side. 43 45
44
iv) Remove mounting bolts, then remove
plate (43).
v) Remove bevel gear (45) from ring gear
(54).
54
CED00405 CED00406
6) Disassembly of carrier assembly

ii) Pull out shaft (47), and remove thrust 47
46 48
washers (48), gear (49), and bearing (50).
50
49
48
CED00407
D41E, P-6 30-75

1
ASSEMBLY OF STEERING
CASE ASSEMBLY
Coat the sliding surfaces of all parts with en-
gine oil before installing.
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
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
30-76 D41E, P-6

1
(2)
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
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
D41E, P-6 30-77

1
(2)
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
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.
30-78 D41E, P-6

1
(2)
• 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.
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.
D41E, P-6 30-79

1
(2)
• 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}
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
30-80 D41E, P-6

1
(2)
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.
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
D41E, P-6 30-81

1
(2)
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- 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
30-82 D41E, P-6

1
(2)
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.
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
D41E, P-6 30-83

1
(2)
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

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.
30-84 D41E, P-6

1
(2)
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. 1

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

q
6 Steering case: 80 ¬ 2
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). 3
6. Install tool J1 to final drive assembly.
7. Using tool J1, sling final drive assembly (2),

and remove mounting bolts. 4
8. Lift off final drive assembly (2).

4 Final drive assembly (each): 390kg
CED00130
INSTALLATION OF FINAL
DRIVE ASSEMBLY
removal.
1
6 Final drive (each): 14 ¬ (SAE30CD)
3 Plug: 152.0±24.5Nm {15.5±2.5kgm}
2
6 Steering case oil: 80 ¬ (SAE30CD)
3
2 Guard mounting bolt:
3 Guard mounting bolt:
277±32Nm {28.25±3.25kgm}
4
3 Final drive mounting bolt:
277±32Nm {28.25±3.25kgm}
D41E, P-6 30-85

1
DISASSEMBLY OF FINAL
DRIVE ASSEMBLY
• 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

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

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

from case.
CED00238
30-86 D41E, P-6

1
J6
CED00239
9. Remove bearing inner race (10), then remove

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

bly (9).
13
9
CED00242
D41E, P-6 30-87

1
12. 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
CED00244
• Pinion assembly
13. Remove oil seal and bearing housing (18).
14. 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
30-88 D41E, P-6

1
15. Remove pinion assembly (21) from case.

21
CED00247
16. 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).
CED00248
• Bearing outer race

17. Remove bearing outer races (25), (26), and (27)
from case.
D41E, P-6 30-89

1
ASSEMBLY OF FINAL DRIVE

ASSEMBLY
• Bearing outer race
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.
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.
3 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.
fl Pinion rotating torque:
Max. 2.9Nm {0.3kgm}
30-90 D41E, P-6

1
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.
3 Oil seal, bearing housing mounting
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
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
D41E, P-6 30-91

1
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.
2 Holder mounting bolt:
3 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 le-

ver, 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
30-92 D41E, P-6

1
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:
3 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.
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.
D41E, P-6 30-93

1
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:
3 Cage mounting bolt:
1084±74Nm {110.5±7.5kgm}
15. Install sprocket assembly (2) to final drive case

(1).
3 Sprocket mounting bolt:
1084±74Nm {110.5±7.5kgm}
30-94 D41E, P-6

1
DISASSEMBLY AND ASSEMBLY IDLER
REMOVAL OF IDLER
ASSEMBLY
1. Expand the track shoe. For details, see EXPAN-

SION OF TRACK SHOE ASSEMBLY.
2. Remove guide plates (1) and shims (2) on both
sides.
fl Check the number of the shims.
3. Pull out front idler and recoil spring assembly

(3) and lift it off by slinging the rod portion.
4 Idler and recoil spring assembly:
200 kg
4. Remove bolt (4) to disconnect idler (5) and re-

coil spring (6).
4 Idler: 95 kg
4 Recoil spring: 110 kg
INSTALLATION OF IDLER
ASSEMBLY

removal.
1
fl Standard shim thickness: 4 mm
fl Adjust the shim thickness so that clearance

A between the track frame and guide plate
will be 0.5 – 1.0 mm.
2 Threads of guide plate mounting bolt:

Adhesive (LT-2)
D41E, P-6 30-95

1
1
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.
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).
30-96 D41E, P-6

1
1
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
nut (6).
3 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
D41E, P-6 30-97

1
1
DISASSEMBLY OF IDLER
ASSEMBLY
1. Remove dowel pin (1), then remove support
(2).
2. Remove floating seal (3) from support (2) and

idler (4).
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

idler (4) and shaft (5) and support assembly (7).
5. Remove dowel pin (8), then remove support (7)

from shaft (5).
6. Remove bushings (9) and (10) from idler (4).
30-98 D41E, P-6

1
1
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).
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
dust get stuck to it.
fl Remove all grease and oil from the contact
surface of the O-ring and the floating seal.
L1-2
CED00198
D41E, P-6 30-99

1
1
4. Assemble shaft (5) and support assembly (7) to

idler (4), then turn over.
5. Add oil between shaft (5) and idler (4).
5 Oil: 150 cc (EO30-R)
4
CED00199
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.
fl Remove all grease and oil from the contact
surface of the O-ring and the floating seal.
L1-2
CED00201
30-100 D41E, P-6

1
7. Install O-ring, then install support (2) with dowel

pin (1).
D41E, P-6 30-101

1
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
DISASSEMBLY OF TRACK ROLLER ASSEMBLY

7 8 5
6
10
4
9
3
2
11
CED00100
1. Remove pin (1), then remove collar (2).
2
CED00101
2. Remove floating seal (3) from collar (2) and roller

(4). 3
3
2
CED00102 CED00103
3. Pull out roller (4) from shaft (5).

fl It is filled with 100 – 115 cc. of oil, so drain
the oil at this point or lay a cloth to prevent 5 6
the area from becoming dirty.
4. Remove floating seal (6) on opposite side from

4 4
roller (4) and shaft (5).
CED00104 CED00105
30-102 D41E, P-6

1
5. Remove pin (7), then remove collar (8) from

shaft (5).
9,10
6. Remove bushings (9) and (10) from roller (4).
5
6
8
4
7
CED00106 CED00107
D41E, P-6 30-103

1
ASSEMBLY OF TRACK ROLLER

ASSEMBLY
1. Using tool L2-1, press fit bushings (9) and (10)
to roller (4). L2-1
2. Assemble collar (8) to shaft (5), and install pin 5

(7).
9 L2-2
3. Using tool L2-2, install floating seal (6) to shaft 6a
4 6
(5). 6c
fl When assembling the floating seal, clean 10
7 8
the contact surface A (bold line) of O-ring
(6c) and floating seal (6a), remove all grease CED00108 CED00109
and oil, and dry it. Make sure that no dirt or

dust sticks to the contact surface of the float-
ing seal.
fl After inserting the floating seal, check that
the angle of the seal is less than 1 mm, and
that protrusion a is between 5 – 9 mm.
4. Using tool L2-2, install floating seals (6) and (3)

to roller (4).
fl For details of the precautions when install- 4 L2-2
ing floating seals (6b) and (6d), and (3b) 5
and (3d), see the precaution for Step 3. 3b
3
3d
6b 4
6
6a
CED00112 CED00113
5. Assemble shaft (5) to roller (4).
6. Turn over roller (4) and shaft (5) assembly.

L2-2
4
7. Using tool L2-2, install floating seal (3) to collar 3a
(2). 3 3c
fl For details of the precautions when install-
ing floating seals (3a) and (3c), see the pre- 5 2
caution for Step 3.
CED00114 CED00115
30-104 D41E, P-6

1
8. Assemble collar (2) to shaft (5), and install pin

1
(1). 2
CED00116
9. Using tool L4, apply basic pressure to roller oil

filler port, and check for leakage of air from
L4
seal.
fl Basic pressure: 0.1 MPa {1 kg/cm2}
fl Method of checking
The basic pressure shall be maintained for
10 seconds and the indicator of the gauge
shall not go down.
CED00117
10. Using tool L4, fill track roller assembly with oil,
then tighten plug (11).
5 Track roller oil: 100 – 115 cc (EO30-R)
11
CED00119
D41E, P-6 30-105

1
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
DISASSEMBLY OF CARRIER
ROLLER ASSEMBLY
3 4 5
1. Remove plug (1) and drain oil.
2. Remove snap ring (2), then remove cover (3).
3. Remove bolt (4), then remove spacer (5).
2
1
CED00203 CED00204
4. Set carrier roller on block 1, and using push

tool 2, pull out shaft assembly (6) with press, 7
then remove bearing (7).
w
6
CED00205 CED00206
5. Disassembly of shaft assembly

1) Remove collar (8) from shaft assembly (6).
2) Remove floating seal (9). 6 10
3) Remove floating seal (10) from collar (8). 8
4) Remove bearing (12) from shaft (11).
9
CED00207 CED00208
6. Remove outer race (14) from roller (13), then

14,15
turn over and remove outer race (15).
11 12
13
CED00209 CED00210
30-106 D41E, P-6

1
ASSEMBLY CARRIER ROLLER

ASSEMBLY
14,15
1. Press fit outer races (15) and (14) to roller (13).
q
2. Assembly of shaft assembly
1) Using push tool 1, press fit collar (8) to
shaft (11).
fl Press-fitting force of collar (8): 8
65.7 – 108.9 kN {6.7 – 11.1 ton}
2) Using tool L3, assemble floating seal (10). 11
fl When assembling the floating seal, clean
the contact surface A (bold line) of the 13
O-ring and floating seal, remove all CED00210 CED00211
grease and oil, and dry it. Make sure

that no dirt or dust sticks to the contact
surface of the floating seal.
fl After inserting the floating seal, check
that the angle of the seal is less than 1
mm, and that protrusion a is between 4
– 8 mm.
3) Assemble floating seal (9), then using push

tool 2, press fit bearing (12). w
fl For details of the precautions when in-
stalling the floating seal, see the pre- 12
caution for Step 2. L3 9
10
CED00214 CED00215
3. Set shaft assembly (6) on block 3, and assem- 6

ble roller (13). r
4. Assemble bearing (7), then press fit with push

7
tool 4.
fl Rotate the roller when press fitting the bear- 13
ing, and continue to press fit until the rota-
tion of the roller becomes slightly heavier.
13
e
CED00216 CED00217
D41E, P-6 30-107

1
5. Install spacer (5) with bolt (4). 4 5

3 Bolt: 277.5 ± 32.4 Nm {28.3 ± 3.3 kgm} 3
6. Using tool L4, add oil to carrier roller.
5 Carrier roller: 240 cc (GO140B)
7. Fit O-ring to cover (3) and install to roller, then

install snap ring (2).
2
8. Check oil level and tighten plug (1). 1
CED00218 CED00203
30-108 D41E, P-6

1
DISASSEMBLY AND ASSEMBLY TRACK SHOE
REMOVAL OF TRACK SHOE

ASSEMBLY
1. Set master link in position.
fl Set a block so that the master link is at the 2
front directly above the idler.
3. Loosen lubricator (2) and relieve track shoe ten- 1

sion. 1
¤ The adjustment cylinder is under extremely
high pressure. Never loosen lubricator (2)
CED00224 CED00225
more than one turn. If the track tension is
not relieved, move the machine backwards
and forwards.
4. Raise work equipment fully. 3

5. Remove track shoe on master link (3).
6. Using wire and chain block, pull both ends of

master link (3) and remove mounting bolts. 2
7. Disconnect master link (3), support end of track

link with crane, drive machine slowly in reverse,
and lay out track assembly (4).
CED00226
CED00227
D41E, P-6 30-109

1
INSTALLATION OF TRACK
SHOE ASSEMBLY
removal.
1 q e
fl Track shoe tension: 20 – 30mm
2 w
r
3 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.
30-110 D41E, P-6

1
OVERALL DISASSEMBLY OF
TRACK SHOE
fl This section describes only the procedure for
the lubricated track.
1. Shoe (master link portion)
Set the track assembly on a flat floor with the
shoe facing up, then remove the shoe bolt at
the master link, and remove the shoe.
fl Do not use an impact wrench when loosen-
ing the master link bolt.
2. Disassembly into 1/4 parts

DLD00283
Because of the weight of the track assembly, if
the 1/2 assembly is too large and there are prob-
lems with disassembly and assembly work, di-
vide into 1/4 assemblies.
3. Shoe (regular link portion)

Raise the track assembly and set it on the floor
with the shoe facing up, then use a shoe bolt
impact wrench to remove the shoes.
fl When moving the track assembly, be care-
ful not to damage the master link portion.
fl If a gas cutter has to be used to remove the
shoe nut, to prevent deterioration of the seal
due to the heat, keep the temperature of the
CED00448
seal portion below 80°C, and take action to
prevent welding spatter from entering the
gap between the links.
4. Draining oil
Before disassembling the link assembly, drain
the oil from inside the pin and take precautions
so that the link press does not become dirty
with oil.
fl Before disassembling, if it is judged that it
is necessary to rebuild the track as a dry
type track, the following work need not be
carried out.
1) Set the link assembly on a flat floor with the
large plug side facing up, then chamfer the
burrs on the end face of the pin with a
grinder.
fl If the track is disassembled with burrs
still at the end face of the pin, the pin
press-fitting hole of the link will be
scratched, and this will cause leakage
from the pin press-fitting portion after
rebuilding.
2) Using a drill (ø10 mm), make a hole in the
large plug, then remove the large plug.
fl If any dirt or deteriorated oil is stuck to
the pin hole, drill through with a longer
drill to remove it. When doing this, be
DLD00286
careful not to damage the oil hole.
D41E, P-6 30-111

1
3) After removing the large plug, use a baby

grinder (angle of grinder tip: 45° – 60°), and
chamfer the pin hole so that the plug is not
damaged when the plug is knocked in.
4) Turn over the link assembly so that the small
plug side is facing up, remove the burrs at
the end face of the pin with a grinder, then
use tool R2 to knock the small plug to the
inside.
fl If the small plug hole is blocked with
burrs, grind with a grinder until the hole
can be seen completely. DLD00287
5) Using a drill (ø10 mm), chamfer the small
plug hole.
6) Blow with compressed air to remove the
metal particles when draining the oil inside
the pin or removing the burrs, then wash
the link assembly with high-pressure water
or steam.
R2
CED00449
5. Disassembly of link
1) Set the link assembly on a link press, then
hit with a hammer so that the bushing and
jaw are in tight contact.
fl If the link tread and outside diameter of
the bushing are worn, adjust the height
of the shoe or guide plate, and center
the disassembly jig with the pin and
bushing center to prevent damage to the
link hole when disassembling.
fl If the centering is not carried out prop-
erly, the link hole may be damaged, the
pin may break, or the bushing may crack
during disassembly.
2) Operate the left cylinder and remove the
left link and pin and bushing press-fitting
portion at the same time.
fl Check the removal force of the pin and
bushing, and use this value as reference
to judge if it is possible to obtain the
necessary pin and bushing press-fitting
force when turning and reassembling.
fl Do not push the disassembly jig inside
more than is necessary as the spacer
may break.
30-112 D41E, P-6

1
3) Return the left cylinder, then operate the

right cylinder and remove the right link and
pin and bushing press-fitting portion at the
same time.
4) Return the right cylinder, remove the left
and right links, pins, bushings, and spacers,
then feed the following set for one link as-
sembly into the jaw.
fl To decide if the seal can be used again,
carry out inspection when the seal is
still installed to the link, so do not re-
move the seal from the link.
fl If oil is remaining, this can be used as a
guideline for reuse of the seal, so mark
such links or seals.
fl If the end face of the bushing and seal
surface are damaged, it will cause oil
leakage, so be extremely careful when
handling.
6. Inspection
Check the following items to determine if the
part can be reused as a lubricated track or as a
grease-filled track. Carry out a comprehensive
check to determine if the link assembly can be
rebuilt as a lubricated track or as a grease-filled
track.
fl When making judgments about reuse of
parts, see “Guidance for Reusable Parts, Un-
dercarriage, Lubricated Track”.
1) Check the pins, bushings, links, and spacers
visually for damage, and carry out a color
check or use a flaw detector to check parts
that are suspected of being damaged. Any
part that is cracked must not be used again,
so scrap it.
2) Check the external appearance of the seal
and the end face of the bushing visually to
determine if they can be used again.
fl If only the bushing is replaced with a new
part, the worn or damaged part of the seal
lip will contact the end face of the bushing
directly, so it may not be able to carry out
its sealing function. For this reason, always
replace the seal together with the bushing,
or rebuild as a grease-filled track.
D41E, P-6 30-113

1
3) Using calipers, measure spacer thickness "a"

and overall length "b" of the sliding portion
of the bushing and spacer. Check if it is
possible to obtain the specified seal mount-
ing dimension when reassembling.
fl If the amount of wear of the spacer and
bushing is greater than the specified
amount, the assembly precision of the a
b
seal portion cannot be guaranteed, so
replace with new parts, or rebuild as a
grease-filled track.
4) Using a micrometer, cylinder gauge, and DLD00293
calipers, measure the outside diameter of
the pin and the inside diameter of the bush-
ing at the worn portion, and judge if the
parts can be used again.
fl If the amount of wear is greater than
the specified amount, there will be play
during travel, and it will also cause oil
leakage, so replace with new parts or
rebuild as a grease-filled track.
fl For details of the dimensions when mak-
ing judgment, see MAINTENANCE
STANDARDS.
5) Using a micrometer and cylinder gauge,
measure the outside diameter of the pin and DLD00294
bushing press-fitting portion, and the inside
diameter of the pin and bushing press-fit-
ting portion of the link to determine if the
permitted interference can be obtained.
However, when rebuilding as a lubricated
track, check that the standard interference
for the pin and link can be obtained.
fl If the permitted interference can not be
obtained, replace with new parts or re-
place with an oversize part.
fl For details of the dimensions when mak-
ing judgment, see MAINTENANCE
STANDARDS.
DLD00295
DLD00296
30-114 D41E, P-6

1
fl Precautions for storage

1) To prevent rust of the counterbore portion
of the link, leave the seal installed to the
link and be careful not to damage the seal
lip during storage.
2) Coat the pin and bushing press-fitting por-
tion, shoe mating surface, and master link
mating surface of the link with rust preven-
tion oil to prevent rust.
3) Coat the whole circumference of the pins,
bushings, and spacers with rust prevention
oil to prevent rust, and be particularly care- DLD00297
ful not to damage the end face of the bush-
ing during storage.
D41E, P-6 30-115

1
OVERALL ASSEMBLY OF
TRACH SHOE
1. When rebuilding as lubricated track
1. Preparatory work
1) Washing seal assembly
Remove the seal assembly from the link,
then separate into the seal ring and load
ring, and clean the parts.
fl The seal ring and load ring deteriorate
easily when brought into contact with
cleaning agent (trichlene, etc.), so wash
the parts quickly. After cleaning, wipe
the parts with a clean cloth to remove
all the cleaning agent.
2) When reusing the pin, chamfer the corner

of the end face smooth with a grinder. Use
a grinder to remove any protruding parts
stuck to the press-fitting portion.
fl If the corner of the end face has become
sharp due to wear, there will be scuffing
at the press-fitting portion and this will
cause oil leakage.
DLD00300
3) Make a mark on the end face at the small

plug end to show the direction of the side
hole (hole in the radial direction) in the pin
when assembling.
fl When reusing the pin, assemble in the
same direction as when the part is new
(side hole on the link tread side).
30-116 D41E, P-6

1
4) If the link, pin, bushing, or spacer are dirty,

wash them. Remove any protruding parts
stuck to the link and bushing with a grinder.
fl These parts easily rust, so wash them
R3
immediately before assembly.
fl Use tool R3 to wash the pin hole.
fl Do not polish or carry out any other
treatment of the end face of the bushing
as this will cause oil leakage.
5) Use tool R4 to knock the large plug into the
pin.
i) Insert the plug into the guide hole CED00451
through the plug insertion window.
ii) Push the bar by hand and insert the plug
as far as possible.
iii) Push the plug with the bar and push the
guide itself against the pin.
iv) Knock in the bar with a hammer.
fl Dimension "a" to knock in from end
face of pin: 6 ± 2 mm
fl If there is no more place to chamfer
at the pin hole because of wear, use
a baby grinder (angle of grinder tip:
45 – 60°) to carry out chamfering.
fl Coat the outside circumference of the
plug with GO90 and knock in the
smaller diameter part first.
6) Installation of seal assembly
When reusing the link and replacing the seal
with a new part, clean the link counterbore,
then push the seal in fully to the bottom.
fl If there is grease stuck to the link counter-
bore and seal assembly, the seal will rotate
and its sealing performance will drop, so do
not coat with grease.
fl If there is oil stuck to the link counterbore
and seal assembly, the seal will rotate and
its sealing performance will drop, so do not
coat with oil. In addition, be careful not to
let oil get into the counterbore portion of
the seal when pushing in.
D41E, P-6 30-117

1
7) In order to keep the protrusion of the pin

and bushing constant and the installation
dimensions of the seal within the specified
value during assembly, adjust the press-fit-
ting jig dimensions of the link press.
fl For details of the standard dimensions,
see PRESS-FITTING JIG DIMENSION
TABLE FOR LINK PRESS.
fl To leave a small space for the pin when
assembling, ensure that the dimension
(dimension "a’") is greater than dimen-
sion "a" at the pin pushing portion of
the left press-fitting jig.
When assembling in order 1 press fit-
ting left link, 2 press fitting right link,
provide the extra space for the pin on
the right press-fitting jig.
fl If the end face of the pin (portion P) or
the side face of the link (portions Q, R)
are worn, add the amount of wear to
the standard dimension when adjusting
the dimension of the press-fitting jig so
that the amount of protrusion of the left
and right pin and bushing is uniform.
DLD00307
8) Adjust the relief pressure of the link press

to make sure that the pushing force of the
press does not exceed the specified value.
fl If the pushing force is too strong, exces-
sive force will be brought to bear on the
spacer, and it will be pushed against the
bushing. This will cause the spacer to
break or will cause abnormal wear be-
tween the spacer and bushing end face.
fl If the interference at the press-fitting
portion is different from when the part
DLD00308
is new, as when reusing a pin or bush-
ing, measure several of the press-fitting
portions, and use the table below to de-
termine the set pushing force according
to the average interference.
fl Pushing force for pin, bushing:
588 kN {60 ton}
•
Pushing force = •
1.8 x average press-fitting force
(Adjust the relief pressure of the link
press and set the pushing force.)
30-118 D41E, P-6

1
2. Assembly of link
1) Use a clean brush to coat the area between
the pin and bushing with oil (GO90), set in
position, then set in front of the jaw of the
link press.
fl When reusing (turning) the bushing, set
the worn surface on the outside circum-
ference of the bushing facing the shoe
mounting surface of the link (facing up
on the link press).
DLD00309
2) Set the left and right bushing end master

link with the shoe mounting surface facing
up, then press fit to the bushing.
fl When doing this, use the pin end mas-
ter link as a support.
fl Press-fitting force for bushing:
49 – 147 kN {5 – 15 ton}
DLD00310
3) Using a shoe bolt hole pitch gauge, press fit

until the distance between the shoe bolt
holes of the left and right link is the speci-
fied value.
fl Use compressed air to remove all metal
particles from burrs caused by press fit-
ting the bushing.
DLD00311
4) Turn over the master link, and check that

the left and right master links have been
press fitted in parallel.
D41E, P-6 30-119

1
5) Measure the amount of protrusion of the

left and right bushings with a depth gauge.
fl Adjust the press-fitting jig for the link
press so that the protrusion of the left
and right bushings is uniform.
DLD00312
6) Feed the master link portion, then set the

pin and bushing in position.
fl When reusing the pin, assemble so that
the side hole is on the link tread side in
the same way as when the part is new.
If the parts are not assembled facing the
specified direction, the strength may
drop, so mark the direction of the side
hole clearly on the end face to prevent
any mistake during assembly.
fl Align the large plugs so that they are on
the left side facing the link press when
assembling.
7) To prevent oil from leaking out from scuff

marks on the pin press-fitting portion, coat
the pin press-fitting hole in the link and the
outside diameter of the pin press-fitting por-
tion with gasket sealant (198-32-19890).
8) Set the right link in position and install the

spacer to the pin.
fl Check that there is no dirt or dust stuck
to the seal surface and bushing end face,
then use a clean cloth or brush to coat
with oil (GO90).
fl Wipe the spacer with a clean cloth, then
install it.
30-120 D41E, P-6

1
9) Using the right jig as the receiving end and

the left jig as the pushing end, press fit the
pin and bushing at the same time.
fl The seal may come off the link due to
the play when press fitting, so press fit
smoothly. If the seal comes off the link,
stop the press-fitting operation and fit
the seal correctly on the link, then start
the press-fitting operation again.
fl Press-fitting force for pin, bushing:
196 – 392 kN {20 – 40 ton}
10) Using a fine adjustment spacer, press fit so

that the end face of the pin is in tight con-
tact with the bottom of the receiving jig.
fl Adjust the depth of the hole in the re-
ceiving jig so that the protrusion of the
left and right pins is uniform.
11) Set the left link in position and install the

spacer to the pin.
fl Coat with oil in the same way as when
installing the right link.
12) Using the left jig as the receiving end and

the right jig as the pushing end, press fit
the left link.
fl When press fitting, be careful that the
left and right seal and spacer do not
come out of position.
fl Provide enough space on the left jig so
that the end face of the pin does not
contact the bottom of the jig.
fl Press-fitting force for link:
196 – 392 kN {20 – 40 ton}
D41E, P-6 30-121

1
13) Press fit the link, spacer, and bushing so

that they are each in tight contact.
fl It is impossible to check from outside if
they are in tight contact, so control the
hydraulic force of the link press and set
the relief pressure to a constant value.
Then apply hydraulic force and push in
until this pressure is reached.
For details of the setting for the relief
pressure, see “Preparatory work”.
fl Check that adjacent links swivel freely
in relation to each other.
14) After assembling each link, use a dial gauge
and pinch bar to measure the end play from
the link previously assembled, to check that
the link is assembled within the specified
value.
fl If the end play does not come within 0 –
0.13 mm even when applying the push-
ing force until the relief valve is actu-
ated, raise the relief pressure setting
gradually to adjust.
fl Adjust the relief pressure setting care-
fully and be sure not to raise the push-
ing force of the link press higher than
necessary. DLD00321
15) Using a shoe bolt hole pitch gauge, check
that the distance between the shoe bolt
holes is within the standard value.
fl If the distance between the shoe bolt
holes is greater than the specified value,
disassemble and check for any abnor-
mality, then press fit again.
fl If the distance between the shoe bolt
holes is smaller than the specified value,
and the shoe cannot be installed, the
wear of the spacer or bushing end face
is probably greater than the repair limit,
so disassemble and replace with a new
part. DLD00322
fl If the end play is too large, the sealing
performance will drop, so set the end
play to a small value.
16) After assembling each link, use tool R6 to
remove the air from inside the pin, and check
the sealing performance.
fl Hold the space inside the pin at a
vacuum of 92.7 ± 2 kPa {695 ± 15 mmHg}
for 5 seconds and check that there is no R6
change in pressure.
If the pressure changes, disassemble and
check the seal for any abnormality, then
assemble again.
CED00454
30-122 D41E, P-6

1
17) Assemble the pin end master link as the

final link.
fl Check that the left and right master links
are press fitted in parallel.
3. Filling with oil

After completion of assembly of the link assem-
bly, add oil through the pin hole.
1) Using tool R7, remove the air inside the pin
from the small plug hole, set to a vacuum
of 92.7 ± 2 kPa {695 ± 15 mmHg}, then fill
with oil (GO90) until the pressure is 0.2 –
0.3 MPa {2 – 3 kg/cm2}.
fl In cold or extremely cold areas, instead
of GO90, fill with Komatsu genuine oil
(150-09-19270) which has excellent low-
R7
temperature qualities. CED00455
fl Be careful not to raise the oil pressure
too high as this will have an adverse
effect on the seal.
fl To determine the oil amount, set the
small plug end at the top (stand the link
assembly on its side), leave for 30 min-
utes, then fill with oil so that depth L of
the space at the pin hole is within the
specified value below.
Dimension L: 30 – 50 mm
2) After completion of filling with oil, use tool

R5 to knock in the small plug to the speci-
fied position.
small plug with GO90.
fl The depth to knock in the plug is as
follows.
Depth from end face: 2.5 ± 1 mm
R5 CED00456
D41E, P-6 30-123

1

Set the link assembly on the bed, then use a
shoe bolt impact wrench and torque wrench to
install the shoe.
3 Shoe bolt (regular link):
Initial torque:
196 ± 19.6 Nm {20 ± 2 kgm}
Tightening angle: 120° ± 10°
CED00448
5. Connecting to make 1/2 assembly 4 3

Set two completely assembled portions of track
on a flat surface in a straight line with the shoes 2
facing up. Pull master link (1) at the pin end to 1
master link (2) at the bushing end, and set at
the mating surfaces. Then put shoe (3) on top,
check that shoe bolt (4) goes in easily by hand,
and connect the two parts with the master bolt.
2 Shoe bolt:
3 Shoe bolt (master link): DLD00327
Initial torque:
196 ± 19.6 Nm {20 ± 2 kgm}
fl When tightening, tighten in the order 1 –
4.
q e
r w
DLD00328
fl Do not use an impact wrench for the master

link.
DLD00298
30-124 D41E, P-6

1
2. When rebuilding as grease-filled track
1. Preparatory work
1) Washing seal assembly
Remove the seal assembly from the link,
then separate into the seal ring and load
ring, and clean the parts.
fl The seal ring and load ring deteriorate
easily when brought into contact with
cleaning agent, so wash the parts
quickly. After cleaning, wipe the parts
with a clean cloth to remove all the
cleaning agent.
2) When reusing the pin, chamfer the corner

of the end face smooth with a grinder so
that press fitting can be carried out
smoothly.
DLD00300
3) Make a mark on the end face at the small

plug end to show the direction of the side
hole (hole in the radial direction) in the pin
when assembling.
fl When reusing the pin, assemble in the
same direction as when the part is new
(side hole on the link tread side).
D41E, P-6 30-125

1
4) Use tools R4 and R5 to knock the large plug

and small plug into the pin.
i) Insert the plug into the guide hole
through the plug insertion window.
(Coat the plug with oil.)
ii) Push the bar by hand and insert the plug
as far as possible.
iii) Push the plug with the bar and push the
guide itself against the pin.
iv) Knock in the bar with a hammer.
Dimension "a" to knock in from end
face of pin:
Small pin: 4.5 ± 1 mm
Large pin: 6 ± 2 mm
fl If the plug was not removed from
the pin during disassembly, it can
be used again as it is.
5) Clean any part where outside diameter of
the pin, front face of the spacer, or end face
or inside diameter of the bushing are dirty.
6) Coat the outside diameter of the pin and
the front face of the spacer with grease.
7) Installation of seal assembly
When reusing the link and replacing the seal
with a new part, clean the link counterbore,
then push the seal in fully to the bottom.
fl If there is grease stuck to the link
counterbore and seal assembly, the seal
will rotate and its sealing performance
will drop, so do not coat with grease.
8) In order to keep the protrusion of the pin
and bushing constant and the installation
dimensions of the seal within the specified
value during assembly, adjust the press-fit-
ting jig dimensions of the link press.
fl For details of the standard dimensions,
see PRESS-FITTING JIG DIMENSION
TABLE FOR LINK PRESS.
fl If the end face of the pin (portion P) or
the side face of the link (portions Q, R)
are worn, add the amount of wear to
the standard dimension when adjusting
the dimension of the press-fitting jig so
that the amount of protrusion of the left
and right pin and bushing is uniform.
30-126 D41E, P-6

1
2. Assembly of link
1) Coat the area between the pin and bushing
with lithium grease (G2-LI), set in position,
then set in front of the jaw of the link press.
fl When reusing (turning) the bushing, set
the worn surface on the outside circum-
ference of the bushing facing the shoe
mounting surface of the link (facing up
on the link press).
DLD00309
2) Set the left and right bushing end master

link with the shoe mounting surface facing
up, then press fit to the bushing.
fl When doing this, use the pin end mas-
ter link as a support.
49 – 147 kN {5 – 15 ton}
DLD00310
3) Using a shoe bolt hole pitch gauge, press fit

until the distance between the shoe bolt
holes of the left and right link is the speci-
fied value.
fl Use compressed air to remove all metal
particles from burrs caused by press fit-
ting the bushing.
4) Turn over the master link, and check that

the left and right master links have been
press fitted in parallel.
DLD00311
5) Measure the amount of protrusion of the

left and right bushings with a depth gauge.
fl Adjust the press-fitting jig for the link
press so that the protrusion of the left
and right bushings is uniform.
DLD00312
D41E, P-6 30-127

1
6) Feed the master link portion, then set the

pin and bushing in position.
When reusing the pin, assemble so that
the side hole is on the link tread side in
the same way as when the part is new.
If the parts are not assembled facing the
specified direction, the strength may
drop, so mark the direction of the side
hole clearly on the end face to prevent
any mistake during assembly.
If the outside diameter of the pin is worn,
assemble so that the face that is not
worn is on the pulling side. However, in
this case also assemble so that the side
hole faces the tread surface of the link.
7) Set the left and right links in position, then
operate the left and right pushing jigs to
press fit the pin and bushing at the same
time.
fl The seal may come off the link due to
the play when press fitting, so press fit
smoothly. If the seal comes off the link,
stop the press-fitting operation and fit
the seal correctly on the link, then start
the press-fitting operation again.
fl Pushing force for pin, bushing:
588 kN {60 ton}
Pushing force •=•
1.8 x average press-fitting force
(Adjust the relief pressure of the link
press and set the pushing force.)
8) Using a shoe bolt hole pitch gauge, meas-
ure the distance between the shoe bolt holes
and stop press fitting when it is within the
standard value.
9) Assemble the pin end master link as the
final link.
fl Check that the left and right master links
are press fitted in parallel.
DLD00311
Set the link assembly on the bed, then use a
shoe bolt impact wrench and torque wrench to
install the shoe.
3 Shoe bolt (regular link):
Initial torque:
196 ± 19.6 Nm {20 ± 2 kgm}
CED00448
30-128 D41E, P-6

1
4. Connecting to make 1/2 assembly 4 3

Set two completely assembled portions of track
on a flat surface in a straight line with the shoes 2
facing up. Pull master link (1) at the pin end to 1
master link (2) at the bushing end, and set at
the mating surfaces. Then put shoe (3) on top,
check that shoe bolt (4) goes in easily by hand,
and connect the two parts with the master bolt.
2 Shoe bolt:
3 Shoe bolt (master link): DLD00327
Initial torque:
196 ± 19.6 Nm {20 ± 2 kgm}
When tightening, tighten in the order 1 –
4.
q e
r w
DLD00328
Do not use an impact wrench for the master

link.
DLD00298
D41E, P-6 30-129

1
DISASSEMBLY AND ASSEMBLY PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS
PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS
Item Jig dimension (mm)

a 2.95
b 1.5
c 34.2
30-130 D41E, P-6

1
DISASSEMBLY AND ASSEMBLY ONE LINK
FIELD DISASSEMBLY OF ONE

LINK
1. Positioning track shoe assembly
Set track shoe assembly on block 1 (height:
approx. 300 mm).
q
CED00458
2. Pins
Using tool R1, remove pins (1) and (2).
fl If the tip of the pin or the side of the link are
unevenly worn, correct with a hand grinder
to ensure that the part is at a right angle to
tool R1.
1 2
R1
CED00459
• When disassembling without removing the track

shoe assembly, use the part marked ª for tool
R1 in the SPECIAL TOOL LIST, then assemble
tool R1 and remove pin (1).
3. Links
1) Put tool R8 and spacer 2 of the dimensions
given below in contact with the tread of
links (3) and (4).
fl Dimensions of spacer 2:
Outside diameter 55 x thickness 47 mm
fl Set tool R8 as close to the tip of the link
R8
as possible.
2) Apply hydraulic pressure slowly to the puller w
until the tip of the link opens 6 – 8 mm, then
disconnect the link.
fl There is danger that the bushing will 4
come out, so do not apply more hydrau-
lic pressure than necessary.
fl If an electric pump is used, there is dan-
ger that more hydraulic pressure will be
applied than necessary, so always use a 3 CED00460
hand pump.
D41E, P-6 30-131

1
3) Disconnect links (5) and (6) in the same way.

R8 w
3
CED00462
4) Using tool R9, remove bushing (7).

7
When doing this, insert a spacer between
the links to maintain the clearance between
the links.
R9
CED00463
30-132 D41E, P-6

1
FIELD ASSEMBLY OF ONE

LINK
1. Bushing
Put tool R10 in contact with end face of link (4),
and press fit bushing (7).
49 – 78 kN {5 – 8 ton}
fl Always use a new bushing.
2. Pins
1) Using tool R4, knock a large plug into oil
hole of pin (1).
fl Always use a new pin.
R4
CED00465
2) To determine pushing pressure when carry-

ing out final assembly, measure outside di-
ameter of pin with a micrometer, and note
down measurement.
CED00468
3) Coat press-fitting hole for pin in link with

gasket sealant (198-32-19890).
fl If the link is used again, finish the press-
fitting hole for the pin smoothly with
sandpaper.
D41E, P-6 30-133

1
4) Put tool R11 in contact with end face of link

(4), and press fit pin (1).
fl Press fit so that the side hole A in the
pin is on the same side as the link tread.
fl Press-fitting force for pin:
147 – 245 kN {15 – 25 ton}
3. Seal
Install seal (8).
fl Check that there is no oil on the contact
surface of the link and seal.
fl Carry out Steps 1 – 3 in the repair shop
beforehand.
CED00467
4. Link sub-assembly
1) Install link sub-assembly (10). 10
to the surface of the seal or the end face
of the bushing, then coat with oil (GO90)
using a clean cloth or small brush.
CED00470
2) Install tool R12 (guide used when press fit-

ting link) to bushing (7).
7
R12
CED00471
30-134 D41E, P-6

1
5. Link
1) To determine pushing pressure when carry-
ing out final assembly, measure dimension
of press-fitting hole for pin in link (3) with a
cylinder gauge, and note down measure-
ment.
3
CED00472
2) Coat press-fitting hole for pin in link with

gasket sealant (198-32-19890).
fl If the link is used again, finish the press-
fitting hole for the pin smoothly with
sandpaper.
3) Install seal (8).

fl Check that there is no oil on the contact
8
to the surface of the seal or the end face
of the bushing, then coat with oil (GO90)
CED00474
4) Using tool R13, press fit pin portion of link

(3) to link sub-assembly (10).
fl Press-fitting force for pin:
196 – 294 kN {20 – 30 ton}
D41E, P-6 30-135

1
5) Using tool R14, press fit bushing portion of

link (3) to link sub-assembly (10). R14
10
fl To prevent the use of any excessive
force, press fit the pin portion and bush-
ing portion gradually in turn.
fl Press-fitting force for pin, bushing:
96 – 196 kN {10 – 20 ton}
CED00476
6. Connecting link
1) Finish inside surface of press-fitting hole for 6
pin in links (5) and (6) smoothly with sand-
paper.
5
CED00477
2) Remove block 1, and lower track shoe as-

sembly to ground. e R8
3) Set lever block 3 to left and right link as- w
6
semblies as shown in diagram on right, then
put tool R8 and spacer 2 in contact with
tread of links (5) and (6).
fl Set tool R8 as close to the tip of the link
as possible.
5
CED00478
4) Install seals (13) and (14) to links (5) and (6).

fl Always use new seals. 6
fl Check that there is no oil on the contact 7
to the surface of the seal or the end face 14
of bushing (7), then coat with oil (GO90)
13
5
CED00479
30-136 D41E, P-6

1
5) Apply hydraulic pressure slowly to puller

until tips of links (5) and (6) open 6 – 8 mm. e 6
fl There is danger that the bushing will
come out, so do not apply more hydrau-
lic pressure than necessary.
fl If an electric pump is used, there is dan-
ger that more hydraulic pressure will be
applied than necessary, so always use a
hand pump. R15
5
CED00480
6) Operate lever block 3, align centers of link

hole and bushing hole, and connect links
with tool R15 (guide pin).
fl Operate lever block 3 slowly and be
careful not to damage the seal or get
sand stuck to the seal surface.
7. Pin R4
1) Using tool R4, knock a large plug into oil
hole of pin (2).
2
CED00481
2) To determine pushing pressure when carry- R14

ing out final assembly, measure outside di-
ameter of pin (2) with a micrometer, and 6
note down measurement.
3) Set track shoe assembly on block 1 again.
4) Using tool R14, press fit pin (2) to links (5)
and (6).
fl Press fit so that the side hole in the pin
is on the same side as the link tread. 5
fl Press-fitting force for pin: 2
49 – 147 kN {5 – 15 ton} q q
5) Temporarily stop press fitting when there is CED00482
15 – 20 mm left for press fitting pin (2).
6) Coat remaining press-fitting portion of pin
(2) with gasket sealant (198-32-19890).
2
CED00483
D41E, P-6 30-137

1
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
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 92.7 ± 2
kPa {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
30-138 D41E, P-6

1
2) Using tool R5, knock in small plug quickly.

small plug with GO90.
fl Knock in the plug to the following depth.
Depth from end face: 4.5±1mm
R5
CED00488
D41E, P-6 30-139

1
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
ASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY
30-140 D41E, P-6

1
fl Coat the sliding surface with engine oil.

fl After assembling each spool assembly, always
check that the spool moves smoothly.
fl If any abnormality is found in the spool or body
during disassembly, replace the whole assem-
bly.
1. Fit O-rings securely to mating surfaces of block

(78), lift valve body (77), tilt valve body (76),
and angle valve body (75), then tighten bolts
(74).
3 Tighten mounting bolts (74) to torque in
table below.
fl Tighten the bolts in 3 stages in the order 1,
2, 3, and 4.
Tightening torque (Nm {kgm})

q e
1st pass 24.5 ± 4.9 {2.5 ± 0.5}
2nd pass 44.1 ± 4.9 {4.5 ± 0.5}
3rd pass 68.6 ± 4.9 {7.0 ± 0.5} r w
CDD00522
2. Assembly of spool assembly
D41E, P-6 30-141

1
• Lift spool assembly

1) Fit U-packing (73) and O-ring to plate (72) 65 69 67 66
and install to body.
fl Assemble the U-packing in the direction
shown in the diagram.
2) Fit U-packing (71) and O-ring to plate (69)
and install to body, then assemble to collar
(68).
3) Assemble seal (70) to plate (67), then align
to plate (69) and install.
4) Assemble O-ring and backup ring to yoke 71 68 70
(66), install to spool (65), then assemble in CDD00518
body.
3 Yoke: 17.2 ± 2.5 Nm {1.75 ± 0.25 kgm}
fl When installing yoke (66) to the spool,
53 56 58 59 61 62 64 73
be extremely careful not to damage the
spool, and hold in position when tight-
ening.
5) Assemble plate (64), retainer (63), spring
(62), and retainer (61) to spool (65), and
tighten valve (60).
fl When installing valve (60) to the spool,
be extremely careful not to damage the 52 54 55 57 60 63 72
spool, and hold in position when tight- CDD00517
ening.
6) Assemble spring (57) and guide (55), fit ball
(56), then tighten plug (54).
fl Free length of spring (57): 27.7 mm 59 56
3 Plug (54):
34.3 ± 4.9 Nm {3.5 ± 0.5 kgm}
7) Install case (58), then push in detent (59)
and install.
8) Assemble plug (53) to case, and install ring
(52).
• Angle, tilt spool assembly 54 55 57

1) Assemble U-packing (49) to body, fit seal
CDD00523
(48) to plate (46), assemble collar (47), then
install plate (46).
2) Assemble O-ring and backup ring to yoke
(45), install to spool (44), then assemble in
body.
fl When installing yoke (45) to the spool, 46 45
be extremely careful not to damage the
ening.
3 Yoke (45):
17.2 ± 2.5 Nm {1.75 ± 0.25 kgm}
44 49 47 48
CDD00516
30-142 D41E, P-6

1
3) Assemble gasket (50), retainer (43), spring

(42), and retainer (41), and install plug (40).
fl Angle spool spring (42): 52.4 mm 39 42 50
Tilt spool spring (42): 55.7 mm
3 Plug (40):
17.2 ± 2.5 Nm {1.75 ± 0.25 kgm} 40
fl When installing plug (40) to the spool,
be extremely careful not to damage the 41
ening.
fl Do not use gasket (50) again. Replace it 43 51
CDD00515
with a new part.
4) Install case (39).
3. Check valve (angle valve)

Assemble valve (38) and spring (37) to body,
then fit O-ring to plug (36) and install.
3 Plug (36): 29.4 ± 4.9 Nm {3 ± 0.5 kgm}
36
4. Fit O-ring and backup ring to LS bypass plug
(35) and install.
3 Plug (35): 29.4 ± 4.9 Nm {3 ± 0.5 kgm}
5. Assembly of unload valve 38 37

CDD00513
1) Fit O-ring to plug (33) and install to body.
3 Plug (33):
139.7 ± 22.1 Nm {14.25 ± 2.25 kgm}
33 32
2) Install seal to spool (34).
3) Assemble piston (31) and spring (30) to
sleeve (29), then install plug (27), and fit O-
ring and backup ring to make sleeve assem-
bly (28).
3 Plug (27):
39.2 ± 4.9 Nm {4 ± 0.5 kgm} 34 29 31 30 27
4) Assemble spring (32) and sleeve assembly 28
CDD00512
(28) to spool (34), and install to body.
D41E, P-6 30-143

1
6. Assembly of pressure compensation valve

• Lift pressure compensation valve 26 23 20
1) Assemble spring (26) to valve (25), then as-
semble in body, fit O-ring to plug (24) at
pressure compensation valve F end, and in-
stall.
3 Plug (24):
139.7 ± 22.1 Nm {14.25 ± 2.25 kgm}
2) Assemble piston (22) and spring (21) to valve
24 25 22 21
(23), then assemble in body.
CDD00511
3) Fit O-ring to plug (20) at pressure compen-
sation valve R end, and install to body.
3 Plug (20):
139.7 ± 22.1 Nm {14.25 ± 2.25 kgm} 18 19 17 15 14
• Angle, tilt pressure compensation valve
1) Assemble valve (19) to body, then fit O-ring
to plug (18) at pressure compensation valve
F end, and install.
3 Plug (18):
139.7 ± 22.1 Nm {14.25 ± 2.25 kgm}
2) Assemble piston (16) and spring (15) to valve
16
(17), then assemble in body.
fl Free length of spring (15): 31.9 mm CDD00510
3) Fit O-ring to plug (14) and install to body.

3 Plug (14):
139.7 ± 22.1 Nm {14.25 ± 2.25 kgm}
7. Suction valve, plug
1) Fit O-ring to pump pressure pick-up plug
(13), plug (12), LS pressure pick-up plug (11),
plug (10), and safety circuit pressure release
plug (9) and install.
3 Pump pressure pick-up plug (13):
23.5 ± 3.9 Nm {2.4 ± 0.4 kgm}
3 Plug (12):
39.2 ± 4.9 Nm {4.0 ± 0.5 kgm}
3 LS pressure pick-up plug (11):
39.2 ± 4.9 Nm {4.0 ± 0.5 kgm}
3 Plug (10):
39.2 ± 4.9 Nm {4.0 ± 0.5 kgm}
3 Safety circuit pressure release plug
(9): 39.2 ± 4.9 Nm {4.0 ± 0.5 kgm}
2) Fit O-rings to plugs (8), (7), and (6) and in-
stall.
3 Plug (8), (7), (6):
44.1 ± 4.9 Nm {4.5 ± 0.5 kgm}
3) Fit O-rings to suction plugs (5), (4), and (3),
and install.
3 Suction plug (5), (4), (3):
44.1 ± 4.9 Nm {4.5 ± 0.5 kgm}
30-144 D41E, P-6

1
8. Main relief valve, safety & suction valve

1) Fit O-ring to safety & suction valve (2) and
install.
3 Safety & suction valve (2):
147.1 ± 9.8 Nm {15 ± 1 kgm}
2) Fit O-ring to main relief valve (1) and install.
3 Main relief valve (1):
53.9 ± 4.9 Nm {5.5 ± 0.5 kgm}
D41E, P-6 30-145

1
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
DISASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
(BLADE LIFT, ANGLE, TILT CYLINDER)
U2 2 1
1. Piston rod assembly
1) Set cylinder assembly (1) to tool U1.
2) Using hydraulic pump or power wrench, dis- U1
connect head assembly (2) with tool U2.
CED00174
3) Pull out piston rod assembly (3).

fl Set a container under the cylinder to
catch the oil.
CED00175
2. Piston assembly, head assembly

1) Set piston rod assembly (3) to tool U1.
2) Using tool U3, loosen nylon nut (4) and re-
move. U3 5 3 6
Width across flats of nut

Name of cylinder (mm)
U1
Blade lift 55
Blade angle 60
Blade tilt 55 CED00176
3) Remove piston assembly (5) and head as-

sembly (6).
4) Disassembly of piston assembly
i) Remove wear ring (7). 7
ii) Remove piston ring (8).
CED00177
30-146 D41E, P-6

1
5) Disassembly of head assembly

i) Remove backup ring (9) and O-ring. 11
ii) Remove packing (10). 12
iii) Remove snap ring (11), then remove dust
seal (12). 13
iv) Remove bushing (13).
9 10
CED00178
D41E, P-6 30-147

1
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) 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
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
30-148 D41E, P-6

1
iv) Assemble wear ring (7).
CED00177

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
Width across Tightening

Name of flats of nuts torque
cylinder U1
(mm) (Nm {kgm})
1,422±142.2
Blade lift 55 {145±14.5}
1,765±176.5
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
D41E, P-6 30-149

1
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
CED00133
3. Secure rod end of lift cylinder (1) to handle on

engine hood with rope.
• Both left and right
1
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
30-150 D41E, P-6

1
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
8
CED00137
INSTALLATION OF WORK
EQUIPMENT ASSEMBLY
removal.
• Refilling with oil (hydraulic tank)

level.
• Greasing
fl After completion of the installation, carry
out greasing of the mounting pins that were
removed.
D41E, P-6 30-151

1
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.
2
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, P-6 Serial No.: B40001 – B40223
6) Remove mounting ring of cover (6), and re-

move cap (8).
7) Lift off blade (5).
Blade: 650 kg
30-152 D41E, P-6

1
(2)
D41E, P-6 Serial No.: B40224 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
2. Angle cylinder assembly

1) Sling angle cylinder assembly (3), and dis-
connect 2 hoses (9).
3
10
2) Remove lock plate, and pull out mounting
pin (10) at cylinder bottom end, then lift off
angle cylinder assembly (3).
9
Angle cylinder assembly: 105 kg
CED00158
3. Tilt cylinder assembly

1) Remove cover (11) of tilt cylinder assembly.
11
CED00159
D41E, P-6 30-153

1
(2)
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
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
30-154 D41E, P-6

1
(2)
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
21 22
CED00162
fl When installing the hoses to the frame in

Steps 1) and 2), install according to the dia-
gram on the right.
ª1: Adjust hose lenght between these points.
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
D41E, P-6 30-155

1
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
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, P-6 Serial No.: B40001 – B40223
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.
30-156 D41E, P-6

1
(2)
D41E, P-6 Serial No.: B40224 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
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
D41E, P-6 30-157

1
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
REMOVAL OF HYDRAULIC
TANK 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 PRES-
SURE IN HYDRAULIC CIRCUIT. Then loosen the
oil filler cap slowly to release the pressure in-
side the hydraulic tank.
1. Drain oil from hydraulic tank.
6 Hydraulic tank: 44 ¬
2. Open air conditioner condenser cover.

1
3. Disconnect filter assembly (1) from tank.
fl Remove with the drain hose still installed,
and put it down.
2
4. Disconnect return hose (2).
5. Disconnect suction tube (3).
6. Lift off hydraulic tank assembly (4).

3
4 Hydraulic tank assembly: 42 kg CED00172
INSTALLATION OF HYDRAULIC
TANK ASSEMBLY
removal.
CED00173
• Refilling with oil (hydraulic tank)

level.
• Bleeding air
Bleed the air from the piping.
Bleeding air from hydraulic cylinder.
30-158 D41E, P-6

1
DISASSEMBLY AND ASSEMBLY ROPS ROOF, GUARD
REMOVAL OF ROPS ROOF,

GUARD ASSEMBLY
1
1. Sling ROPS roof (1).
2. Remove mounting bolts, then lift off ROPS roof.
4 ROPS roof: 220 kg

(cab specification machine)
3. Sling ROPS roof guard (2).
4. Remove mounting bolts, then lift off ROPS roof

guard (2). 1 CED00167
4 ROPS roof guard: 350 kg
CED00168
INSTALLATION OF ROPS
ROOF, GUARD ASSEMBLY
removal.
1
3 ROPS roof guard mounting bolt:
549 ± 58.9 Nm {56 ± 6 kgm}
D41E, P-6 30-159

1
DISASSEMBLY AND ASSEMBLY ROPS
REMOVAL OF ROPS
ASSEMBLY
1. Sling the ROPS assembly temporarily and re-

move 4 each of mounting bolts (2) on both sides.
2. Lift off ROPS assembly (1).
4 ROPS assembly: 2,002 kg
INSTALLATION OF ROPS
ASSEMBLY

removal.
30-160 D41E, P-6

1
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB
REMOVAL OF OPERATOR'S
CAB ASSEMBLY

1. Remove the ROPS assembly. For details, see

REMOVAL OF ROPS ASSEMBLY.
2. Remove the lunch box belt.
3. Remove the mounting bolts of left cover (1)
and turn over the cover. Remove connectors (2)
and (3) and the cover. 1
4. Remove right cover (4) and center cover (5).
5. Remove footrest (6) and cover (7).
D41E, P-6 30-161

1
6. Remove hot and cool box (9).
7. Remove dashboard bracket (11).
8. Disconnect connectors (12) (CN20), (13) (CN21),

and (14). 2
fl The No. of connector (14) on the machine
side is CN26 and that on the cab side is
CN19.
9. Disconnect 4 washer hoses (15). 2
10. Remove cab mounting bolts marked ‡.
30-162 D41E, P-6

1
11. Lift off operator's cab assembly (16).

3456
Operator's cab assembly: 410 kg
INSTALLATION OF
OPERATOR'S CAB ASSEMBLY
removal.
1
• Take care not to make a mistake in connect-
ing the connectors.
2
• Bind washer hose (19), washer connector
(20), and cab power source wiring harness
on the cab side with strings and pass them
through hole (b) on the floor frame to con-
nect them to the machine body side.
fl After connecting the hose and connector,
install the grommet on the wiring harness
side securely.
D41E, P-6 30-163

1
(2)
3
fl When the cab is removed from the floor frame,
arrange for the following sealants to retain pres-
surization and watertightness when the cab is
assembled again.
124-Z11-8120 ....... 1 unit (Seal B)
17A-Z11-3541 ....... 5units (Seal (D) - (G))
17A-Z11-2320 ....... 2 units (C)
198-Z11-3960 Three Bond (1207B)
....... 1 unit (Liquid sealant (A))
1. Installation of seal to air conditioner box

1) Remove dirt, oil and grease from the posi-
tion on the top surface of floor frame for
coating liquefied sealants. Implement the
cleaning on both sides.
2) Coat section A on the top surface of floor
frame (31) with liquefied sealant, Three Bond
1207B. (See the diagram to the left)
3) Install air conditioner box (32).
4) Coat the section on both sides of air condi-
tioner box (32) in contact with U-shaped
frame (the range on the floor frame shown
in the diagram) for 8 mm with liquid gasket
Three Bond 1207B.
5) Coat adhesive (LT-1A) on the inner surface
around seal B (sealing surface with the air
conditioner box).
30-163-1 D41E, P-6

(2)
6) Set seal B inside guide plate (33) of air con-

ditioner box.
fl Pull seal B downward and install by
pressing hard on liquid sealant coated
in 2).
fl Fix with adhesive (LT-1A) so that clear-
ance (fl) between seal B and the floor
frame will be zero.
7) Coat the outer surface around seal B (seal-

ing surface with the cab) with grease (G2-
LI).
fl This is for improving sliding after installing
the cab to prevent dislocation and/or defor-
mation of the seal.
2. Installing seal to the cab mating surfaces

1) Sling cab assembly.
2) Remove dirt, oil and grease from the seal
pasting surfaces.
fl Take care not to allow the seal to enter
under the cab.
• General
Seeing the diagram, install seals C, D, E, F and
G in this order.
fl Install seal without gap at the seal joint posi-

tions.
D41E, P-6 30-163-2

(2)
• Details
1) Make the end face of seal C with the wall

without any gap. (See the diagram above
for portion.)
2) Before cutting the end of C, adhere seal D
to the groove, then adhere seal E.
fl Check that the ends of D and E have no
gap between C.
3) Cut seal C at a position where it is flush
with seal E.
fl Use remaining portion of seal E as seal
F.
4
fl When installing the operator's cab, observe
the following points.
1) Lower the operator's cab assembly slowly
onto the floor frame.
fl Since the reaction force of the seal
sponge is large, lower the operator's cab
assembly carefully.
fl Check that the air conditioner duct seal
on the cab side is fitted to the air condi-
tioner duct on the dashboard side with-
out making clearance.
fl Since the clearance between the air con-
ditioner duct on the cab side and the
monitor is narrow, lower the operator's
cab assembly carefully.
2) Tighten the mounting bolts temporarily.
fl Note that the bolt length and washer at
the door inlet are different from others.
3) Check that the seal between air conditioner
bracket (23) and cab (16) is fitted securely.
4) Check that there is not clearance at joint (a)
of the seal and floor frame.
30-164 D41E, P-6

1
(2)
5) Check that clearance (e) between air condi-

tioner duct (26) on the cab side and monitor
(27) is even for both sides. Furthermore,
check that air conditioner duct seal (f) on
the cab side is fitted to surfaces (C) on both
sides of air conditioner duct (28) on the dash-
board side without shifting to the right or
left.
fl If clearance (e) between the air condi-
tioner duct on the cab side and monitor
is not even, loosen the air conditioner
duct mounting screws on the cab side
and move the duct so that the clearance
will be even.
If the duct on the cab side or air condi-
tioner side is shifted to the right or left,
adjust it similarly to the above.
6) Tighten the mounting bolts of the dashboard
bracket.
5
• If the antenna is leaning, loosen the wing
screw and set the antenna vertically, and
then tighten the wing screw.
6
1) Measure the internal pressure of the cab
according to the following procedure.
fl Criterion:
Measured value > 58.8 Pa {6 mmH2O}
fl Engine speed: Full
fl Operation of blower: Hi
fl Recirculated/Fresh air lever: Fresh air po-
sition
fl If the measured value does not satisfy
the criterion, check the control box for a
fall of the plug, etc.
D41E, P-6 30-165

1
2) The internal pressure of the cab may be

measured by the following simple method.
i) Prepare a transparent vinyl hose.
fl Outside diameter: 10 mm, Length:
3,000 mm
ii) Fill about a half of the hose with water.
iii) Remove the lock lever of the sliding
glass on the side of the cab. Insert ei-
ther end of the vinyl hose from outside
and secure it to the top of the back seat
with a tape.
iv) Seal the lock lever hole with tapes.
v) Set the water levels in the vinyl hose on
the outside of the cab flash with each
other.
vi) Run the engine at high idling and read
water level difference (e).
fl The air on [1] side is the internal air
of the cab, which is "pressurized".
The air on [2] side is the atmosphere,
which is at the "atmospheric pres-
sure".
• Parts to be installed to cab unit

1) Install open lock hook stopper mounting grip
(29).
2) Install cab mounting L-plate (30) to the cab

temporarily.
30-166 D41E, P-6

1
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
REMOVAL OF FLOOR FRAME

ASSEMBLY
¤ Disconnect the cable from the negative (–) ter- 1
¤ Close the fuel supply piping valve.

¤ Bleed refrigerant gas from air conditioner.
1. Remove ROPS roof and guard.
For details, see REMOVAL OF ROPS ROOF,
GUARD.
CED00082
2. Remove operator’s cab assembly.

For details, see REMOVAL OF OPERATOR CAB
ASSEMBLY.
3. Drain coolant.
4. Remove hood assembly.

For details, see REMOVAL OF HOOD ASSEM-
BLY.
5. Lift off operator’s seat (1).
Operator’s seat: 45 kg
6. Remove inside covers (bottom, left, right) of

floor frame.
7. Disconnect connector (2) (CN58) and (3) (CN8)

and remove the wiring harness clamp.
8. Disconnect starting motor main wiring harness

(4) and remove the clamp at the rear of the
engine.
9. Disconnect connector (5) (CN87), (6) (CN30), (7)

(CN31), (8) (CN32), and (9) (CN33).
10. Disconnect 2 ground harness (11) from left side

of floor frame.
11. Disconnect connector (12) (CN-4).
12. Remove bracket (13) of fuse box.

fl This is in order to remove the gear shift
lever cable.
13. Disconnect battery (+) wiring harness (14).
14. Disconnect connectors (32) (CN90), (33) (CN88),

and (34) (CN89) and remove clamps (35) and
(36).
D41E, P-6 30-167

1
(3)
15. Disconnect 2 gear shift lever cables (15) from

frame. 1
15
CED00086
16. Disconnect fuel control rod (16), then discon-

nect clutch assembly (17) from frame. 2 16
17
CED00087
17. Disconnect 6 steering PPC hoses (18).

fl Make match marks on each hose.
18
CED00089
18. Disconnect main control valve control rods (19).

3 19
19. Disconnect safety rod (20).
20
CED00088
30-168 D41E, P-6

1
20. Remove mounting bolts of center floor plate.
21. Remove decelerator pedal, and disconnect de- 21

celeration cable (21). 4
CDD00090
22. Disconnect brake rod (22) and inching rod (23)

at turnbuckle. 5
23. Remove brake pedal and floor plate assembly.
23 22
CED00091
24. Disconnect parking brake cable (24). 6
24
CED00092
25. Disconnect connector (25) from holder.
26. Disconnect connector (26) (CN-28).
25
26
CED00093
D41E, P-6 30-169

1
27. Disconnect 2 air conditioner hoses (27). 7

fl Fit blind plugs to prevent dirt or water from
getting inside the hoses. 27
28. Disconnect 2 heater hoses (28).
28
CED00094
29. Remove dashboard mounting bolts (29) (2 each

on left and right). 29
CED00095
30. Remove floor frame mount bolts (30). 30
CDD00096
31. Lift off floor frame assembly (31).
Floor frame assembly: 350 kg 31
CED00097
30-170 D41E, P-6

1
(3)
INSTALLATION OF FLOOR
FRAME ASSEMBLY
removal.
1
fl Adjust the gear shift lever linkage.
For details, see, ADJUSTING GEAR SHIFT
LEVER LINKAGE.
2
fl Adjust the fuel control linkage.
Adjusting fuel control linkage.
3
fl Adjust the main control valve control linkage.
Adjusting main control valve control linkage.
4
fl Adjust the decelerator pedal.
For details, see ADJUSTING DECELERATOR
PEDAL.
5
fl Adjust the inching and brake pedals.
For details, see ADJUSTING INCHING,
BRAKE PEDAL LINKAGE.
6
fl Adjust the parking brake lever linkage.
For details, see ADJUSTING PARKING
BRAKE LINKAGE.
7
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 compres-
sor oil (DENSO: ND-OIL8, ZEXEL: ZXL100PG).
The tightening torques for the air condi-
tioner gas piping are as follows.
Thread size Tightening torque

(Nm {kgm})
16 x 1.5 11.8 – 14.7 {1.2 – 1.5}
22 x 1.5 19.6 – 24.5 {2.0 – 2.5}
24 x 1.5 29.4 – 34.3 {3.0 – 3.5}
• Charging air conditioner with gas

Using tool X, charge the air conditioner circuit
with air conditioner gas (R134a).
D41E, P-6 30-171

1
(3)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB GLASS (STUCK GLASS)
REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS

(STUCK GLASS)
ª Among the panes of window glass of the op- (1) : Front window glass
erator's cab, the 3 panes of (1) and (2) on both (2) : Left door window glass
sides are stuck. : Right door window glass
In this section, the procedure for replacing the (3) : Both-sided adhesive tape
stuck glass is explained. (4) : Trim seal
(5) : Door handle
30-172 D41E, P-6

1
(2)
REMOVAL
ª Remove the window glass to be replaced ac-

cording to the following procedure.
1. Using seal cutter [1], cut the adhesive between

broken window glass (6) and operator's cab
(metal sheet) (7).
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 fric-
tional heat, apply lubricant to it.
(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.
D41E, P-6 30-173

1
(2)
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 af-
fect 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 (7) and window glass (8) 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.
3. Stick both-sided adhesive tape (3) along the in-

side edges of the front window glass sticking
section and both door window glass sticking
sections.
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.
30-174 D41E, P-6

1
(2)
4. Install trim seals (4) to both door window glasses

(2).
fl Install each trim seal (4) so that its finishing

end and starting end will be jointed at posi-
tion (c) and dimension (b) between the cor-
ner and position (c) will be 90 mm.
D41E, P-6 30-175

1
(2)
5. 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 (7). Adjust it so
that the difference between black coated
part and the metal sheet of operator's
cab (7) will be even on the right, left,
upper, and lower sides.
fl When positioning each door window
glass (2), align handle holes (d) of door
(9) (on the glass side and door metal
sheet side) first. Then, adjust the door
window glass so that the positional re-
lationship between it and door metal
sheet will be even all around the win-
dow.
2) After positioning the glasses, stick tapes [6]
between front window glass (1) and opera-
tor's cab (7) and the right, left, and lower
parts of each door window glass (2) and
each door (9), and then draw positioning
line (e).
3) Cut the tapes between window glasses (1)
and (2) and operator's cab (7) 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.
6. Apply adhesive.
2 Adhesive:
Sikaflex 256HV manufactured by
Sika Japan
fl Do not use primer.
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.
30-176 D41E, P-6

1
(2)
1) Break aluminum seal (11) of the outlet of

adhesive cartridge (10) and install the noz-
zle.
2) Cut the tip of the adhesive nozzle (12) so

that dimensions (f) and (g) will be as fol-
lows.
• Dimension (f): 10 mm
• Dimension (g): 15 mm
3) Set adhesive cartridge (10) to caulking gun

[7].
fl An electric caulking gun is more effi-
cient.
4) Remove release tape of the both-sided ad-

hesive tape (3a) on the glass side.
D41E, P-6 30-177

1
(2)
5) Apply adhesive (13) to the outside of both-

sided adhesive tape (3) of the operator's
cab.
fl Apply adhesive (13) to dimensions (h)

and (j) of both-sided adhesive tape (3)
of operator's cab (7).
• Dimension (h): 10 mm
• Dimension (j): 15 mm
fl Apply adhesive (13) higher than both-
sided adhesive tape (3).
fl Apply the adhesive evenly.
7. 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 (7).
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
applying the adhesive.
2) After sticking the window glass, press all
around it until it is stuck to the both-sided
adhesive tape.
fl Press the corners of the window glass
firmly.
30-178 D41E, P-6

1
(2)
3) Mask front window glass (1) and operator's

cab (7) 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.
2 Caulking material:
SEKISUI SILICONE SEALANT
fl The using limit of the caulking material
is 6 months after the date of manufac-
ture. Do not use the caulking material
after this limit.
5) After applying caulking material (14) 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.
D41E, P-6 30-179

1
(2)
8. Install both door window glasses.

1) Using tool X1, match both door window
glasses (2) to lines (e) on positioning tapes
[6] drawn in step 5 and install them to both
doors (9).
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
applying the adhesive.
2) After sticking each window glass, press all
around it until it is stuck to the both-sided
adhesive tape.
fl Press the corners of each window glass
firmly.
fl If adhesive (13) is projected from the
trim seals (4) of stuck door window
glasses on both sides, remove it with
rubber spatula [9].
30-180 D41E, P-6

1
(2)
3) Fill the clearance between each door win-

dow glass and trim in the range of dimen-
sion (k).
1] Mask the range of dimension (k) of each
door window glass.
2] Fill clearance (m) between each door
window glass (2) and trim seal (4) with
caulking material.
fl The using limit of the caulking material
is 6 months after the date of manufac-
ture. Do not use the caulking material
after this limit.
fl Apply the caulking material to joint (c)
of the trim seal, too.
2 Caulking material:
SEKISUI SILICONE SEALANT
9. Fix the window glasses.

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.)
2) Immediately after sticking both door win-

dow glasses, install door handles (5) and fix
the glasses.
D41E, P-6 30-181

1
(2)
10. 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.
11. Protect the stuck window glasses.

1) Keep the stopper rubbers, styrene foam
blocks, and rubber bands installed for 10
hours (at temperature of 20°C and humidity
of 65%).
2) After applying the adhesive, wait for at least
24 hours, before operating the machine ac-
tually.
30-182 D41E, P-6

1
(2)
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
Dimensions of shape of sprocket tooth
(Actual size) ............................................ 40-26
Track frame, recoil spring ........................... 40-27
Idler ................................................................ 40-28
Track roller .................................................... 40-30
Carrier roller ................................................. 40-31
Track shoe .................................................... 40-32
Main control valve ....................................... 40-38
Cooling fan drive pump .............................. 40-49
Cooling fan drive motor .............................. 40-50
Work equipment cylinder ............................ 40-52
Work equipment .......................................... 40-54
D41E, P-6 40-1

MAINTENANCE STANDARD DAMPER, UNIVERSAL JOINT
DAMPER, UNIVERSAL JOINT
3 66.2±7.4Nm
(6.75±0.75kgm)
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 D41E, P-6

MAINTENANCE STANDARD HYDRAULIC+POWER TRAIN PUMP
HYDRAULIC+POWER TRAIN PUMP

SAR (2) 36 + 28
1 1
4 2 2
3 3
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 }
D41E, P-6 40-3

MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION
(1/3)
3 24.5±4.9Nm
(2.5±0.5kgm)
A
Y
C C
A
3 277.0±31.9Nm
(28.25±3.25kgm) SDD00891
D41E, P-6 40-5

(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)
3
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 D41E, P-6

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)

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)
D41E, P-6 40-7

(3/3)
40-8 D41E, P-6

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
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
D41E, P-6 40-9

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
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
D41E, P-6 40-11

(2/3)
40-12 D41E, P-6

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
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
{25.31 kg} {0.55 kg}
Modulating valve spring 248 N 241.1 N

8 64.0 42.0 62.1
(large) {25.31 kg} {24.59 kg}
Modulating valve spring 63.8 N 60.6 N

9 57.5 39.0 55.8
(small) {6.51 kg} {6.18 kg}
10 (inside load piston) at 1.0 (adjustment in pressure for each 0.5 mm shim:
modulating valve spring 65.1 KPa {0.664 kg/cm2})
Adjust shim
11 (valve end) at modulating 0.0 (adjustment in pressure for each 0.5 mm shim:
valve spring 15.3 KPa {0.156 kg/cm2})
D41E, P-6 40-13

(3/3)
40-14 D41E, P-6

Unit: mm

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})
D41E, P-6 40-15

MAINTENANCE STANDARD BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE
BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE
40-16 D41E, P-6

MAINTENANCE STANDARD BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE
Unit: mm

Thickness of brake plate Replace
5.0 4.7
1
Tolerance Repair limit
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
Tolerance Repair limit
Correct
Distortion of clutch plate or replace
Within 0.3 0.6

4 Thickness of clutch lining
6.0 5.5
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}
D41E, P-6 40-17

MAINTENANCE STANDARD STEERING PPC VALVE
STEERING PPC VALVE
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 D41E, P-6

MAINTENANCE STANDARD STEERING PISTON
STEERING PISTON
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
D41E, P-6 40-19

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
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 D41E, P-6

MAINTENANCE STANDARD BRAKE VALVE
BRAKE VALVE
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)
D41E, P-6 40-21

MAINTENANCE STANDARD PARKING BRAKE CYLINDER
PARKING BRAKE CYLINDER
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 D41E, P-6

MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
40-24 D41E, P-6

MAINTENANCE STANDARD FINAL DRIVE
Unit: mm

Wear of sprocket tooth
1 tip diameter
708.7 ±2.0 697
Wear of sprocket tooth 0

2 628.8 614.5
root diameter –5 Rebuild
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

Rebuild
7 Thickness of tread 28.4 – 11 or replace
D41E, P-6 40-25

MAINTENANCE STANDARD DIMENSIONS OF SHAPE OF SPROCKET TOOTH (ACTUAL SIZE)
DIMENSIONS OF SHAPE OF SPROCKET TOOTH (ACTUAL SIZE)

fl Make the dimensions of the scale the actual size and copy on to an OHP sheet.
40-26 D41E, P-6

MAINTENANCE STANDARD TRACK FRAME, RECOIL SPRING
TRACK FRAME, RECOIL SPRING

fl The diagram shows the D41E-6.
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
D41E, P-6 40-27

MAINTENANCE STANDARD IDLER
IDLER
40-28 D41E, P-6

MAINTENANCE STANDARD IDLER
Unit: mm

Outside diameter of
1
protrusion ø 527 —
2 Outside diameter of ø 471

ø 489
tread Rebuild
or replace
3 Width of protrusion 69 60
4 Overall width 138 128
5 Width of tread 34.5 39

Clearance between idler size Shaft Hole clearance limit
6 shaft and bushing
–0.250 +0.074 0.250 –
ø 50 1.5
–0.280 0 0.354

Replace
Interrence between idler size Shaft Hole clearance limit
7 and bushing
+0.117 +0.030 0.057 –
ø 61 —
+0.087 +0 0.117
Side clearance of idler
8
(both sides) 0.260 – 0.660 1.5
Clearance between guide Rebuild

9 0.2 – 3.8 12.0
plate and support or replace
Clearance between guide Adjust

10 1.0 3.0
plate and side plate shim or
replace
Standard shim thickness at
11 4.0 plate
side plate mount portion

Thickness of tread surface Rebuild
12 or replace
(center of tread width) 18 9
— Oil level 165 cc (Engine oil: EO30-CD) —
D41E, P-6 40-29

MAINTENANCE STANDARD TRACK ROLLER
TRACK ROLLER
Unit: mm

Outside diameter of
1
track roller 175 150
Outside diameter Single 198

2 —
of flange (outside) Double 208
3 Outside diameter (double) —

202
of flange (inside)
4 Width of track roller tread 34.5 40.5

surface (single) Rebuild
or replace
5 Width of track roller tread 35.5 41.5
surface (double)
6 Width of flange (single) 18 13
7 Width of flange 18 13
(outside of double)
(inside of double)
Overall width of track

9 178 —
roller

Clearance between shaft size Shaft Hole clearance limit
Replace
10 and bushing
bushing
–0.250 +0.030 0.250 –
50 1.5
–0.270 0 0.300

11 Play in axial direction Replace
0.27 – 0.73 1.5

Rebuild
12 Thickness of tread
59 46.5 or replace
— Oil level 255 cc (Gear oil: GO140) —
40-30 D41E, P-6

MAINTENANCE STANDARD CARRIER ROLLER
CARRIER ROLLER
Unit: mm

1 Outside diameter of flange
170 —
2 Outside diameter of 150 126 Rebuild

carrier roller tread surface
or replace
3 Width of carrier roller 46
41
tread surface

Clearance between shaft size Shaft Hole clearance limit
5 and support
–0.1 +0.250
41 0.1 – 0.45 1.0
–0.2 0
Standard Tolerance Standard Interference

size Shaft Hole interference limit Replace
Interference between
6 shaft and seal guard
+0.17 +0.025 0.115 –
41.5 —
+0.14 0 0.17

Play in axial direction
7
of roller 0 – 0.5 0.58

8 Thickness of tread Rebuild
20 8 or replace
— Oil level 200 cc (Gear oil: GO140) —
D41E, P-6 40-31

MAINTENANCE STANDARD TRACK SHOE
TRACK SHOE
LUBRICATED TRACK LINK (1/2)
SINGLE SHOE, SWAMP SHOE
fl P portion shows the link of bushing press fitting end.
ª1. Single shoe

ª2. Swamp shoe (for D41P if equipped)
40-32 D41E, P-6

Unit: mm

1 Link pitch
171.7 174.7
When turned Reverse or

Standard size
Normal load Impact load replace
2 Bushing outside diameter
60.5 51 54.5

Repair or
3 Link height
106 95 replace
Thickness of link metal

4 32
(bushing press-fitting portion)
5 144
Replace
6 Shoe bolt pitch 103.8
7 57
8 Inside width 69.3
Repair or
9 Link Overall width 36.4
replace
10 Tread width 31.6
11 Protrusion of pin 2.95
12 Protrusion of regular bushing 1.5
13 Overall length of pin 199

Adjust or
replace
14 Overall length of bushing 112.7
15 Thickness of bushing metal 12
16 Thickness of spacer 9.2
17 Bushing 49 – 78.4 kN {5 – 8 ton}

Press-fitting —
force
18 Regular pin 127.4 – 166.0 kN {13 – 17 ton}
D41E, P-6 40-33

(2/2)
fl P portion shows the link of bushing press fitting end.
ª1. Single shoe

ª2. Swamp shoe (for D41P if euipped)
40-34 D41E, P-6

Unit: mm
Tightening torque Additinal tightening

(Nm {kgm}) angle (deg.)
a. Regular link
196.1 ± 19.6 {20 ± 2} 120 ± 10
19 Shoe bolt Retighten
Tightening torque Additinal tightening Lower limit torque
(Nm {kgm}) angle (deg.) (Nm {kgm})
b. Master link
196.1 ± 19.6 {20 ± 2} 180 ± 10 343.2 {35}
No. of shoes (each side) D41E-6: 41

D41P-6: 44 –
Tolerance Standard
Standard size
Shaft Hole interference
Interference between
20 bushing and link
+0.304 +0.074
55.7 0.190 – 0.304
+0.264 +0
Interference between +0.372 -0.062 Repair or

21 33.2 0.210 – 0.372
regular pin and link +0.272 -0 replace
Tolerance Standard
Standard size clearance
Clearance between Shaft Hole
22
regular pin and bushing
+0.172 +0.902
33.4 0.230 – 0.830
+0.072 +0.402
D41E, P-6 40-35

SINGLE SHOE
Unit: mm

1 Height
53 25
2 Thickness 11.5 Rebuild or

Replace
3 Length of base 24
4 Length at tip 8
40-36 D41E, P-6

SWAMP SHOE
D41P (if equipped)
Unit: mm

1 Height
83 70 Rebuild or
Replace
2 Thickness 18 5
D41E, P-6 40-37

MAINTENANCE STANDARD MAIN CONTROL VALVE
MAIN CONTROL VALVE

3 SPOOL VALVE (BLADE LIFT, TILT, ANGLE)
(1/5)
3 66.2±7.4Nm
(6.75±0.75kgm)
C A D B
E E
J J
X
H H
G
G
C A F F
D B
X SAD00908
40-38 D41E, P-6

(2/5)
3 44.1±4.9Nm
(4.5±0.5kgm)
3 44.1±4.9Nm
(4.5±0.5kgm)
3 147±9.8Nm A-A
(15±1kgm)
3 53.9±4.9Nm
(5.5±0.5kgm)
B-B
SAD00909
D41E, P-6 40-39

(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)
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}
40-40 D41E, P-6

(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)
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}
D41E, P-6 40-41

(5/5)
3 17.2±2.5Nm
(1.75±0.25kgm)
3 17.2±2.5Nm
(1.75±0.25kgm)
H-H
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}
40-42 D41E, P-6

4 SPOOL VALVE (BLADE LIFT, TILT, ANGLE, RIPPER)

D41E-6
(1/5)
40-44 D41E, P-6

(2/5)
D41E, P-6 40-45

(3/5)
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}
40-46 D41E, P-6

(4/5)
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}
D41E, P-6 40-47

(5/5)
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}
40-48 D41E, P-6

MAINTENANCE STANDARD COOLING FAN DRIVE PUMP
COOLING FAN DRIVE PUMP

SAR(1)20
Unit: mm

1 Side clearance
0.10 – 0.15 0.15
Clearance between inside Replace

2 diameter of plain bearing and 0.06 – 0.10 0.20
outside diameter of gear shaft
Standard size Normal load Impact load
3 Pin driving-in depth 0
10 –0.5 —
4 Spline shaft rotating torque 2.0 – 4.9 Nm {0.2 – 0.5 kgm}
Speed Discharge Standard dis- Discharge

Discharge amount pressure charge amount amount limit
(rpm) (MPa {kg/cm2}) (¬/min) (¬/min) —
– Oil: SAE10WCD
Oil temperature: 45 – 55 °C
3,500 20.59 {210} 66 61
D41E, P-6 40-49

1
MAINTENANCE STANDARD COOLING FAN DRIVE MOTOR
COOLING FAN DRIVE MOTOR

LMF16
Unit: mm

Free length Installed Installed Free Installed If spring is
1 Suction safety valve x O.D. length load length load damaged or
deformed,
3.33 N 2.55 N replace it
29.3 x 6.5 18.2 —
{0.34 kg} {0.26 kg}
40-50 D41E, P-6

MAINTENANCE STANDARD WORK EQUIPMENT CYLINDER
WORK EQUIPMENT CYLINDER

• BLADE LIFT CYLINDER
• BLADE TILT CYLINDER
• BLADE ANGLE CYLINDER
40-52 D41E, P-6

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 – Replace

Lift 50 1.0 bushing
–0.076 +0.080 0.218
Clearance
between piston –0.025 +0.039 0.025 –
2 Tilt 40 0.5
rod bushing –0.064 0 0.103
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
Lift 863 ± 86.3 Nm {88 ± 8.8 kgm}
Tightening
4 torque of Tilt 932 ± 93.0 Nm {95 ± 9.5 kgm}
cylinder head
Angle 1,030 ± 100 Nm {105 ± 10.5 kgm}
Tighten
Tightening Lift 1.42 ± 0.14 kNm {145 ± 14.5 kgm}
5 torque of
Tilt 1.42 ± 0.14 kNm {145 ± 14.5 kgm}
cylinder piston
lock nut Angle 1.77 ± 0.17 kNm {180 ± 18.0 kgm}
D41E, P-6 40-53

MAINTENANCE STANDARD WORK EQUIPMENT
WORK EQUIPMENT
40-54 D41E, P-6

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 120 —
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
D41E, P-6 40-55

CUTTING EDGE, END BIT
3 260±34Nm
(26.5±3.5kgm)
2 1
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 —
40-56 D41E, P-6

90 OTHERS
Power train hydraulic circuit diagram ...... 90- 3

Work equipment hydraulic
circuit diagram ....................................... 90- 4
Electrical circuit diagram with cab (1/2) ...... 90 - 5
Electrical circuit diagram with cab (2/2) ...... 90 - 7
Electrical circuit diagram without cab (1/2) .... 90 - 9
Electrical circuit diagram without cab (2/2) .... 90 -11
Cab electrical circuit diagram .................... 90-13
D41E, P-6 90-1

POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
D41E, P-6 90-3

WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
90-4 D41E, P-6

ELECTRICAL CIRCUIT DIAGRAM (1/2)
WITH CAB
D41E, P-6 90-5

WITH CAB
D41E, P-6 90-7

WITHOUT CAB
D41E, P-6 90-9

WITHOUT CAB
D41E, P-6 90-11

CAB ELECTRICAL CIRCUIT DIAGRAM
D41E, P-6 90-13

1

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SEBM028803

• D41E,P-6 mounts the SA6D102E-2 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

90 OTHERS ................................................................................ 90-1

00-2 D41E, P-6

‡ 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- 1 (3) 10- 9 10-52 10- 97 20-123 (1)

D41E, P-6 00-2-1

00-2-2 D41E, P-6

30-163 (2) 40- 39

D41E, P-6 00-2-3

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)