D41e 6
D41e 6
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012406
• 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.
C 2005 1
All Rights Reserved 00-1
Printed in Japan 06-05(03) (9)
CONTENTS
No. of page
012406
90 OTHERS ................................................................................ 90-1
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1
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‡ 00- 1 (9) ‡ 01- 8 (9) ‡ 10- 32 (9) ‡ 10- 58 (9) ‡ 10- 89 (9)
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‡ 00- 2 -1 (9) 01- 9 -1 (6) 10- 33 10- 59 -1 (6) ‡ 10- 92 (9)
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00-2-3
(9)
SAFETY SAFETY NOTICE
SAFETY
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.
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.
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
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.
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
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.
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).
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
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q’ty Container Main applications, features
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
mm mm Nm kgm
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
Sealing surface
mm mm Nm kgm
00-12
FOREWORD STANDARD 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
00-13
FOREWORD STANDARD TIGHTENING TORQUE
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
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.
Thread diameter Tightening torque
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
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)
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
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
00-16
FOREWORD CONVERSION TABLE
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
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
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
FOREWORD CONVERSION TABLE
0 1 2 3 4 5 6 7 8 9
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
0 1 2 3 4 5 6 7 8 9
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
FOREWORD CONVERSION TABLE
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
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
FOREWORD CONVERSION TABLE
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 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
FOREWORD CONVERSION TABLE
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
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22 04-05
GENERAL SPECIFICATIONS
SPECIFICATIONS
012406
Ground
With power angle tiltdozer KPa {kg/cm2} 40.21 {0.41} 27.46 {0.28}
With power angle tilt +
KPa {kg/cm2} 45.11 {0.46} 31.38 {0.32}
winch + ROPS cab
Overall
length
Note: The values for the weight and ground pressure in { } are reference values.
01-4
(9)
GENERAL SPECIFICATIONS
hydraulically actuated
Wet type, single disc, manual/pedal operated,
Steering brake
hydraulically actuated
01-5
(9)
GENERAL SPECIFICATIONS
012406
Main control valve
3-spool type, manually operated
Type (lift + tilt + angle)
Type Double-acting piston type
Blade lift cylinder
01-6
(9)
GENERAL SPECIFICATIONS
01-7
(9)
GENERAL WEIGHT TABLE
WEIGHT TABLE
¤ This weight table is for use when handling components or when transporting the machine.
Unit: kg
• Damper assembly 26 26
Universal joint 7 7
012406
Transmission valve assembly 12 12
• Idler assembly 50 x 2 50 x 2
01-8
(9)
GENERAL WEIGHT TABLE
Unit: kg
Operator's seat 35 35
01-9
(9)
GENERAL TABLE OF FUEL, COOLANT AND LUBRICANTS
SAE 10WCD
Hydraulic oil system SAE 10W-30CD 73 37
SAE 15W-40CD
012406
0.15 0.15
Serial No.: 50201 and up
0.165 0.165
Serial No.: B20001 – B40000
Serial No.: 50001 – 50074
Track roller (each) 0.16 0.16
GO 140
Gear oil Serial No.: 50075 and up
0.255 0.255
Carier roller (each) 0.20 0.20
01-10
(9)
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
10-3
(9)
STRUCTURE AND FUNCTION ENGINE CONTROL
ENGINE CONTROL
Serial No.: B20001 – B40000
Serial No.: 50001 – 50200
w 2
1 q
012406
3
SLD00792
Lever positions
[1]: Low idling
[2]: High idling
[3]: High idling
[4]: Low idling
10-4
(9)
STRUCTURE AND FUNCTION POWER TRAIN SYSTEM
10-7
(9)
STRUCTURE AND FUNCTION POWER TRAIN HYDRAULIC PIPING DRAWING
012406
10-8
(9)
STRUCTURE AND FUNCTION POWER TRAIN HYDRAULIC PIPING DRAWING
10-9
6
STRUCTURE AND FUNCTION POWER TRAIN HYDRAULIC SYSTEM DIAGRAM
012406
10-10
(9)
012406
(9)
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
10-11
STRUCTURE AND FUNCTION DAMPER, UNIVERSAL JOINT
1 12
2
11
3 4
10
012406
6 5
8
7 13
SDD00798
10-12
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
TRANSMISSION CONTROL
Serial No.: B20001 – B40000
Serial No.: 50001 – 50200
i q
u
y
t
e
3
w
r
2
012406
SLD00799
10-13
(9)
STRUCTURE AND FUNCTION TRANSMISSION
24. Bushing
25. Output shaft (bevel pinion)
26. Seal cage
27. Bearing cage
28. Cage Outline
29. Rear housing • The transmission has 3 forward speeds and
30. No. 5 clutch spring 3 reverse speeds and uses a combination of
31. No. 4 clutch spring disc clutches with planetary gear systems.
32. No. 3 clutch spring • The transmission uses 4 sets of planetary
33. No. 2 clutch spring (small) gear system and disc clutch and one rotat-
33a.No. 2 clutch spring (large) ing clutch (for 1st). The control valve sends
34. No. 1 clutch spring (small) hydraulic pressure to lock two of these
34a.No. 2 clutch spring (large) clutches in position to provide the selected
35. Clutch plate speed and direction of rotation.
36. Clutch disc • The No. 1 clutch locks REVERSE, the No. 2
37. Tie bolt clutch locks FORWARD, the No. 3 clutch
38. Strainer locks 3rd, the No. 4 clutch locks 2nd, and
the No. 5 clutch locks 1st.
• When the transmission is at neutral, both
the No. 1 clutch and No. 2 clutch are disen-
gaged.
(One of the No. 3, 4, or 5 clutches is en-
gaged.)
10-17
(9)
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
D D
a P1
C C
B B
A
012406
SDD00810
Outline
• The transmission control valve sets the main
relief pressure as follows.
a. From priority valve (inlet port)
Set pressure
P1. Modulating valve pressure pickup plug Speed range
P4. Inching valve pressure pickup plug (MPa {kg/cm2})
2.89 ± 0.15
N1
{29.5 ± 1.5}
2.94 ± 0.15
F1, R1
{30.0 ± 1.5}
2.99 ± 0.15
F2, R2, F3, R3
{30.5 ± 1.5}
(when the engine is at rated)
• Furthermore, there is an inching valve in-
stalled in the circuit between the speed valve
and directional valve, and this makes it pos-
sible to carry out fine adjustment of the
travel speed.
10-23
(9)
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
1 2 3 4 5 6 7 8 9 10
11
12
13
012406
A-A
14
15 16 17 18
B-B 19 SDD00811
10-24
012406 STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
10-25
(9)
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
MODULATING VALVE
012406
valve.
For example, when the gear is shifted from
R1 to R2, the oil from the pump passes
through the speed valve spool, flows to the
2nd clutch and fills the circuit up to the clutch
piston port.
The time taken for the circuit to be filled up
to the clutch piston port is called the “filling
time”.
When the circuit up to the clutch piston port
is filled with oil, the oil pressure starts to
rise. The time taken for the pressure to rise
to the set pressure is called the “build-up
time”. The filling time and build-up time
together are called the “modulating time”.
10-26
(9)
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
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).
10-27
(9)
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
012406
piston (3), compresses tension springs (4)
and (5) and moves the load piston (3) to the
right to close the passage between cham-
ber B and chamber E.
This operation repeatedly opens and closes
chamber B and chamber E to balance the
back pressure of chamber H and chamber D
with the tension of tension springs (4) and
(5). As a result, the pressure inside the cir-
cuit gradually rises and finally load piston
(3) comes into contact with the valve body
and cannot move any further.
When this happens, the rise in pressure of
modulating valve (1) is completed and the
pressure becomes the set pressure.
Modulating valve (1) repeatedly opens and
closes the passage between chamber B and
chamber E to let the oil from the pump flow
into chamber F and keep the clutch oil pres-
sure at the set pressure of modulating valve
(1).
The oil relieved from chamber B to cham-
ber E flows from chamber E into the oil
cooler circuit.
10-28
(9)
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
INCHING VALVE
Outline
• The inching valve is in the circuit between
the speed valve and directional (F-R) valve.
The amount that the inching pedal is oper-
ated adjusts the amount of oil (oil pressure)
sent from the speed valve to the directional
valve. The inching pedal changes the pres-
sure of the FORWARD or REVERSE clutch
to partially or fully disengage the clutches
and allow fine control of the travel, or to
make it possible to stop the machine.
• To reduce the shock when operating the
inching pedal, an inching valve with modu-
lation is employed.
Operation
1. Inching pedal not operated
Spool (1) is connected to the inching pedal,
so when the inching pedal is not being op-
erated, it is pushed fully to the right by the
inching control return spring. As a result,
valve (2) is pushed to the right by sleeve (3)
012406
10-29
(9)
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
012406
springs (6) and (7), and the clutch is par-
tially engaged.
When this happens, the passage between
chamber D of modulating valve (4) and drain
port E opens, so the oil from chamber D is
drained through orifice d. Load piston (8) of
modulating valve (4) moves to the position
of orifice "d", and the main pressure is kept
lowered.
10-30
(9)
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
10-31
1
STRUCTURE AND FUNCTION STEERING, BRAKE, INCHING CONTROL
012406
10-32
(9)
STRUCTURE AND FUNCTION STEERING, BRAKE, INCHING CONTROL
10-32-1
(9)
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
012406
10-33
STRUCTURE AND FUNCTION BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE
2 1 3
012406
B C
A A
Y
Z
B C
SDD00824
1. Steering piston
2. Steering unit
3. Breather
10-34
(9)
STRUCTURE AND FUNCTION BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE
012406
1. Steering piston
2. Steering unit
3. Breather
10-43-1
10-42
(9)
012406 STRUCTURE AND FUNCTION BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE
10-43-2
10-43
(9)
STRUCTURE AND FUNCTION BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE
012406
10-43-3
10-44
(9)
012406 STRUCTURE AND FUNCTION BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE
10-43-4
10-45
(9)
STRUCTURE AND FUNCTION BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE
Outline
1. Bevel gear shaft 3. Steering brakes
• The power transmitted from the engine • The steering brakes are used to stop or
→ damper → transmission is transmit- turn the machine by braking the power
ted to the bevel pinion (transmission from the steering clutches to the final
output shaft) and bevel gear (10), which drive.
are meshed by the bevel gear shaft sys- • The steering brakes are a wet, single
tem. From here, it is sent at right angles disc, hydraulically boosted type. They
to the left and right by the bevel gear are hydraulically operated by the steer-
shaft, and the rotation speed is reduced ing PPC valve, which is actuated by op-
at the same time. eration of the steering lever, and the
• The bevel gear shaft system uses a spi- brake valve, which is actuated by the
ral bevel gear for the bevel pinion and brake pedal, and they are interconnected
bevel gear, and lubrication is carried out with the clutches. Lubrication is carried
by splash lubrication. out by splash lubrication.
• The bevel gear shaft system consists of • The steering brakes have two functions
bevel gear (10) and the following parts (parking brake and brakes to stop the
which form the planetary gear reduc- machine when traveling). The steering
tion system: ring gear (9), planetary pin- brakes are used as the parking brake by
ion (12), carrier (8), bevel gear shaft (1), setting the safety lever to the LOCK po-
bevel gear shaft bearing (13), and bevel sition.
gear shaft cage (11). • The steering brake consists of the fol-
lowing parts: brake hub (20), which is
2. Steering clutch joined by a spline to bevel gear shaft
012406
• In the planetary gear reduction system, (1), brake plate (18), brake lining (4),
sun gear (7) and bevel gear shaft (1) are brake cam case (5), brake backup plate
joined by a spline, and the power sent (3), eccentric camshaft (24) which sup-
from bevel gear shaft (1) to the left and ports the brake cam case, reaction re-
right final drives is transmitted or cut ceiving pin (2), which is secured to the
off in order to change the direction in steering case, and torque receiving pin
which the machine turns. (25).
• The steering clutches are a wet, single Eccentric camshaft (24) is supported to
disc, hydraulically boosted type. They the top cover and steering case by nee-
are hydraulically operated by the steer- dle bearing (23), and the brake lever is
ing PPC valve, which is actuated by op- installed to the top of the shaft.
eration of the steering lever, and they
are interconnected with the brakes. Lu-
brication is carried out by splash lubri-
cation.
• The steering clutches consist of the fol-
lowing parts: clutch hub (6), which is
joined by a spline to sun gear (7) of the
planetary gear reduction system, clutch
plate (17), clutch lining (16), clutch cam
case (19), clutch backup plate (15), ec-
centric camshaft (24), which supports the
clutch case, reaction receiving pin (14),
which is secured to the steering case,
and torque receiving pin (25).
Eccentric camshaft (24) is supported to
the top cover and steering case by nee-
dle bearing (23), and the clutch lever is
installed to the top of the shaft.
10-43-5
10-46
(9)
STRUCTURE AND FUNCTION BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE
10-43-6
10-47
(9)
STRUCTURE AND FUNCTION BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE
012406
10-43-7
10-48
(9)
STRUCTURE AND FUNCTION BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE
10-43-8
10-49
(9)
STRUCTURE AND FUNCTION BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE
012406
2. Steering brake applied
(steering lever operated)
If the steering lever is operated fully, the
steering PPC valve is switched, and the steer-
ing clutch is disengaged. At the same time,
hydraulic pressure acts on the brake piston,
and the brake piston pushes the brake lever
installed to the top of eccentric camshaft
(24A).
In this condition, brake cam case (5) pushes
brake lining (4) into contact with brake plate
(18) through eccentric camshaft (24A), and
stops the rotation of bevel gear shaft (1).
The hydraulic force applied to the brake pis-
ton can be controlled by the amount that
the steering lever is operated. This makes it
possible to control the braking force and
thereby control the turning radius and turn-
ing time.
10-43-9
10-50
(9)
012406 STRUCTURE AND FUNCTION BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE
10-43-10
10-51
1
STRUCTURE AND FUNCTION STEERING PPC VALVE
A C
D B
012406
a D b B
f
c
SAD00833
a. Port P (from power train pump) Outline
b. Port P1 (to right steering clutch piston) • The steering PPC valve is in the circuit be-
c. Port T (to transmission case) tween the power train pump and steering
d. Port P3 (to right steering brake piston) clutch piston and brake piston.
e. Port P2 (to left steering clutch piston) • The steering PPC valve is interconnected
f. Port P4 (to left steering brake piston) with the steering, directional, and speed le-
ver, and when the lever is operated to the
right or left to turn the machine, the steer-
ing PPC valve is actuated and sends hy-
draulic pressure to the steering clutch pis-
ton or brake piston.
• It is possible to control the amount of oil
discharged from the steering PPC valve by
adjusting the amount the lever is operated.
This makes it possible to control the turning
speed.
10-44
(9)
STRUCTURE AND FUNCTION STEERING PPC VALVE
D
Pp
PP
P T
012406
ing spring (5).
As a result, the notch in valve (4) is shut off
from pump pressure chamber PP. At almost SAD00835
10-46
(9)
STRUCTURE AND FUNCTION STEERING PPC VALVE
SAD00838
10-47
(9)
STRUCTURE AND FUNCTION STEERING PISTON
STEERING PISTON
012406
1. Brake piston
2. Clutch piston
Outline
• The steering piston consists of clutch piston • The brake piston is actuated by hydraulic
(2) and brake piston (1). pressure from the steering PPC valve which
• Clutch piston (2) is actuated by the hydrau- is actuated by the operation of the steering
lic pressure from the steering PPC valve, lever and brake, which is actuated by the
which is actuated by the operation of the brake pedal. The brake piston controls the
steering lever. The clutch piston controls the brake lever installed to the top of the brake
clutch lever installed to the top of the clutch eccentric camshaft of the steering unit.
eccentric camshaft of the steering unit.
10-48
(9)
STRUCTURE AND FUNCTION PRIORITY VALVE
PRIORITY VALVE
A B
C
A
012406
1 2 3 4
10 9 8 7 6 E 5 A. Drain port
A-A SDD00840
B. To brake valve
C. To transmission valve
D. To steering PPC valve
E. From power train pump
10-49
STRUCTURE AND FUNCTION PRIORITY VALVE
Outline
• The priority valve is in the circuit from the
power train pump to the steering PPC valve,
brake valve, and transmission valve. It pre-
vents the hydraulic pressure in the steering
and brake circuit from dropping momentar-
ily when the transmission is shifted.
Operation
• When the transmission is not being shifted,
transmission valve port A of priority valve
spool (1) is opened, and the circuit from the
pump to the steering PPC valve and brake
valve becomes the pressure set by the trans-
mission valve.
• When the transmission is shifted, if the pres-
sure at transmission valve port A of the pri-
ority valve momentarily drops, priority valve
spool (1) closes port A, and the circuit pres-
sure from the pump to the steering PPC
valve and brake valve is set to the pressure
determined by the priority valve in order to
prevent the pressure from dropping.
• Relief set pressure:
2.7 MPa (28 kg/cm2) (65 ¬/min)
012406
10-50
(9)
STRUCTURE AND FUNCTION BRAKE VALVE
BRAKE VALVE
A 1
A
2
A 3 4 B C D 5
012406
11 10 9 E 8 7 6
1. Parking brake valve A-A
SDD00842
2. Main brake valve
3. Body
4. Return spring
5. Plug
6. Return spring
7. Valve
8. Piston Outline
9. Shaft • The brake valve is in the circuit between the
10. Modulating spring brake piston and power train pump through
11. Guide the transmission modulating valve and pri-
ority valve. It consists of the main brake
A. Port Br (R) (to right brake piston) valve and the parking brake valve.
B. Port P (pump port) • When the brake pedal is depressed, oil flows
C. Port T2 (main brake valve drain) to the brake piston, and the brake piston
D. Port Br (L) (to left brake piston) presses the disc and plate together to apply
E. Port T1 (parking brake valve drain) the brake.
10-51
(9)
STRUCTURE AND FUNCTION BRAKE VALVE
OPERATION
1. Brake released (safety lever free, brake pedal released)
012406
• When the brake pedal at the “released” po- • When safety lever (14) is at the “free” posi-
sition (not being depressed), brake pedal tion, the oil entering from port A passes
(12) pushes the rod, and guide (11), shaft through port B, enters parking brake cylin-
(9), and brake valve (7) are pushed to the der (15), and pushes the cylinder piston to
right. the right. This pushes the brake cylinder rod
The oil from the power train pump enters to the right, but no force is brought to bear
port A and is stopped at port C. The oil on brake eccentric camshaft (16) because of
from brake piston (13) is drained from port the oblong portion provided in the lever.
D to port E, and the brake is released.
10-52
(9)
STRUCTURE AND FUNCTION BRAKE VALVE
• When the brake pedal (12) is depressed, between port D and drain port E opens, and
guide (11) and shaft (9) are returned to the the pressure beyond port D is maintained
left, and the force of modulating spring (10), and prevented from rising.
which was acting on brake valve (7), be- If the pedal is depressed further, the above
comes weaker, so brake valve (7) also moves action is repeated, and when the valve
to the left. When this happens, the passage reaches the end of its stroke, the brake is
between port C and port D opens, and the completely applied.
passage between port D and drain port E • The pressure beyond port D is determined
tries to close. The oil from the power train by the tension of return spring (6), which
pump enters port A, passes through ports receives a load in accordance with the
B, C, and D, and flows to the back pressure amount that the brake pedal is depressed.
port of brake piston (13). • Therefore, if the brake pedal is depressed
Some of the oil from port D passes through slightly, the hydraulic pressure beyond port
orifice and enters port H. When the pres- D is set low and the brake is partially ap-
sure of the oil entering port H rises, the plied. If the brake pedal is depressed a long
force pushing brake valve (7) to the right way, the hydraulic pressure is set high and
increases. When it becomes greater than the the brake is fully applied.
tension of return spring (6), the passage
10-53
(9)
STRUCTURE AND FUNCTION BRAKE VALVE
012406
10-54
(9)
STRUCTURE AND FUNCTION POWER TRAIN OIL FILTER
X
A
2
X
B
012406
X-X
SED00846
Specifications
1. Power train oil filter
Performance
2. Head
0.2 ± 0.02 MPa
3. Filter cartridge Cracking pressure {2.0 ± 0.2 kg/cm2}
Mesh size 10 µm
A. To power train circuit
B. From power train pump Filtering area 3,600 cm2
10-55
1
STRUCTURE AND FUNCTION FINAL DRIVE
FINAL DRIVE
Serial No.: B20001 - B20500 fl The diagram shows the D41P-6.
012406
Outline
1. Sprocket • The final drive uses a single-stage spur gear
2. Final drive case reduction system. It is lubricated by splash
3. Pinion (No. of teeth: 11) type lubrication using the rotation of the
4. Gear (No. of teeth: 81) gear.
5. Cover The final drive is designed so that it can be
6. Floating seal removed or installed as a single unit.
7. Sprocket shaft • Floating seal (6) is installed to the rotating
8. Hub and sliding portion of the sprocket to pre-
vent entry of soil or sand from outside and
to prevent leakage of oil.
10-56
(9)
012406 STRUCTURE AND FUNCTION FINAL DRIVE
10-57
1
STRUCTURE AND FUNCTION FINAL DRIVE
012406
Outline
1. Sprocket • The final drive uses a single-stage spur gear
2. Final drive case reduction system. It is lubricated by splash
3. Pinion (No. of teeth: 11) type lubrication using the rotation of the
4. Gear (No. of teeth: 81) gear.
5. Cover The final drive is designed so that it can be
6. Floating seal removed or installed as a single unit.
7. Sprocket shaft • Floating seal (6) is installed to the rotating
8. Hub and sliding portion of the sprocket to pre-
vent entry of soil or sand from outside and
to prevent leakage of oil.
10-57-1
10-62
(9)
012406 STRUCTURE AND FUNCTION FINAL DRIVE
10-57-2
10-63
1
STRUCTURE AND FUNCTION FRAME ASSEMBLY
012406
10-58
(9)
STRUCTURE AND FUNCTION TRACK FRAME
10-59
(9)
STRUCTURE AND FUNCTION RECOIL SPRING
RECOIL SPRING
D41E Serial No.: B20001 – B20980
D41P Serial No.: B20001 – B20983
012406
1. Support connection
2. Housing
3. Nut
3A. Spacer (ª)
4. Rod
5. Dust seal, oil seal
6. Recoil spring Outline
7. Cylinder • The recoil spring moves rod (4) forward or
8. Piston (rod and piston form integrated unit) backward to adjust the track tension. The
9. U-packing recoil spring is moved by pumping in or
10. Wear ring releasing grease from lubricator (12). Recoil
11. Bushing spring (6) also acts to absorb any sudden
12. Lubricator shock applied to the idler.
10-60
(9)
STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM
6
5
4
3
2
1
012406
9
SLD00853
10-61
STRUCTURE AND FUNCTION WORK EQUIPMENT CONTROL
t
w
e
2
012406
o
!0
SLD00854
10-62
(9)
STRUCTURE AND FUNCTION WORK EQUIPMENT CONTROL
10-63
6
STRUCTURE AND FUNCTION WORK EQUIPMENT CONTROL
012406
10-64
(9)
012406 STRUCTURE AND FUNCTION
1. Hydraulic tank
2. Hydraulic, power train pump
(SAR36+28)
3. Main control valve
3A. Main relief valve
Set pressure: 20.6MPa
{210kg/cm2}
3B. Unload valve
3C. Blade lift valve
3D. Blade tilt valve
3E. Blade angle valve
3F. Pressure compensation valve
3G. Suction valve
3H. Suction & safety valve
Set pressure: 24.5MPa
{250kg/cm2}
4. Slow return valve
5. Blade lift cylinder
6. Blade angle cylinder
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
(9)
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
10-65
STRUCTURE AND FUNCTION HYDRAULIC TANK, FILTER
2 B B
1 A-A
012406
A
A
SAD00857
1. Drain plug
2. Hydraulic filter
3. Hydraulic tank
4. Hydraulic tank oil filler cap
4A. Key cylinder
4B. Vacuum valve
4C. Pressure valve
10-66
STRUCTURE AND FUNCTION HYDRAULIC TANK, FILTER
4 4A
4C 4B
B-B
B
A
012406
C
C
C-C SED00858
Specifications
Item Specified value
10-67
(9)
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
012406
10-68
(9)
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
(2/5)
2
6
5 3
A-A
4
012406
10
11
B-B
SAD00860
1. Suction valve (angle cylinder head) 7. Auxiliary valve port plug (angle)
2. Suction valve (tilt cylinder bottom) 8. Angle spool
3. Auxiliary valve port plug (lift) 9. Tilt spool
4. Suction & safety valve 10. Lift spool
5. Suction valve (lift cylinder bottom) 11. Main relief valve
6. Auxiliary valve port plug (tilt)
10-69
(9)
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
(3/5)
1 2
9 3
8 4
012406
6 C-C
11
10
12
E-E
D-D
SAD00861
10-70
(9)
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
(4/5)
3
5
012406
F-F 4
6 7
G-G
10 9
SAD00862
10-71
(9)
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
(5/5)
1 2
H-H
5 4
012406
6 7
10 J-J 9
SAD00863
10-72
(9)
(9)
(9)
(9)
(9)
(9)
STRUCTURE AND FUNCTION CLSS
CLSS
OUTLINE
Features
CLSS stands for Closed center Load Sens-
ing System, and has the following features.
1) Fine control performance that is not af-
fected by the load.
2) Flow dividing control using a pressure
compensation valve to enable division
of the oil flow regardless of any differ-
ence in load. (Possible to operate lift,
tilt, and angle at the same time)
Structure
The CLSS consists of a fixed displacement
gear pump, control valve, and the actua-
tors.
012406
BASIC PRINCIPLE
1. Flow control
The flow of oil to the actuators is controlled
by the unload valve, which keeps ∆PLS con-
stant. (∆PLS is the difference in pressure
between pump discharge pressure PP and
control valve outlet pressure PLS (actuator
load pressure)).
ª Differential pressure ∆PLS =
pump discharge pressure PP – control
valve outlet pressure PLS
If ∆PLS becomes lower than the set pres-
sure of the unload valve, the oil supply is
increased; if it becomes higher than the set
pressure, oil is drained from the unload
valve to the tank to reduce the oil supply.
fl For details of the operation, see OPERA-
TION OF UNLOAD VALVE.
10-73
(9)
STRUCTURE AND FUNCTION CLSS
012406
10-74
(9)
STRUCTURE AND FUNCTION CLSS
10-75
(9)
STRUCTURE AND FUNCTION CLSS
1. Unload valve
Function
• When the work equipment control lever of oil sent to the actuators in proportion
is at HOLD, the unload valve relieves all to the area of opening of the spool.
the oil discharged from the pump at low • The unload valve is controlled by the
pressure (cracking pressure: 0.35 MPa difference in pressure on both sides of
{3.6 kg/cm2}) to the tank circuit to reduce the spool, so it also acts as a pressure
the loss of pressure from the pump to compensation valve to reduce the
the tank. change in the oil flow caused by the
• The unload valve controls the amount load pressure.
012406
Operation
1) Control lever at HOLD (unload valve set
to low pressure)
• When the work equipment spool is MPa {0 kg/cm2}. In this way, pump
at HOLD, the LS circuit is connected pressure PP acting on the lower side
to port TS through the throttle of LS of unload valve (1) is set only by
bypass plug (5), so LS circuit pres- load F1 of spring (2). (SA (area at
sure PLS = PTS = . 0 MPa {0 kg/cm2}. end of spool) x PP = F1)
.
Chamber A and chamber A1 are con- • If pump discharge pressure PP rises
nected through the orifice, but cham- and reaches the load of spring (2),
ber A1 is connected to port TS from unload valve (1) moves up and the
the drill hole in sleeve (3) through oil discharged from the pump flows
the drill hold in selector piston (4). from drill hole "b" in unload valve
Therefore, chamber A1 = PTS = . 0 (1) to tank circuit T.
.
10-76
(9)
STRUCTURE AND FUNCTION CLSS
10-77
(9)
STRUCTURE AND FUNCTION CLSS
012406
ter-in pressure loss is determined by
the area of the opening of notch "a"
of spool (8), so the flow of oil to the
cylinder corresponds to the area of
opening, and has no relation to the
load pressure.
10-78
(9)
012406 STRUCTURE AND FUNCTION CLSS
10-79
(9)
STRUCTURE AND FUNCTION CLSS
fl The diagram shows the condition immediately after the lift cylinder has reached the end of its
stroke.
012406
4) At relief
• When spool (8) is operated, the oil • In this condition, all of the oil dis-
discharged from the pump flows charged from the pump is sent to
from port D to the cylinder. When the cylinder, but the cylinder is
this happens, LS circuit pressure PLS stopped, so the pressure in the pump
goes to chamber B. circuit rises.
• When the cylinder reaches the end • When pump pressure PP reaches the
of its stroke and stops, PP = . P1 =. set pressure of relief valve (10), the
. .
PLS, and unload valve (1) is pushed relief valve is actuated, and the pres-
down by the load of spring (2), so sure is set to the maximum set pres-
the unload flow becomes 0. sure for the pump circuit.
10-80
(9)
STRUCTURE AND FUNCTION CLSS
fl This diagram shows the condition when port A1 is under heavy load and port A2 is under
light load.
012406
10-81
(9)
STRUCTURE AND FUNCTION AIR CONDITIONER
AIR CONDITIONER
AIR CONDITIONER PIPINT
Serial No.: B20001 – B40000
Serial No.: 50001 – 50200
012406
10-86
(9)
STRUCTURE AND FUNCTION AIR CONDITIONER
10-86-1
6
STRUCTURE AND FUNCTION ACTUAL ELECTRIC WIRING DIAGRAM
012406
10-86-2
(9)
STRUCTURE AND FUNCTION ELECTRICAL CIRCUIT DIAGRAM
10-87
(9)
STRUCTURE AND FUNCTION ELECTRICAL CIRCUIT DIAGRAM
WITHOUT CAB
D41E, P-6
fl For details of this page, see page 90-13.
*1. Serial No.: 20501 – B40000
012406
Serial No.: B20001 – B40000
Serial No.: 50001 – 50200
10-88
(9)
(9)
STRUCTURE AND FUNCTION ENGINE CONTROL SYSTEM
10-91
(9)
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
012406
• The machine monitor system uses sensors • The machine monitor system consists of the
installed at various parts of the machine to monitor panel, sensors, warning buzzer and
observe the machine condition. It processes power source.
this information swiftly and displays it on The monitor panel and sensors are con-
the panel to keep the operator informed of nected with wiring harnesses, and the power
the machine condition. supply for the monitor panel is taken from
The information displayed on the panel can the battery. If any abnormality occurs in the
be broadly divided into the following cat- machine (detected by the sensor), the moni-
egories: tor and warning lamp flash and the buzzer
sounds to protect the machine. The buzzer
1. The monitor group, which informs the can be stopped temporarily by operating the
operator when there is an abnormality cancel switch.
in the machine.
2. The gauge group (coolant temperature,
power train oil temperature, fuel level),
which always displays the condition of
the machine.
10-92
(9)
STRUCTURE AND FUNCTION MACHNE MONITOR SYSTEM
Below
Turn off Turn off OFF
120°C
Power
train oil 120-130°C Flashes Red Flashes OFF
temperature
Above
Flashes Flashes ON
130°C
Warning
When ON
there is (when engine Turn off
Battery defective is stopped)
Red OFF
charge charging Flashes
(below (when engine Flashes
SKD00624
10V) is running)
ON
(when engine Turn off OFF
Engine oil Below is stopped)
pressure specified Red
value Flashes
SKD00625
(when engine Flashes ON
is running)
012406
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
SKD00634
10-95
(9)
STRUCTURE AND FUNCTION SENSORS
SENSORS
• The signal from the sensor is input directly
to the machine monitor panel.
• The engine oil pressure sensor signal is
judged to be normal when the contacts are
open and the signal wire is separated from
the chassis ground
012406
10-96
STRUCTURE AND FUNCTION SENSORS
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Thermistor
Function
• The engine oil pressure sensor is installed fied pressure, the curve of the diaphragm
at the front on the left side of the cylinder becomes smaller, so the contact and con-
block. When the engine oil pressure is above tact link come into contact and the circuit is
the specified value, diaphragm (4) bends, turned ON. The monitor panel display and
so contact (3) and contact ring (2) are sepa- warning lamp flash, and the alarm buzzer
rated and the circut is turned OFF. When sounds.
the engine iol pressure goes below the speci-
012406
Function
• The engine coolant temperature sensor is
installed to the thermostat housing on the
right side of the engine. It detects the tem-
perature with thermistor (3) and sends a
signal to the monitor panel.
The monitor panel moves the gauge indica-
tor to the range that corresponds to the sig-
nal, and if it is above the specified tempera-
ture, and monitor panel display and warn-
ing lamp flash, and the buzzer sounds.
10-97
(9)
STRUCTURE AND FUNCTION SENSORS
012406
1. Connector Function
2. Float • The fuel level sensor is insalled to the center
3. Arm of the front face of the fuel tank. Float (2)
4. Body moves up and down in accordance with the
5. Spring level of the remaining fuel.
6. Contact The movement of the float passes throgh
7. Spacer arm (3), which actuates a variable resist-
ance, and this sends a signal to the monitor
panel to display the level of the remaining
fuel.
10-98
(9)
TESTING AND ADJUSTING
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.
20-1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
Engine S6D102-1
Standard value
Item Measurement conditions Unit Service limit value
for new machine
High idling 2,650 ± 50 2,650 ± 50
Engine speed Low idling rpm 825 ± 25 825 ± 25
Rated speed 2,400 2,400
(normal temperature)
Valve clearance Intake valve mm 0.25 —
Exhaust valve 0.51 —
(SAE30 oil)
Oil temperature: MPa
Compression pressure 2 — —
40 – 60°C {kg/cm }
(Engine speed)
012406
(Water temperature:
Operating range) KPa
Blow-by pressure {mmH2O} Max.0.50{50.8} —
(SAE30 oil)
At rated output
(SAE15W-40 oil)
(Oil temperature:Min80°C)
MPa
Oil pressure At high idling 0.275 – 0.516 0.275 – 0.516
{kg/cm2}
{2.81 – 5.27} {2.81 – 5.27}
20-2
(9)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
• 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
Cate-
gory Item Measurement conditions Unit Standard value Permissible value
{30.5 ± 1.5}
Steering actuating 3.5 ± 0.34 3.0
pressure • Engine at high idling MPa {36 ± 3.5} {30.5}
Brake actuating • Power train oil {kg/cm2}
temperature: 2.65 ± 0.25 2.2
pressure (Brake
70 – 80°C {27 ± 2.5} {22}
pedal operated)
Pedal 0.08 ± 0.01
Inching circuit operated {0.8 ± 0.1} —
actuating
Pedal 2.55
pressure
not operated 2.7 +0.4
0 {28+40 } {26}
Hydraulic pump • Engine at high idling +8 17.7
20.6 +0.8
0 {210 0}
relief pressure • Hydraulic oil temperature: 45 – 55°C {180}
temperature:
Within operating FORWARD 3rd 7.6 ± 0.5 7.6 ± 0.5
Travel speed
012406
range km/h
• Run-up distance: REVERSE 1st 3.0 ± 0.3 3.0 ± 0.3
10 – 30 m
• Measurement
REVERSE 2nd 5.5 ± 0.5 5.5 ± 0.5
distance: 20 m
REVERSE 3rd 9.4 ± 0.8 9.4 ± 0.8
• Blade: No load
1.9 ± 0.2 2.3
• Ground level → Max. lifting
Work equipment
height
• Engine at high idling
20-4
2
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Cate-
gory Item Measurement conditions Unit Standard value Permissible value
LEFT ANGLE
6.1 ± 0.3 6.6
Blade angling
Sec.
speed
• Engine at full throttle
RIGHT ANGLE
• Hydraulic oil temperature:
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
• Posture of work equipment
Work equipment
20-5
2
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR MACHINE MONITOR
sensor signal
Monitor item
table above are the Monitor auxiliary signal output T-adapter.
Signal
following voltages. Engine oil Starting Alternator
Monitor
display
ª 1 Engine oil presure signal signal
pressure signal signal
H: 3.5 – 30V Monitor ª1 ª2 ª3
L: Approx. 0V item CN49 8 CN49 5 CN49 4 ª 4
ª 2 Starting signal
H: 3 – 30V Preheating H ON
— —
L: Approx. 0V CN49 6 L OFF
Once the starting
signal is H, even if Engine oil L ON
pressure H H —
it then changes to CN49 8 H OFF
L, the starting signal
is stored in memory Battery charge L ON
H H —
inside the monitor CN49 4 H OFF
panel as H until the
starting switch is Table 2 (Buzzer signal)
turned OFF.
ª 3 Alternator Starting switch ON
signal CN49 1 – 2 20 – 30V
A Starting switch OFF
H: 27.5 – 30V (+24V input)
012406
0V
L: Max. 5V
Machine monitor
2) Turn starting
Display portion
switch ON and
check display.
Coolant CN15 3) Connect
temperature 1–2 socket.
* Serial No. B20001 – B30000, 50001 – 50200: 102˚C, Serial No. B30001 and up, 50201 and up: 104˚C
20-6
7
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR MACHINE MONITOR
Measure resistance
resistance of
120°C Approx. 2.3 kΩ sensor.
2) Turn starting
130°C Approx. 1.8 kΩ
Power train oil CN58 switch ON and
temperature 1–2 50°C 90°C 102°C check display.
3) Connect
socket.
Display portion
Machine panel
BDD00073
F Approx. 12 Ω
Machine monitor
CN3
Fuel level E 1/10 F
1–2
SYD00340
20-7
7
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR MACHINE MONITOR
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
012406
20-8
TESTING AND ADJUSTING
Adjusting work equipment control linkage and safety lever linkage .............................................. 20-117
Measuring power train oil pressure .................................................................................................... 20-118
Testing and adjusting work equipment circuit pressure .................................................................. 20-122
Testing and adjusting track shoe tension ........................................................................................... 20-123
Measuring leakage inside cylinder ...................................................................................................... 20-124
Bleeding air from hydraulic cylinder ................................................................................................... 20-125
Procedure for releasing parking brake ................................................................................................ 20-126
Testing and adjusting operator's cab .................................................................................................. 20-127
Testing and adjusting "open" and "close" lock and steady rest of operator's cab door .............. 20-128
20-101
(8)
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
790-261-1311 Adapter —
2
790-261-1321 Adapter —
Blow-by pressure
Blow-by pressure E 799-201-1504 4.9 KPa {500 mmH2O}
gauge
F Commercially —
Valve clearance Feeler gauge
available
2 Commercially —
Smoke meter
available
012406
79A-264-0020 Push-pull scale 0 – 290 N {0 – 30 kg}
Operating effort I
79A-264-0090 Push-pull scale 0 – 490 N {0 – 50 kg}
20-102
(9)
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE
CLEARANCE
1. Remove the cylinder head cover. 1
2. Set cranking tool N to the flywheel.
3. Rotate the crankshaft in the normal direction to
a point where timing pin (1) enters the hole in
the gear.
fl Push pin (1) in lightly while cranking. N
4. At the position in Step 3, adjust the clearance
of the valves marked ‡ in the valve arrange-
ment chart. At the same time, make match marks
on the crankshaft pulley and timing gear case,
then remove timing pin (1). BED00024
BED00026
5 6 3 4
BED00027
20-103
(9)
TESTING AND ADJUSTING MEASURING BLOW-BY
MEASURING BLOW-BY
fl Raise the coolant temperature to the operating
range before measuring.
012406
BED00029
TLD00021
20-104
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
BED00024
2. Adjusting
• If timing pin does not mesh.
1) Remove the injection pump.
For details, see REMOVAL OF FUEL INJEC-
TION PUMP.
2) Rotate the camshaft of the injection pump
to align timing pin (3) with timing pin pointer
(4).
3) Install the injection pump.
For details, see INSTALLATION OF FUEL IN-
012406
JECTION PUMP.
20-105
(9)
TESTING AND ADJUSTING MESURING EXHAUST COLOR
012406
Measuring with G2
1) Insert probe [1] into the outlet port of ex-
haust pipe, and tighten the clip to secure it
to the exhaust pipe.
2) Connect the air hose, the socket of the ac-
celerator switch, and the probe hose to tool q
G2.
fl Keep the pressure of the air supply be-
low 1.5 MPa (15 kg/cm2).
3) Connect the power cord to the AC socket.
fl When connecting the cord, check that
the power switch of tool G2 is OFF. BED00034
4) Loosen the cap nut of the suction pump,
and fit the filter paper.
fl Fit the filter paper securely so that the
exhaust gas cannot leak.
G2
5) Turn the power switch of tool G2 ON.
6) Accelerate the engine suddenly, and depress
the accelerator pedal of tool G2 at the same
time to collect the exhaust gas color on the
filter.
7) Place the filter paper used to catch the ex-
haust gas color on top of at least 10 sheets
of unused filter paper inside the filter paper
holder, and read the value shown.
TLD00140
20-106
(9)
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL LINKAGE
20-109
7
TESTING AND ADJUSTING ADJUSTING DECELERATOR PEDAL LINKAGE
012406
3) Adjust installed length "c" of cable (5) at the
engine end to the following dimension. 1 a
BED00061
fl Dimension "c": 232.5 mm
20-110
7
ADJUSTING FUEL CONTROL LINKAGE
TESTING AND ADJUSTING ADJUSTING DECELERATOR PEDAL LINKAGE
20-110-1
7
(9)
ADJUSTING FUEL CONTROL LINKAGE
TESTING AND ADJUSTING ADJUSTING DECELERATOR PEDAL LINKAGE
012406
20-110-2
7
TESTING AND ADJUSTING ADJUSTING ENGINE STOP SOLENOID
2) Fit a spring balance to bolt (2), pull cut-off 3. Replacing and adjusting solenoid
lever (1) in the installation direction of the
solenoid and measure the operating effort.
fl Use a spring balance with a maximum 4. Checking after replacing solenoid and
measurement of 98 N {10 kg}. installing to machine
• If the operating effort is less than 9.8 N
{1.0 kg}:
The operating effort is normal, so
012406
20-111
(9)
TESTING AND ADJUSTING ADJUSTING ENGINE STOP SOLENOID
012406
3. Replacing and adjusting solenoid
1) Install ball joint (7) to solenoid (6), then
secure with locknut (8).
fl Check that the starting switch is OFF
before doing this.
Locknut:
2.94 – 4.90 Nm {0.3 – 0.5 kgm}
2) Install solenoid (6) to bracket (9).
fl Check that the paint on the solenoid
mounting surface of the bracket (hatched
portion in View Z) has been removed. If
there is any paint remaining, remove it
completely.
20-111-1
(9)
TESTING AND ADJUSTING ADJUSTING ENGINE STOP SOLENOID
20-111-2
(9)
TESTING AND ADJUSTING ADJUSTING ENGINE STOP SOLENOID
012406
8) Turn the starting switch OFF and measure
actuation dimension d of cut-off lever (1).
• Actuation dimension d: 25 mm
20-111-3
(9)
TESTING AND ADJUSTING ADJUSTING ENGINE STOP SOLENOID
20-111-4
2
TESTING AND ADJUSTING ADJUSTING ENGINE STOP SOLENOID
012406
justing solenoid.
• If the operating effort is more than 9.8 N
{1.0 kg}:
The operating effort is abnormal, so
go on to Step 2. Reducing operating
effort.
20-111-5
(9)
TESTING AND ADJUSTING ADJUSTING ENGINE STOP SOLENOID
20-111-6
7
TESTING AND ADJUSTING ADJUSTING ENGINE STOP SOLENOID
012406
4) Turn the starting switch to the "ON" posi-
tion to turn on solenoid (7) and measure
dimension "e" when solenoid (7) operates,
then fix rod 2 (11) with the locknuts
fl Dimension "e" when solenoid operates:
307 mm
fl When the starting switch is turned to
the "ON position, solenoid (7) may not
be turned on [if rod 2 (11) was fully ex-
tracted (to position "A" = FREE position)
when the starting switch was turned to
the "OFF" position previous time].
In this case, push rod 2 (11) toward so-
lenoid (7). (If the starting switch is kept
at the "ON" position with the rod ex-
tracted, solenoid (7) will burn. Take care.)
fl Part C: Left-handed screw, Part D: Right-
handed screw
20-111-7
7
TESTING AND ADJUSTING ADJUSTING ENGINE STOP SOLENOID
"h").
fl Dimension h: 25 mm
20-111-8
7
TESTING AND ADJUSTING ADJUSTING ENGINE STOP SOLENOID
012406
20-111-9
7
TESTING AND ADJUSTING ADJUSTING STEERING, DIRECTIONAL, GEAR SHIFT LEVER
ADJUSTING STEERING,
DIRECTIONAL, GEAR SHIFT
LEVER
Serial No. B20001 – B30000, 50001 – 50200
012406
BDD00071
20-112
7
TESTING AND ADJUSTING ADJUSTING STEERING, DIRECTIONAL, GEAR SHIFT LEVER
ADJUSTING STEERING,
DIRECTIONAL, GEAR SHIFT
LEVER
Serial No.: B30001 – B40000, 50201 and up
012406
BDD00071
20-113-1
(9)
TESTING AND ADJUSTING ADJUSTING STEERING, DIRECTIONAL, GEAR SHIFT LEVER
BED00057
20-113-2
(9)
TESTING AND ADJUSTING TESTING MAIN BRAKE AND PARKING BRAKE
012406
fl If the inching pedal is released suddenly
in Step 7), the machine may move
momentarily, but if the machine does
not move when it is released slowly, the
braking effect is normal.
20-114
(9)
TESTING AND ADJUSTING TESTING MAIN BRAKE AND PARKING BRAKE
20-115
7
TESTING AND ADJUSTING TESTING WEAR OF BRAKE LINING AND CLUTCH LINING
012406
2. Testing wear of clutch lining
1) Start the engine and set the parking brake
lever to the FREE position.
¤ Check that the directional lever is at
neutral. Never operate the lever to the
forward or reverse direction or make the
machine move during operation.
2) Set the steering lever to the neutral position
and measure protrusion b of clutch piston
(2) from the end face of the case.
fl If dimension b is greater than 39 mm,
the clutch lining is worn, so replace the
lining.
20-116
(9)
ADJUSTING BRAKE, CLUTCH LEVER
TESTING AND ADJUSTING ASSEMBLY AND LINING CLEARANCE
20-116-1
(9)
ADJUSTING BRAKE, CLUTCH LEVER
TESTING AND ADJUSTING ASSEMBLY AND LINING CLEARANCE
012406
3) Assemble left and right lever assemblies (9)
to clutch shaft (7).
4) Align the serration of the shaft and lever
when installing to make clearance b between
clutch piston (11) and roller (10) of the lever
assembly as small as possible.
fl Check that the protrusion of clutch piston
(11) is 3.0 mm (when pulled in fully)
before starting adjustment.
fl Make the maximum value of clearance
b less than 14 mm.
If it is more than 14 mm, turn the
meshing of the serration one notch and
install again.
5) Push the lever fully into the serration, then
tighten lock bolt (12).
Lock bolt:
53.9 – 122.5 Nm {5.5 – 12.5 kgm}
20-116-2
(9)
ADJUSTING BRAKE, CLUTCH LEVER
TESTING AND ADJUSTING ASSEMBLY AND LINING CLEARANCE
20-116-3
(9)
ADJUSTING BRAKE, CLUTCH LEVER
TESTING AND ADJUSTING ASSEMBLY AND LINING CLEARANCE
012406
• Because of the structure of the link, if the
clearance is adjusted with the adjustment bolt
after the brake lining is worn, the main brake is
adjusted, but the parking brake is not adjusted.
(See the diagram on the right.)
20-116-4
(9)
TESTING AND ADJUSTING ADJUSTING BRAKE PEDAL LINKAGE
BED00041
3. Adjust the length of rod (5) to dimension "d",
then install to lever (6).
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.
20-116-5
(9)
TESTING AND ADJUSTING ADJUSTING INCHING PEDAL LINKAGE
5 7 3
6 4
BED00043
012406
3. Turn only joint (7) and connect rod (3) and rod
(5).
20-116-6
(9)
TESTING AND ADJUSTING 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.
20-116-7
(9)
TESTING AND ADJUSTING ADJUSTING PARKING BRAKE LINKAGE
012406
20-116-8
(9)
ADJUSTING WORK EQUIPMENT CONTROL
TESTING AND ADJUSTING LINKAGEAND SAFETY LEVER LINKAGE
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
fl Dimension "c": 91 mm
9
4
e,f d
5
BDD00065
20-117
(9)
TESTING AND ADJUSTING TESTING AND ADJUSTING TRACK SHOE TENSION
20-123
(9)
TESTING AND ADJUSTING MEASURING LEAKAGE INSIDE CYLINDER
1. Measurement posture
1) Blade lift cylinder
• Set the front of the track on a block,
then fully extend the cylinder rod.
2) Blade tilt cylinder
• Fully extend the cylinder rod, and lower
the tip of the blade to the ground.
3) Blade angle cylinder
• Fully extend the angle cylinder rod, and
lower the blade to the ground.
2. Measuring
1) Disconnect the head piping, and block the
piping at the chassis end with a blind plug.
¤ Be careful not to disconnect the piping
at the bottom end.
012406
2) Start the engine, run the engine at high
idling, and apply the relief pressure to the
bottom end of the cylinder.
3) Wait for 30 seconds, then measure the
amount of leakage over the next 1 minute.
20-124
(9)
TESTING AND ADJUSTING TESTING AND ADJUSTING OPERATOR'S CAB
Length: 3,000 mm
ii) Secure the inside end of the hose to the
top of the back seat (2) with a tape.
iii) Remove the lock lever of the sash glass
on the side of the cab.
iv) Insert the other end of the hose in the
bolt hole and take it out.
v) Seal the hole of sash glass with tape.
vi) Bend the hose in the shape of letter U
and fill the hose with water up to about
the half level.
vii) Set the water level in the vinyl hose out
of the cab to that in the cab.
viii)Run the engine at high idling and meas-
ure water level difference.
(Pa {mmH2O})
fl Inside of cab: ”Negative pressure”
Out of cab: ”Atmospheric pressure”
20-127
(8)
TESTING AND ADJUSTING "OPEN" AND "CLOSE" LOCK AND
TESTING AND ADJUSTING STEADY REST OF OPERATOR'S CAB DOOR
1) Check of condition
i) Check the installed height of damper
rubber (1). (Check both sides, 4 pieces
on each.)
• Stick adhesive tape 1, etc. to the
contact face of damper rubber (1)
and open and close the door 2 - 3
times. Then, check the contact face
of adhesive tape 1 against the op-
erator's cab.
Normal: When the door is closed, the
damper rubber comes in con-
tact lightly.
Abnormal: When the door is closed, the
damper rubber does not come
in contact or comes in contact
so strongly that the adhesive
tape is removed.
ii) Check the relationship between the door
notch and striker (on both sides).
012406
• Close door (2) and check the engag-
ing condition of latch (3) and striker
(4).
fl Check deviation a of latch center
x and striker center y from each
other from the direction of A.
2) Adjusting
i) Adjusting height of damper rubber
20-128
(8)
TESTING AND ADJUSTING "OPEN" AND "CLOSE" LOCK AND
TESTING AND ADJUSTING STEADY REST OF OPERATOR'S CAB DOOR
1) Check of condition
i) Check the relationship between open
lock latch (3) and striker (4) from the
direction of B.
fl Check part b to see if the claw of
latch (6) rides over the bent part of
striker (4). (If normal, the claw does
012406
20-129
(8)
TROUBLESHOOTING
20-201
(9)
2
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
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.
012406
ure or other unnecessary parts will be disas- Confirm the extent of the failure yourself, and
sembled. judge whether to handle it as a real failure or as
• It will become impossible to find the cause a problem with the method of operation, etc.
of the failure. fl When operating the machine to reenact the
It will also cause a waste of manhours, parts, or troubleshooting symptoms, do not carry out
oil or grease, and at the same time, will also lose any investigation or measurement that may
the confidence of the user or operator. make the problem worse.
For this reason, when carrying out troubleshoot- 5. Troubleshooting
ing, it is necessary to carry out thorough prior Use the results of the investigation and inspec-
investigation and to carry out troubleshooting in tion in Items 2 – 4 to narrow down the causes of
accordance with the fixed procedure. failure, then use the troubleshooting flowchart to
2. Points to ask user or operator locate the position of the failure exactly.
1) Have any other problems occurred apart from fl The basic procedure for troubleshooting is
the problem that has been reported? as follows.
2) Was there anything strange about the ma- 1) Start from the simple points.
chine before the failure occurred? 2) Start from the most likely points.
3) Did the failure occur suddenly, or were there 3) Investigate other related parts or infor-
problems with the machine condition before mation.
this? 6. Measures to remove root cause of failure
4) Under what conditions did the failure occur? Even if the failure is repaired, if the root cause of
5) Had any repairs been carried out before the the failure is not repaired, the same failure will
failure? occur again.
When were these repairs carried out? To prevent this, always investigate why the prob-
6) Has the same kind of failure occurred be- lem occurred. Then, remove the root cause.
fore?
3. Check before troubleshooting
1) Check for symptoms of any abnormality in
the machine.
2) Check the CHECKS BEFORE STARTING items.
20-202
2
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
Step 1
Examination, confirmation of symptoms
Step 2
Determining probable location of cause
Step 3
Preparation of troubleshooting tools
Step 6
Re-enacting failure
Step 4 Step 5
Go to jobsite Ask operator questions to confirm details of
failure.
20-203
2
(9)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
012406
ful when handling wiring harnesses.
20-204
2
(9)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
20-205
2
(9)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
‡ 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.
012406
20-206
2
(9)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
‡ 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.
position.
20-207
2
(9)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
012406
[2] Dry the inside of the connector with a dryer.
If water gets inside the connector, use a dryer
to dry the connector.
fl Hot air from the dryer can be used, but
regulate the time that the hot air is used
in order not to make the connector or
related parts too hot, as this will cause
deformation or damage to the connec-
tor.
20-208
2
(9)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
20-209
2
(9)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
012406
should be confirmed with special test equipment.
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from en-
tering. If the opening is left open or is blocked
with a rag, there is danger of dirt entering or of
the surrounding area being made dirty by leak-
ing oil so never do this.
Do not simply drain oil out on to the ground,
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
20-210
2
(9)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.
012406
7) Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the ma-
chine, carry out oil cleaning to remove the sludge
or contaminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3µ) particles that the filter
built into the hydraulic equipment cannot re-
move, so it is an extremely effective device.
20-211
2
(9)
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
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
12. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace
equipment
Electrical
13. Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace
012406
14. Check for looseness, corrosion of starting motor terminal, —
wiring Tighten or replace
15. Check operation of gauges — Repair or replace
Hydraulic, mechani-
20-212
2
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
20-213
2
(9)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
<Example>
[1] M-4. CAUTION items light up or flash
[3]
YES
Defective monitor panel Replace
ªA 2
Defective contact, or
Is voltage disconnection in wiring harness
YES between CN49 between CN49 (4) - CN31 (4) -
(4) and chassis 3 YES CN17 (5) - alternator terminal R, Repair or
ground normal? or same wiring harness - CN16 replace
Is voltage between
(2) - starting motor terminal R -
• 10 - 30V alternator terminal
1 battery relay short circuiting with
• Start engine. NO R and chassis chassis ground
Does engine oil ground normal?
Defective alternator or
pressure caution Repair
• 10 - 30V NO defective regulator
lamp also light
up? • Remove wiring
harness connected to alternator terminal R.
• Start engine. ªB 4 YES • Start engine.
Defective monitor panel Repair
When cranking, is
voltage between
Defective contact, or
NO CN49 (5) and chassis disconnection in wiring
ground normal? Repair or
harness between CN49 (5)
NO replace
• 10 - 30V - CN31 (5) - CN32 (8) -
• Turn starting starting switch terminal C
switch ON.
012406
[4] fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.
20-214
2
(9)
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
012406
(cab specification) (cab specification)
CN5 — 1 Front right lamp D6 CN23 X 3 Neutral limit switch K6
CN5 1 Left rear speaker I9 CN24 — 1 J8
— (cab specification) Horn switch
CN6 — 1 Front left lamp E6 CN24 — 1 Service power source J4
CN6 — 1 Left rear speaker J8 CN26 KES 4 J3
(cab specification) Intermediate connector
CN7 — 1 Horn D6 CN27 X 3 Intermediate connector J3
Additional lamp power source H9
CN7 — 1 (cab specification) J8 CN28 X 2 Power train oil temperature sensor I3
CN8 X 2 Intermediate connector F1 CN30 — 2 Intermediate connector K4
Room lamp I3
CN8 — 1 (cab specification) I9 CN31 SWP 16 Intermediate connector D7
Washer motor I3
CN9 KES 2 (cab specification) E6 CN32 SWP 16 Intermediate connector D7
Front wiper motor I3
CN9 — 4 (cab specification) G9 CN33 X 4 Intermediate connector D6
CN10 KES 2 Washer motor F7 CN35 — 6 Intermediate connector B6
(cab specification)
CN10 9 4 Magnet relay
— Radio (cab specification) H9 CN36 KES (air conditioner specification) A7
CN11 Washer motor Air conditioner relay
KES 2 (cab specification) E6 CN37 KES 4 (air conditioner specification) A7
CN11 Left wiper switch
— 6 (cab specification) K1 CN38 KES 3 Bimetal timer A6
Washer motor Blower resistor
CN12 KES 2 (cab specification) F7 CN39 KES 3 (air conditioner specification) D6
CN12 Front wiper switch
— 2 (cab specification) K2 CN41 M 2 Buzzer A8
CN13 6 Intermediate connector 4 Pressure switch
SWP E1 CN43 KES (air conditioner specification) C6
CN13 Right wiper switch Blower switch
— 6 (cab specification) K2 CN44 KES 4 (air conditioner specification) A8
CN14 1 Air conditioner compressor 3 Air conditioner switch
X (air conditioner specification) G2 CN45 KES (air conditioner specification) A8
CN14 Rear wiper switch
— 6 (cab specification) K2 CN46 KES 4 Glow switch D8
20-215-1
7
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
012406
(cab specification)
CN5 DT 2 Front left lamp D6 CN24 — 1 Horn switch K8
CN5 — 1 Left rear speaker J9 CN24 — 1 K4
(cab specification) Service power source
CN6 DT 2 Front right lamp D5 CN25 — 1 Backup power sorce K4
CN6 — 1 Left rear speaker J9 CN26 KES 4 J3
(cab specification) Intermediate connector
CN7 — 1 Horn D6 CN27 DT 3 Backup alarm K6
CN7 Additional lamp power source H9
— 1 (cab specification) J8 CN28 DT 2 Power train oil temperature sensor I3
CN8 J3
X 2 Intermediate connector B5 CN30 — 2 Intermediate connector D7
CN8 Room lamp I3
— 1 (cab specification) I9 CN31 SWP 12 Intermediate connector D7
CN9 Washer motor I3
KES 2 (cab specification) E6 CN32 SWP 12 Intermediate connector D7
CN9 Front wiper motor I3
— 4 (cab specification) G9 CN33 DT 4 Intermediate connector D6
CN10 2 Washer motor F7 CN36 KES 4 Magnet relay A7
KES (cab specification) (air conditioner specification)
CN10 Air conditioner relay
— 9 Radio (cab specification) H9 CN37 KES 4 (air conditioner specification) A7
CN11 Washer motor
KES 2 (cab specification) E6 CN38 DT 3 Bimetal timer A6
CN11 Left wiper switch Blower resistor
— 6 (cab specification) K1 CN39 KES 3 (air conditioner specification) D6
CN12 Washer motor
KES 2 (cab specification) F7 CN40 SWP 6 Gear speed pilot lamp B9
CN12 Front wiper switch
— 2 (cab specification) K1 CN41 M 2 Buzzer A8
CN13 SWP 6 Intermediate connector E6 CN43 KES 4 Pressure switch C6
(air conditioner specification)
CN13 Left wiper switch Blower switch
— 6 (cab specification) K2 CN44 KES 4 (air conditioner specification) A9
CN14 2 Air conditioner compressor 3 Air conditioner switch
DT-T (air conditioner specification) G2 CN45 KES (air conditioner specification) A8
CN14 Rear wiper switch
— 6 (cab specification) K2 CN46 KES 4 Glow switch D8
20-215-3
(9)
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
20-215-4
(9)
TROUBLESHOOTING CONNECTOR ARRENGEMENT DIAGRAM
012406
20-215-5
(9)
TROUBLESHOOTING CONNECTOR ARRENGEMENT DIAGRAM
012406
20-215-6
(9)
TROUBLESHOOTING CONNECTOR ARRENGEMENT DIAGRAM
012406
20-215-7
(9)
TROUBLESHOOTING CONNECTOR ARRENGEMENT DIAGRAM
012406
20-215-8
(9)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
X type connector
No. of
pins T-adapter
Male (female housing) Female (male housing) Part No.
2 799-601-7020
3 799-601-7030
4 799-601-7040
6 799-601-7050
8 799-601-7060
12 799-601-7310
14 799-601-7070
20-217
(9)Å Å
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
X type connector
No. of
pins T-adapter
Male (female housing) Female (male housing) Part No.
16 799-601-7320
012406
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
20-218
Å (9) Å
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
M type connector
No. of
pins T-adapter
Male (female housing) Female (male housing) Part No.
2 799-601-7090
3 799-601-7110
012406
4 799-601-7120
6 799-601-7130
8 799-601-7390
20-219
(9)Å Å
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
S type connector
No. of
pins T-adapter
Male (female housing) Female (male housing) Part No.
8 799-601-7140
10
799-601-7150
(White)
012406
Part number: 08056-11071 Part number: 08056-11081
12
799-601-7350
(White)
16
799-601-7330
(White)
20-220
Å (9) Å
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
20 Tro
ublesh
ooting
S type connector
No. of
pins T-adapter
Male (female housing) Female (male housing) Part No.
10
—
(Blue)
— —
12
799-601-7160
(Blue)
012406
16
799-601-7170
(Blue)
20-221
(9) Å Å
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
5 799-601-2710
012406
Body part number: 79A-222-2620 Body part number: 79A-222-2610
(Q’ty: 5) (Q’ty: 5)
9 799-601-2950
13 799-601-2720
20-222
Å (9) Å
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
17 799-601-2730
21 799-601-2740
20-223
(9) Å Å
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
8 799-601-7180
12 799-601-7190
012406
Housing part number: 79A-222-3440
—
(Q’ty: 5)
16 799-601-7210
20 799-601-7220
20-224
Å (9) Å
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
10 799-601-7510
12 799-601-7520
14 799-601-7530
18 799-601-7540
20 799-601-7550
20-225
(9) Å Å
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
L type connector
No. of
pins T-adapter
Male (female housing) Female (male housing) Part No.
2 —
— —
Connector for PA
No. of
pins T-adapter
Male (female housing) Female (male housing) Part No.
012406
9 —
— —
Bendix MS connector
No. of
pins T-adapter
Male (female housing) Female (male housing) Part No.
10 799-601-3460
— —
20-226
Å (9) Å
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
2 —
Part number: 08027-10210 (Natural color) Part number: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
012406
4 —
Part number: 08027-10410 (Natural color) Part number: 08027-10460 (Natural color)
08027-10420 (Black) 08027-10470 (Black)
6 —
Part number: 08027-10610 (Natural color) Part number: 08027-10660 (Natural color)
08027-10620 (Black) 08027-10670 (Black)
20-227
(9) Å Å
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
8 —
Part number: 08027-10810 (Natural color) Part number: 08027-10860 (Natural color)
08027-10820 (Black) 08027-10870 (Black)
012406
5 799-601-7360
— —
6 799-601-7370
— —
20-228
Å (9) Å
20 Tr
oubl TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
esho
oting
F type connector
No. of
pins T-adapter
Male (female housing) Female (male housing) Part No.
4 —
— —
012406
20-229
(9) Å Å
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9210
799-601-9210
012406
Part number: 08191-11201, 08191-12202, Part number: 08191-13101, 08191-13102,
08191-11205, 08191-12206 08191-13105, 08191-13106
Pin (male terminal) Pin (female terminal)
799-601-9220
799-601-9220
20-230
Å (9) Å
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9230
799-601-9230
012406
799-601-9240
799-601-9240
20-231
(9) Å Å
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9250
799-601-9250
012406
Part number: 08191-52201, 08191-52202 Part number: 08191-53101, 08191-53102
Pin (male terminal) Pin (female terminal)
799-601-9260
799-601-9260
20-232
Å (9) Å
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9270
799-601-9270
012406
799-601-9280
799-601-9280
20-233
(9) Å Å
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9290
799-601-9290
012406
Part number: 08191-92203, 08191-92204, Part number: 08191-93103, 08191-93104,
08191-92205, 08191-92206 08191-93105, 08191-93106
20-234
Å (9) Å
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
DT Series connector
No. of
pins T-adapter
Body (plug) Body (receptacle) Part No.
2 799-601-9020
Part number: 08192-12200 (normal type) Part number: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
012406
Part number: 08192-13200 (normal type) Part number: 08192-13100 (normal type)
08192-23200 (fine wire type) 08192-23100 (fine wire type)
4 799-601-9040
Part number: 08192-14200 (normal type) Part number: 08192-14100 (normal type)
08192-24200 (fine wire type) 08192-24100 (fine wire type)
6 799-601-9050
Part number: 08192-16200 (normal type) Part number: 08192-16100 (normal type)
08192-26200 (fine wire type) 08192-26100 (fine wire type)
20-235
(9) Å Å
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
DT Series connector
No. of
pins T-adapter
Body (plug) Body (receptacle) Part No.
8GR : 799-601-9060
8B : 799-601-9070
8
8G : 799-601-9080
8BR : 799-601-9080
Part number: 08192-1820 (normal type) Part number: 08192-1810 (normal type)
08192-2820 (fine wire type) 08192-2810 (fine wire type)
012406
12GR : 799-601-9110
12B : 799-601-9120
10
12G : 799-601-9130
12BR : 799-601-9140
Part number: 08192-1920 (normal type) Part number: 08192-1910 (normal type)
08192-2920 (fine wire type) 08192-2910 (fine wire type)
20-236
Å (9) Å
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
2 799-601-9010
1 —
Part number: 08192-31200 (Contact size #12) Part number: 08192-31100 (Contact size #12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
20-237
(9) Å Å
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
DT Series connector
No. of
pins T-adapter
Body (plug) Body (receptacle) Part No.
24 799-601-9360
40
799-601-9350
(A)
012406
— Part number: 7821-93-3120
40
799-601-9350
(B)
20-238
Å (9) Å
TESTING AND ADJUSTING T-ADAPTER TABLE
T-ADAPTER TABLE
fl The part Nos. of the T-adapter boxes and T-adapters are shown in the columns and those of the
wiring harness checker assemblies are shown in the lines.
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
Port No. Connector type Pin No.
012406
799-601-3460 BENDIX (MS) 10P fi fi
799-601-3510 BENDIX (MS) 5P fi fi
799-601-3520 BENDIX (MS) 14P fi fi
799-601-3530 BENDIX (MS) 19P fi fi
799-601-2910 BENDIX (MS) 14P fi fi
799-601-3470 CASE fi
799-601-2710 MIC 5P fi fi fi fi
799-601-2720 MIC 13P fi fi fi fi
799-601-2730 MIC 17P fi fi fi fi fi fi fi
799-601-2740 MIC 21P fi fi fi fi fi fi fi
799-601-2950 MIC 9P fi fi fi fi
799-601-2750 ECONO 2P fi fi
799-601-2760 ECONO 3P fi fi
799-601-2770 ECONO 4P fi fi
799-601-2780 ECONO 8P fi fi
799-601-2790 ECONO 12P fi fi
799-601-2810 DLI 8P fi fi
799-601-2820 DLI 12P fi fi
799-601-2830 DLI 16P fi fi
799-601-2840 Extension cable fi fi fi
799-601-2850 CASE fi
799-601-7010 X 1P fi fi
799-601-7020 X 2P fi fi fi fi
799-601-7030 X 3P fi fi fi fi
799-601-7040 X 4P fi fi fi fi
20-240
(9)
TESTING AND ADJUSTING T-ADAPTER TABLE
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.
799-601-7050 SWP 6P fi fi fi
799-601-7060 SWP 8P fi fi fi
799-601-7310 SWP 12P fi
799-601-7070 SWP 14P fi fi
799-601-7320 SWP 16P fi
799-601-7080 M 1P fi fi
799-601-7090 M 2P fi fi fi fi
799-601-7110 M 3P fi fi fi fi
799-601-7120 M 4P fi fi fi fi
799-601-7130 M 6P fi fi fi fi
799-601-7340 M 8P fi
799-601-7140 S 8P fi fi fi fi
799-601-7150 S 10P-White fi fi fi fi
799-601-7160 S 12P-Blue fi fi fi
799-601-7170 S 16P-Blue fi fi fi fi
799-601-7330 S 16P-White fi
799-601-7350 S 12P-White fi
012406
799-601-7180 AMP040 8P fi
799-601-7190 AMP040 12P fi fi
799-601-7210 AMP040 16P fi fi fi fi
799-601-7220 AMP040 20P fi fi fi fi
799-601-7230 Short connector X-2 fi fi fi fi
799-601-7240 Case fi fi
799-601-7270 Case fi
799-601-7510 070 10P fi
799-601-7520 070 12P fi
799-601-7530 070 14P fi
799-601-7540 070 18P fi
799-601-7550 070 20P fi
799-601-7360 Relay connector 5P fi
799-601-7370 Relay connector 6P fi
799-601-7380 JFC connector 2P fi
799-601-9010 DTM 2P fi fi
799-601-9020 DT 2P fi fi
799-601-9030 DT 3P fi fi
799-601-9040 DT 4P fi fi
799-601-9050 DT 6P fi fi
799-601-9060 DT 8P-Gray fi fi
799-601-9070 DT 8P-Black fi fi
799-601-9080 DT 8P-Green fi fi
799-601-9090 DT 8P-Blown fi fi
799-601-9110 DT 12P-Gray fi fi
20-241
(9)
TESTING AND ADJUSTING T-ADAPTER TABLE
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.
799-601-9120 DT 12P-Black fi fi
799-601-9130 DT 12P-Green fi fi
799-601-9140 DT 12P-Blown fi fi
799-601-9210 HD30 18-8 fi fi
799-601-9220 HD30 18-14 fi fi
799-601-9230 HD30 18-20 fi fi
799-601-9240 HD30 18-21 fi fi
799-601-9250 HD30 24-9 fi fi
799-601-9260 HD30 2-16 fi fi
799-601-9270 HD30 24-21 fi fi
799-601-9280 HD30 24-23 fi fi
799-601-9290 HD30 24-31 fi fi
012406
799-601-9310 Plate For HD30 fi fi fi
799-601-9320 For measuring box For DT, HD fi fi fi
799-601-9330 Case fi
799-601-9340 Case fi
799-601-9350 DRC26 40P fi
799-601-9360 DRC26 24P fi
799-601-9410 For NE, G sensor 2P fi
799-601-9420 For boost pressure,
3P
fuel fi
799-601-9430 PVC socket 2P fi
AMP 2-963215-1
799-601-9710 AMP 2-963217-1 16P fi
for HST controller
AMP 1-963215-1
799-601-9720 AMP 1-963217-1 16P fi
for HST controller
AMP 2-1437285-2
799-601-9730 AMP 2-1437285-8 26P fi
for HST controller
20-242
(9)
TROUBLESHOOTING OF ENGINE SYSTEM
(S MODE)
20-251
2
(9)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
[Questions]
Sections [A] + [B] in the chart on the right corre-
spond to the items where answers can be ob-
tained from the user. The items in [B] are items
that can be obtained from the user, depending
on the user’s level.
[Check items] Causes
The serviceman carries out simple inspection to
narrow down the causes. The items under [C] in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information [A] that he has obtained from the
user and the results of [C] that he has obtained
012406
from his own inspection.
[Troubleshooting] (1) (2) (3)
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
(a)
Question
A
[A] (b)
(c)
(d)
(e)
B
[B]
C
[C]
Check item
i
ii
shooting
Trouble-
iii
20-252
2
(9)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
n)
ctio
for locating the cause of the failure. How-
inje
ever, do not use this when making calcula-
sive
tions to narrow down the causes.
e
renc
*2. Use the # in the Cause column as reference
xces
zle
noz
ent
for [Degree of use (Operated for long pe-
erfe
p (e
r
g
inde
lem
tion
riod)] in the [Questions] section as reference.
imin
, int
pum
er e
c
, cyl
As a rule, do not use it when calculating the
rger
inje
on t
ion
lean
012406
ring
points for locating the cause, but it can be
cha
ecti
zed
ject
air c
included if necessary to determine the order
urbo
, sei
ston
r inj
e in
for troubleshooting.
rope
ged
ged
ctiv
n pi
ed t
Clog
Clog
Defe
Wor
Seiz
Imp
*1
ª1 Confirm recent repair history
*2
ª2 Degree of use Operated for long period
20-253
2
(9)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
ead
d)
ion)
eize
• Excessive injection of fuel.
yl. h
ject
er s
nd c
e in
lung
ck, p t
a
er a
e se
essiv
elem rence
harg
zle
valv
(exc
noz
p (ra
cylin nt
terfe
rboc
lve,
e
der
r
ed m ce
ion
ump
le
timin
pum
r, in
aran
u
f
f va
f
t
en t
u
c
p
rope ized inje
n pis cleaner
arge
ct o
e cle
ion
rope jection
ion
e
,
ring
betw
Legend
onta
ject
ject
logg
Clog urboch
valv
: Possible causes (judging from Questions and check items)
ton
, se
in
e in
e in
air
age
c
d, c
: Most probable causes (judging from Questions and Check items)
e
ged
ged
ctiv
ctiv
ctiv
ed t
leak
she
: Possible causes due to length of use (used for a long period)
Clog
Defe
Defe
Defe
Wor
Seiz
Imp
Imp
Cru
Air
: Items to confirm the cause.
012406
Blue under light load
Engine oil must be added more frequently
Suddenly
Power was lost
Gradually
Non-specified fuel has been used
Dust indicator is red
Interference sound heard around turbocharger
Blow-by gas is excessive
Engine pickup is poor and combustion is irregular
When exhaust manifold is touched immediately after
Check items
on reduced cylinders
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Adjust
Repair
Clean
Remedy
20-254
2
(9)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
5 causes
Step 1
Clarify the relationship between the three
symptoms in the [Questions] and [Check items]
section and the 5 Cause items in the vertical
column.
Three symptoms
012406
Step 2
Add up the total of and marked where the
horizontal lines for the three symptoms and the
vertical columns for the causes intersect.
(1) Clogged air cleaner element:
(2) Air leakage between turbocharger
and cyl. head:
(3) Clogged, seized injection nozzle:
(4) Defective contact of valve, valve seat:
(5) Worn piston ring, cylinder:
Step 3
The calculations in Step 2 show that the closest
relationship is with [Clogged air cleaner
element]. Follow this column down to the
troubleshooting area and carry out the
troubleshooting item marked . The Remedy is
given as [Clean], so carry out cleaning, and the
exhaust gas color should return to normal.
20-255
2
(9)
TROUBLESHOOTING S-1
t
elem alve sea
Charging rate
Ambient 100% 90% 80% 75% 70%
r
filte
temperature
,v
ent
er
20°C 1.28 1.26 1.24 1.23 1.22
uze
r
r
alve
inde
eate
rain
p ga
0°C 1.29 1.27 1.25 1.24 1.23
v
, cyl
air h
r, st
f
aner
act o
pum
–10°C 1.30 1.28 1.26 1.25 1.24
filte
ring
ake
ir cle
cont
• The specific gravity should exceed the value for the
d
fuel
l int
ston
e e
charging rate of 70% in the above table.
f
ctive
trica
ged
ged
ged
n pi
• In cold areas the specific gravity must exceed the value
Defe
Clog
Clog
Clog
Elec
Wor
for the charging rate 75% in the avobe table.
Confirm recent repair history
Degree of use of machine Operated for long period
Gradually became worse
Ease of starting
Starts when warm
Questions
012406
Engine oil must be added more frequently
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
Blow-by gas is excessive
Check items
Replace
Correct
Clean
Clean
Clean
Remedy
Replace Defe
ctive
Replace regu
Legend
Defe lato
ctive r
Replace Defe a ltern
ctive ator
Replace Defe or d
eter
ctive iora
ªAdjust Defe injec ted
batt
tive tion ery
nozz
Replace Defe
injec
tion le
tive t i m
Correct Leak injec
tion
ing
age, pum
Clean c l o
TROUBLESHOOTING
2
(9)
S-1
20-257
TROUBLESHOOTING S-2
ed)
KIND OF
seiz
FLUID -22 -4 14 32 50 68 86 104˚F
-30 -20 -10 0 10 20 30 40˚C
ger
key
nk
ASTM D975 No.2
el ta
u
Diesel fuel
aft,
l
ck, p
ston
ASTM D975 No.1
e sh
in fu
p pi
p (ra
ng
iner
driv
oid
e
ole
pipi
m
fl In winter, if ASTM D975 No.1 diesel oil is
n
stra
pum
olen
i
stra
u
nk
mp
h
p
not available, a 50-50 mixture of ASTM D975
fuel
her
in ta
ump
eed
n pu
ut s
ed
ion
reat
king
l us
en f
c
fuel
ject
p
ctio
el fi
Legend
l
air b
feed
e
r fue
, lea
brok
u
e in
inje
f
f
e
ged
rope
ged
ged
ged
ctiv
: Most probable causes (judging from Questions and Check items)
ctiv
ffici
ed,
ken
: Possible causes due to length of use (used for a long period) Clog
Defe
Clog
Defe
Clog
Clog
Insu
Seiz
Imp
012406
Bro
Remedy
20-258
2
(9)
TROUBLESHOOTING S-2
.)
being injected)
r, etc
)
tuck
leve
cap
General causes why exhaust smoke comes out but
er s
pray
cker
engine does not start
lung
tank
stem
ve s
ater
e, ro
k, p
ttery
fuel
i
ir he
(valv
el sy
t
r
c
• Lack of rotating force due to defective electri-
line
defe
(rac
ent
iner
le in
d ba
ke a
in fu
cal system
tem
er
der
ump
zle,
elem
rain
stra
r ho
rate
e sys
• Insufficient supply of fuel
inta
n
r
noz
i
i
, cyl
a
on p
s
• Insufficient intake of air
ump
terio
e
ner
valv
ed
ical
ing,
h
lter,
tion
reat
ring
l us
a
ecti
ectr
ed p
e
ken
ogg
e
el fi
Legend
d
l
njec
air b
air c
r fue
j
ston
e or
, bro
e in
e el
: Possible causes (judging from Questions and check items)
e, cl
u
f e
f
rope
ged
ged
ged
: Most probable causes (judging from Questions and Check items)
ged
ged
ctiv
ctiv
ctiv
ctive
n pi
kag
: Possible causes due to length of use (used for a long period)
Defe
Defe
Defe
Clog
Clog
Clog
Clog
Clog
Wor
Defe
Imp
Lea
: Items to confirm the cause.
Confirm recent repair history
Degree of use of machine Operated for long period
Questions
When fuel lever is placed at FULL position, it does not contact stopper
When engine is cranked with starting motor,
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
There is leakage from fuel piping
When exhaust manifold is touched immediately after starting
engine, temperature of some cylinders is low
When fuel filter is drained, no fuel comes out
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
Speed does not change when operation of certain cylinders is stopped
When fuel cap is inspected directly, it is found to be clogged
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
20-259
2
(9)
TROUBLESHOOTING S-3
ap
y
seat
• Insufficient intake of air
spra
nk c
• Insufficient supply of fuel
lve
el ta
ive
nce
• Improper condition of fuel injection
d va
fect
er
er
in fu
fere
• Improper fuel used
r lin
ung
e an
ent
ng
, de
er
er
nter
rain
pipi
e
hole
e
lem
p pl
rain
valv
zzle
ranc
d
cylin
er, i
p st
er e
fuel
pum
r, st
n no
her
clea
t of
pum
harg
lean
reat
filte
king
ring
ntac
ctio
tion
lve
Legend
air b
feed
air c
urbo
uel
, lea
inje
r va
ston
e co
njec
: Possible causes (judging from Questions and check items)
rope
ged
ged
ged
ged
ged
: Most probable causes (judging from Questions and Check items)
ged
ctiv
ed t
ed i
n pi
: Possible causes due to length of use (used for a long period)
Clog
Clog
Clog
Defe
Clog
Clog
Clog
Seiz
Seiz
Wor
Imp
: Items to confirm the cause.
Confirm recent repair history
Degree of use of machine Operated for long period
Questions
012406
Blue under light load
Color of exhaust gas
Black
Clanging sound is heard from around cylinder head
Mud is stuck to fuel tank cap
Check items
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 compression pressure is measured, it is found to be low
When turbocharger is rotated by hand, it is found to be heavy
When valve clearance is checked directly, it is found to be
outside standard value
When fuel tank cap is inspected directly, it is found to be clogged
When feed pump is operated, operation is too light or too heavy
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
20-260
2
(9)
TROUBLESHOOTING S-4
c.)
• Overheating
r, et
)
tuck
leve
fl If there is overheating and the engine stops,
er s
cker
carry out troubleshooting for overheating.
rod
lung
tank
e, ro
ent
key
ring
ting
k, p
ston
fuel
(valv
• Failure in power train
ipm
aft,
a
nec
c
p pi
f t be
p (ra
g
le in
er
equ
n
tem
er
e sh
rain
con
p ipi
p um
train
in
fl If the engine stops because of a failure in
ksha
r ho
pum
s
nk
r tra
liary
driv
y
p st
in
on,
fuel
the power train, carry out troubleshooting
in ta
er, s
r tra
athe
e
feed
cran
v
gea
ion
pist
pu m
i
p
x
l
for the chassis.
king
pum
p au
v
owe
e
fuel
ject
l
zed
i
c
zed
zed
r
zed
Legend
f
i
air b
feed
ynam
fuel
, lea
pum
e in
in p
fuel
: Possible causes (judging from Questions and check items)
, sei
ent
, sei
, sei
, sei
ged
ged
ged
ged
: Most probable causes (judging from Questions and Check items)
ctiv
en d
ffici
ken
ure
ken
ken
ken
ken
ken
: Possible causes due to length of use (used for a long period)
Clog
Clog
Defe
Clog
Clog
Insu
Brok
Fail
Bro
Bro
Bro
Bro
Bro
Bro
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
Add
20-261
2
(9)
TROUBLESHOOTING S-5
p
le
pum
nozz
• Air in fuel system
eed
• Defective governor mechanism
and
nd f
• Defective electric governor mechanism
mp
nk a
nk
(engine with electric governor)
d pu
el ta
k
el ta
r
l rac
erno
rn o r
n fee
in fu
n fu
o
fl If hunting stops when electric governor rod is
er
gov
ontr
ove
in ta low
wee
iner
wee
rain
hole
disconnected, carry out troubleshooting for the
of g
t of
of c
t bet
o
stra
nk
t bet
p st
is to
chassis.
her
men
ion
i on
i
p um
ircui
,
circu
ilter
reat
eed
erat
erat
just
fuel
c
Legend
air in
air b
feed
g sp
air in
fuel
e ad
e op
e op
: Possible causes (judging from Questions and check items)
ent
idlin
: Most probable causes (judging from Questions and Check items)
ged
ged
ged
ged,
ctiv
ged,
ctiv
ctiv
ffici
: Possible causes due to length of use (used for a long period)
Clog
Clog
Clog
Defe
Defe
Defe
Clog
Insu
Clog
Low
: Items to confirm the cause.
012406
to Operation Manual
Rust, water are found when fuel tank is drained
Leakage from fuel piping
When feed pump is operated,
1) No response, light, return is quick
Check items
improperly adjusted
When control rack is pushed, it is found to be heavy, or
does not return
When fuel cap is inspected directly, it is found to be clogged
When feed pump strainer is inspected directly, it is
found to be clogged
When fuel filter, strainer are inspected directly, they are
found to be clogged
Correct
Correct
Adjust
Adjust
Adjust
Adjust
Clean
Clean
Clean
Remedy
Add
20-262
2
(9)
TROUBLESHOOTING S-6
ent
• Insufficient supply of fuel
stm
ray
seat
• Improper condition of fuel injection
e sp
adju
nk
lve
• Improper fuel used
el ta
ctiv
e
d va
tive
(if non-specified fuel is used, output drops)
renc
in fu
r
defe
c
e an
• Lack of output due to overheating
ung
ng
ent
defe
iner
erfe
iner
r
hole
pipi
e
inde
zle,
lem
p pl
valv
ranc
stra
, int
ge,
stra
noz
fl If there is overheating and lack of output,
fuel
er e
pum
, c yl
her
rger
nka
t of
a
mp
e
ter,
carry out troubleshooting for overheating.
tion
reat
lean
king
ring
ntac
d pu
er li
cha
tion
lve
l
Legend
f i
air b
air c
inje
l lev
fuel
urbo
, lea
e co
r va
ston
njec
: Possible causes (judging from Questions and check items)
f e
: Most probable causes (judging from Questions and Check items)
t fue
rope
ged
ged
ged
ged
ged
ged
ctiv
ed t
n pi
ed i
: Possible causes due to length of use (used for a long period)
Clog
Clog
Clog
Defe
Clog
Clog
Clog
Seiz
Seiz
Wor
Ben
Imp
: Items to confirm the cause.
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
20-263
2
(9)
TROUBLESHOOTING S-7
d)
ad
)
tion
eize
d he
njec
er s
at
• Insufficient intake of air
ray
r an
e se
lung
e sp
ve i
• Improper condition of fuel injection
arge
valv
essi
• Excessive injection of fuel
ctiv
ck, p
renc
och
and
( exc
defe
p (ra
ent
turb
erfe
lve
g
r
ce
inde
mp
lem
zle,
uffle
imin
, int
pum
een
aran
f va
u
z
er e
, cyl
n no
ed m
rger
on t
w
ct o
e cle
ion
ion
t
lean
ir be
ring
ctio
c ha
ecti
onta
ject
ject
logg
Legend
valv
air c
a
inje
urbo
r inj
ston
e in
e in
: Possible causes (judging from Questions and check items)
c
e of
d, c
e
r
: Most probable causes (judging from Questions and Check items)
rope
rope
ged
ctiv
ctiv
ged
ctiv
n pi
ed t
she
kag
: Possible causes due to length of use (used for a long period)
Defe
Defe
Defe
Clog
Clog
Wor
Seiz
Imp
Imp
Cru
Lea
: Items to confirm the cause.
012406
Noise of interference is heard from around turbocharger
Dust indicator lamp is red
Blow-by gas is excessive
Engine pickup is poor and combustion is irregular
When exhaust manifold is touched immediately after
starting engine, temperature of some cylinders is low
Check items
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Adjust
Clean
Remedy
20-264
2
(9)
TROUBLESHOOTING S-8
r
arge
General causes why oil consumption is excessive
och
• Abnormal combustion of oil
Turb
al
d
hea
• External leakage of oil
n se
ace
stem
e
ping l cooler
hos
• Wear of lubrication system
surf
der
oke
er
e sy
r lin
cylin
her
), br
seal
plug
i
or o
reat
k
inde
end
nd
ui de
inta
n or
eal,
ain
er e
or b
ilter
, cyl
bine
m, g
om
ar s
il pa
il dr
il pi
ing
blow
oil f
ther
r
ring
in fr
n re
oole
t tur
(ste
mo
mo
mo
on r
Legend
m
brea
l at
roke
ston
cked
al a
oil c
e fro
e fro
e fro
: Possible causes (judging from Questions and check items)
e fro
lve
pist
a
: Most probable causes (judging from Questions and Check items)
n va
n se
n se
ged
n, b
n pi
t su
kag
ken
kag
kag
kag
ken
: Possible causes due to length of use (used for a long period)
Clog
Wor
Wor
Wor
Wor
Wor
Dus
Lea
Bro
Lea
Lea
Lea
Bro
: Items to confirm the cause.
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
20-265
2
(9)
TROUBLESHOOTING S-9
end
ine
turb
pe
ose
er
n pi
e r
r lin
er h
harg
drai
inde
eath
ide
boc
lack
rger
e gu
, cyl
r, br
t tur
is b
r
cha
oole
ring
valv
ilter
al a
h
oke
Legend
urbo
t
brea
oil c
oil f
ston
e se
lve,
t sm
: Possible causes (judging from Questions and check items)
t
: Most probable causes (judging from Questions and Check items)
ged
n va
ged
ged
ged
ctiv
n pi
aus
: Possible causes due to length of use (used for a long period) Clog
Defe
Clog
Clog
Clog
Wor
Wor
Exh
: Items to confirm the cause.
012406
Questions
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
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
—
20-266
2
(9)
TROUBLESHOOTING S-10
)
tion
ge
ter
on)
njec
linka
el fil
(pist
ive i
g, fu
trol
mp
er
er
cess
l con
pipin
d pu
v
lung
o
ng
y
c
p (ex
spra
f fue
ead
timi
e fee
p
fuel
mp
pum
h
lder
nt o
tion
nsid
from
side
n pu
le ho
stme
injec
tion
i
el in
o
l
Legend
age
a
t i
e
injec
injec
nozz
adju
oil s
fuel
of fu
: Possible causes (judging from Questions and check items)
leak
: Most probable causes (judging from Questions and Check items)
ctive
ctive
ctive
ctive
ctive
ctive
age
rnal
: Possible causes due to length of use (used for a long period) Defe
Defe
Leak
Defe
Defe
Defe
Defe
Exte
: Items to confirm the cause.
Suddenly increased
Black
Exhaust smoke color
White
Seal on injection pump has come off
There is irregular combustion
Check items
Correct
Correct
Correct
Adjust
Adjust
Adjust
Remedy
20-267
2
(9)
TROUBLESHOOTING S-11
et
gask
k
bloc
ing
ler
head
l coo
, O-r
der
g
cylin
ittin
core
ead,
in oi
by p
er h
r tra
oler
s in
Legend
ylind
rack
: Possible causes (judging from Questions and check items)
used
owe
il co
en p
en c
s ca
Brok
Hole
Brok
Inter
012406
Suddenly increased
Oil level
Gradually increased
Hard water is being used as cooling water
Engine oil level has risen, oil is cloudy white
Check items
Remedy
20-268
2
(9)
TROUBLESHOOTING S-12
AMBIENT TEMPERATURE
KIND OF
FLUID -22 -4 14 32 50 68 86 104˚F Causes
-30 -20 -10 0 10 20 30 40˚C
SAE 30
SAE 10W
Engine oil
SAE 10W-30
g
ipin
SAE 15W-40
n
n
l pa
sor
l pa
lic p
ing
sen
e oi
e oi
alve
drau
braz
l
d
sure
nsid
urna
e
tor v
insi
d hy
an
pipe
valv
mp
oil p
pres
pe i
g, jo
il
ilter
iner
gula
she
l pu
in o
lief
Legend ion
il pi
il in
stra
oil f
l
arin
, cru
e re
e re
e oi
e oi
suct
uel
o
012406
of o
n be
ctiv
ctiv
ged
ged
ged
ctiv
ctiv
king
er, f
ken
Defe
Defe
Defe
Defe
Lack
Clog
Clog
Clog
Wor
Wat
Lea
Bro
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
—
Add
20-269
2
(9)
TROUBLESHOOTING S-13
• Water in oil
• Fuel in oil (diluted, and smells of diesel fuel)
• Entry of oil from other component
Causes
ber)
r
ham
ove
ion c
ad c
seal
bust
e he
ent
mp
com
ipm
nsid
ace
n pu
t (pre
e
surf
-ring
equ
leev
ng i
k
i
aske
bloc
njec
seal
pipi
ary
er s
re, O
ad g
g
i
de i
der
hold
l
from
ittin
t
rear
osta
aux
d, he
r co
cylin
insi
by p
zzle
oole
ged
r hea
erm
mp
fuel
Legend
part
side
e no
e pu
ama
ade
linde
e th
oil c
ks in
sm
ctiv
ctiv
ctiv
ctiv
en cy
n, d
kag
ken
Hole
Defe
Defe
Defe
Crac
Wor
Lea
Brok
Bro
012406
: Items to confirm the cause.
Confirm recent repair history
Questions
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
20-270
2
(9)
TROUBLESHOOTING S-14
en)
• Drop in heat dissipation efficiency
ure
e
k et
t op
aug
lley
• Defective cooling circulation system
erat
gas
g
ns
s no
n pu
emp
ture
or fi
ead
r
fl Carry out troubleshooting for chassis.
doe
oole
rn fa
oil t
e
pera
diat
d, h
valv
tat (
g
core
oil c
, wo
ittin
e
sion
d ra
h ea
ump
tem
a t
e
mos
ng w
r
ator
by p
essu
ping
k en
she
mis
der
ater
er p
Legend
ther
, bro
radi
, cru
ooli
cylin
ans
p
e pr
ade
ew
: Possible causes (judging from Questions and check items)
wat
s li
e
in tr
of c
: Most probable causes (judging from Questions and Check items)
ged
ged
ged
sm
ctiv
ctiv
ctiv
belt
ken
ken
: Possible causes due to length of use (used for a long period)
Clog
Defe
Hole
Clog
Defe
Lack
Clog
Defe
Rise
Bro
Bro
Fan
: Items to confirm the cause.
Suddenly overheated
Condition of overheating
Always tends to overheat
Water temperature Rises quickly
gauge Does not go down from red range
Fan belt whines under sudden load
Cloudy white oil is floating on cooling water
012406
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
—
Add
20-271
2
(9)
TROUBLESHOOTING S-15
etc.)
General causes why abnormal noise is made
)
ition
d
d)
ion)
hea
ver,
eize
r
f pos
line
ject
er le
and
er s
• Abnormality due to defective parts
ce
n
out o
der
rock
aran
lung
rger
• Abnormal combustion
ive
e
ylin
c
e
,
• Air sucked in from intake system
oard
e cle
cess
alve
eren
a
ck, p
renc
och
pum ozzle
g, c
m (v
ing b
ash
x
valv
f
p (ra
turb
erfe
n rin
r
p (e
e
n
ackl
yste
lt in
ion
divid
, int
t of
pum
een
isto
n
ject
b
lve s
i
n be
ush
men
rger
fler (
train
etw
of p
ion
ion
n
ic va
ed b
n, fa
i
cha
just
air b
muf
ized
ject
ject
ear
r
Legend
a
ynam
z
urbo
r ge
d fa
e ad
ve w
e in
side
, sei
e in
e
: Possible causes (judging from Questions and check items)
e of
, s
rme
rope
: Most probable causes (judging from Questions and Check items)
ctiv
ged
ctiv
ct in
en d
ctiv
ed t
sing
essi
kag
: Possible causes due to length of use (used for a long period)
Defe
Defo
Defe
Defe
Clog
Defe
Brok
Seiz
Imp
Lea
Mis
: Items to confirm the cause. Exc
Confirm recent repair history
Degree of use of machine Operated for long period
Questions
012406
Black
Metal particles are found in oil filter
Blow-by gas is excessive
Noise of interference is heard from around turbocharger
Engine pickup is poor and combustion is abnormal
Check items
stopped
When control rack is pushed, it is found to be heavy, or does
not return
Injection pump test shows that injection amount is incorrect
Fan is deformed, belt is loose
When valve clearance is checked, it is found to be outside
standard value
Remove cylinder head cover and inspect directly
When muffler is removed, abnormal noise disappears
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
20-272
2
(9)
TROUBLESHOOTING S-16
)
stuck
normal noise is made”.
ion
n)
, etc.
d
ctio
gne
ush
lever
per)
General causes why vibration is excessive
inje
isali
en c
cker
dam
sive
ring
nm
brok
e, ro
• Defective parts (abnormal wear, breakage)
aft (
xces
bea
a i
(valv
r
• Improper alignment
lts,
t
h
t sh
wer
klas
ain
p (e
g bo
• Abnormal combustion
tem
utpu
d, m
o
bac
pum
p
s
ntin
y
d
s
de o
g ro
n
n
alve
ing
u
ion
a
a i
o
gine
ar tr
mic v
m
ctin
insi
ject
s
Legend
u
e
r ge
nne
ngin
b
f en
dyna
e in
part
: Possible causes (judging from Questions and check items)
m
n co
rope
ter o
: Most probable causes (judging from Questions and Check items)
n ca
ctiv
se e
ctive
ken
: Possible causes due to length of use (used for a long period)
Defe
Wor
Wor
Imp
Cen
Loo
Defe
Bro
: Items to confirm the cause.
Confirm recent repair history
Degree of use of machine Operated for long period
Questions
Suddenly increased
Condition of vibration
Gradually increased
Non-specified oil is being used
Metal particles are found in oil filter
Metal particles are found when oil is drained
Oil pressure is low at low idling
012406
Check items
Replace
Correct
Correct
Adjust
Remedy
20-273
2
(9)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM
012406
20-304
2
7
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM
012406
20-305-1
(9)
012406 TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM
20-305-2
7
TROUBLESHOOTING E-1
E-1. Starting motor is not cranked when starting switch is turned to START
Serial No. B20001 – B30000, 50001 – 50200
fl Before carrying out troubleshooting, check that fuse FB2, No. 5 is normal.
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.
YES
3 YES 6 YES
Does starting Is voltage between
YES motor pinion starting motor
YES 5 terminal R and
make a sound of
chassis normal?
moving in? Is voltage between
starting motor • Turn starting NO
• Turn starting
terminal S and switch ON.
switch to 4 chassis normal? • Max. 1 V
START. Is voltage between
starting switch • Turn starting
terminal C and switch to START. NO
NO chassis normal? • 18 - 28V
ª Check operation of limit switch before starting
• Turn starting troubleshooting.
ª Note 1) 2 switch to START.
NO
Does battery relay • 18 - 28V
YES make a noise when
starting switch is
turned OFF?
• Turn starting
YES
switch ON → 9
Is resistance of wiring
OFF.
012406
harness between
YES starting switch
terminal BR and
ª Note 1) 8 battery relay (+)
ª Note 1) 1 normal?
Is there continuity
Are specific YES between starting • Between starting
gravity and switch BR and NO
switch terminals B
voltage of ª Note 1) 7 and BR? battery relay: Max. 1 Ω
battery normal? • Between wiring harness and chassis: Min. 1 MΩ
Is voltage of • Disconnect both starting switch and battery relay ends.
• Turn starting
• Min. 24V starting switch
switch ON. NO
• Specific gravity: terminal B
NO • Remove terminal
Min. 1.26 normal?
B.
• Connect (-) pole
of tester to (-)
terminal of NO
battery.
• 20 - 29V
NO
20-306
7
2
TROUBLESHOOTING E-1
fl Before carrying out troubleshooting, check that fuse FB2, No. 5, is normal.
ª Note. 1) 4 YES
Is voltage between
YES terminal B of start-
ing motor and chas-
3 sis ground normal?
• 20 - 30 V NO
YES Is rushing sound • Turn starting
of starting motor
pinion heard? switch ON.
5 YES
Is voltage between
terminal C of start-
NO ing switch and chas-
sis ground normal?
• 20 - 30 V NO
• Turn starting
ª Note. 1) 2 switch to START
position.
When starting
YES switch is oper-
ated, does battery YES
relay make noise? 8
• Turn starting Is resistance of wir-
switch ON and YES ing harness between
BR of starting switch
OFF. ª Note. 1) and (+) of battery re-
7 lay normal?
Is there continuity
ª Note. 1) 1 YES between termi- • Between BR of
starting switch NO
nals B and BR of and battery relay: Max. 1 Ω
012406
Are voltage and ª Note. 1) 6 starting switch? • Between wiring harness and chassis ground: Min. 1 MΩ
specific gravity of • Disconnect both starting switch and battery relay sides.
battery normal? Is voltage between • Turn starting
terminal B of start- switch ON. NO
• 20 - 30 V NO ing switch and chas- • Disconnect
sis ground normal? terminal B.
• Specific
gravity: Min. • 20 - 30 V
1.26 • Connect (–) pin
NO
of tester to (–)
terminal of
battery.
NO
20-307-1
(9)
TROUBLESHOOTING E-1
Cause Remedy
9 YES
Defective battery relay Replace
Is there continuity
between (–) termi-
nal of battery and Defective contact in wir-
frame ground? ing harness between (–) Repair or
NO terminal of battery - replace
frame ground
Disconnection or defec-
tive contact in wiring har- Repair or
ness between terminal replace
BR of starting switch - (+)
012406
20-307-2
7
TROUBLESHOOTING E-2
E-2. Engine does not start (defective operation of engine stop solenoid)
Serial No. B20001 – B30000, 50001 – 50200
Cause Remedy
012406
E-2. Related electrical circuit diagram
20-308
2
7
TROUBLESHOOTING E-2
Cause Remedy
• 20 - 30V
20-309
2
(9)
TROUBLESHOOTING E-3
a) Front lamps
Cause Remedy
012406
starting switch is NO replace
switch ON. and fuse FB1, No. 6
turned OFF?
Table 1
E L M Continuity
OFF No
ON Yes
20-309-1
7
TROUBLESHOOTING E-3
b) Rear lamps
Cause Remedy
Table 2
E L M Continuity
OFF No
ON Yes
20-309-2
7
TROUBLESHOOTING E-3
a) Front lamps
Cause Remedy
012406
starting switch is NO replace
switch ON. and fuse FB1, No. 6
turned OFF?
Table 1
E L M Continuity
OFF No
ON Yes
20-310
2
(9)
TROUBLESHOOTING E-3
b) Rear lamps
Cause Remedy
Table 2
E L M Continuity
OFF No
ON Yes
20-311
2
7
TROUBLESHOOTING E-4
E-4. Automatic preheating is not carried out when glow switch is turned
to AUTO
Serial No. B20001 – B30000, 50001 – 50200
5
Is there continuity
YES between CN46 (2)
and (3) when glow
4 switch is placed at
Is voltage between AUTO?
YES CN46 (3) and
chassis normal in • Check glow
temperature switch as an
3 conditions below? individual part.
Is there continuity • 20 - 30V • Turn starting
YES between CN38 switch OFF.
• Turn starting
(male) (1) and switch ON. NO
2 (2)? • When ambient
Is voltage temperature is
YES • Check bimetal
between CN38 less than –5°C
timer as an
(2) and chassis individual part. NO
Note 1) 1 normal? • Turn starting
Does battery relay • 20 - 30V switch OFF.
make a noise when • Turn starting
starting switch is switch ON. NO
turned OFF?
012406
• Turn starting
switch ON →
OFF. NO
Note 1) If the lamps (front lamps, rear lamps) or horn circuit are normal, it is possible to check instead
if the lamps light up normally or if the horn sounds normally.
20-312
2
7
TROUBLESHOOTING E-4
5
Is there continuity
YES between CN46 (2)
and (3) when glow
4 switch is placed at
Is voltage between AUTO?
YES CN46 (3) and
chassis normal in • Check glow
temperature switch as an
3 conditions below? individual part.
Is there continuity • 20 - 30V • Turn starting
YES between CN38 switch OFF.
• Turn starting
(male) (A) and switch ON. NO
2 (B)? • When ambient
Is voltage temperature is
YES • Check bimetal
between CN38 less than –5°C
timer as an
(B) and chassis individual part. NO
Note 1) 1 normal? • Turn starting
Does battery relay • 20 - 30V switch OFF.
make a noise when • Turn starting
starting switch is switch ON. NO
turned OFF?
012406
• Turn starting
switch ON →
OFF. NO
Note 1) If the lamps (front lamps, rear lamps) or horn circuit are normal, it is possible to check instead
if the lamps light up normally or if the horn sounds normally.
20-313-1
(9)
TROUBLESHOOTING E-4
Cause Remedy
6 YES
Defective heater relay Replace
Is voltage between
YES heater relay
terminal (+) and Defective contact, or
chassis normal? disconnection in wiring Repair or
• 20 - 30V NO harness between CN46 (2) replace
• Turn starting and heater relay (+)
switch ON.
Defective glow switch Replace
NO
Defective contact, or
disconnection in wiring Repair or
harness between CN46 (3) replace
and CN38 (A)
Defective contact, or
disconnection in wiring
Repair or
harness between starting
replace
switch terminal BR and
CN38 (B)
012406
Start troubleshooting
from E-1 Item 7
20-313-2
7
TROUBLESHOOTING E-5
012406
switch ON→
OFF. NO
Note 1) If the lamps (front lamps, rear lamps) or horn circuit are normal, it is possible to check instead
if the lamps light up normally or if the horn sounds normally.
Note 2) This troubleshooting flowchart uses the left wiper as an example. For the other wipers, the
connectors corresponding to CN11 are as shown in the table below.
Note 3) The connector numbers in this troubleshooting flowchart are the connector numbers in the
operator’s cab, not the connector numbers on the chassis (in some cases, the same connector
numbers are used on the chassis and in the operator’s cab).
20-314
2
7
TROUBLESHOOTING E-5
YES
5
When wiper switch
YES is replaced with an-
other one, does
4 wiper operate?
Does washer of • Turn starting
YES wiper which does
switch ON.
not operate spout NO
washer normally? • Turn wiper
3 switch ON.
• Turn starting ª When other wiper switches are normal.
YES Do other wipers switch ON.
operate? • Turn washer NO
2 switch ON.
ª When washer
Is there continuity • Turn starting is normal.
YES between termi- switch ON.
nals B and BR of • Turn wiper NO
Note 1) 1 starting switch? switch ON.
When starting • Turn starting ª When other wipers
switch is oper- switch ON. are normal.
ated, does battery • Disconnect NO
012406
relay make noise? terminal B.
• Turn starting
switch ON and
OFF. NO
Note 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.
Note 2) This troubleshooting flowchart uses the left wiper as an example. For the other wipers, the
connectors corresponding to CN11 are as shown in the table below.
20-315-1
(9)
TROUBLESHOOTING E-5
Cause Cause
7 YES
Defective wiper motor Replace
YES
6 • Is wiper arm
Is there continuity be- normal?
tween connector ter-
minals (male) (2) and Defective wiper motor Replace
(3) just before wiper NO
motor (between (5)
and (2) for front wiper Note 2)
and between (1) and Disconnection or defec-
(2) for rear wiper)? tive contact in wiring har- Repair or
ness between CN11 (4) -
• Max. 10 Ω NO connect (2) ((5) for front replace
• Turn starting wiper) just before wiper
switch OFF. motor
• Circuit diagrams of right, left, and rear wipers • Circuit diagrams of front wiper
20-315-2
7
TROUBLESHOOTING E-6
5 YES
012406
NO
Note 1) If the lamps (front lamps, rear lamps) or horn circuit are normal, it is possible to check instead
if the lamps light up normally or if the horn sounds normally.
20-316
2
7
TROUBLESHOOTING E-6
1 YES
Does washer mo-
tor rotating (Does 5
rotating sound of
motor come out)? Does wiper of
YES washer which does
• Turn starting not spout water
4 operate normally?
switch ON.
• Turn washer • Turn starting
switch ON. YES Do other wash- switch ON.
ers operate nor-
(Wiper switch) mally? • Turn wiper NO
Note 1) 3 switch ON.
Is there continuity • Turn starting ª When wiper is
012406
YES between termi- switch ON. normal.
nals B and BR of • Turn washer NO
Note 1) 2 starting switch? switch ON.
When starting • Turn starting ª When other washers
switch is oper- switch ON. are normal.
NO ated, does battery • Disconnect NO
relay make noise? terminal B.
• Turn starting
switch ON and
OFF. NO
Note 1) If the lamps (front lamps, rear lamps) or horn circuit are normal, it is possible to check instead
if the lamps light up normally or if the horn sounds normally.
20-317-1
(9)
TROUBLESHOOTING E-6
1 YES
Does washer mo-
tor rotating (Does 5
rotating sound of
motor come out)? Does wiper of
YES washer which does
• Turn starting not spout water
4 operate normally?
switch ON.
• Turn washer • Turn starting
switch ON. YES Do other wash- switch ON.
ers operate nor-
(Wiper switch) mally? • Turn wiper NO
Note 1) 3 switch ON.
Is there continuity • Turn starting ª When wiper is
012406
YES between termi- switch ON. normal.
nals B and BR of • Turn washer NO
Note 1) 2 starting switch? switch ON.
When starting • Turn starting ª When other washers
switch is oper- switch ON. are normal.
NO ated, does battery • Disconnect NO
relay make noise? terminal B.
• Turn starting
switch ON and
OFF. NO
Note 1) If the lamps (front lamps, rear lamps) or horn circuit are normal, it is possible to check instead
if the lamps light up normally or if the horn sounds normally.
20-317-1
7
TROUBLESHOOTING E-6
Cause Cause
8 YES
Defective washer motor Replace
YES Is ground wire of
washer motor
7 connected?
Is voltage between Repair or
YES CN26 on cab side Defective ground wire replace
NO
and chassis
6 ground normal? Note 2)
When washer
(wiper) switch is re- • 20 - 30 V Disconnection or defective
placed with an- contact in wiring harness Repair or
• Turn starting NO between CN26 on cab side replace
other one, does
washer operate? switch ON. - CN11 on cab side
• Turn washer
• Turn starting switch ON.
switch ON. Defective washer (wiper) Replace
• Turn washer NO switch
switch ON.
ª When other Note 2)
washer Disconnection or defective
contact in wiring harness Repair or
between CN11 (2), (3) on cab replace
side - fuse on cab side
Breakage of fusible link on
012406
Note 2) This troubleshooting flowchart uses the left washer as an example. For the other washers,
the connectors corresponding to CN11 in the cab are as shown in the table below.
20-317-2
7
TROUBLESHOOTING
TROUBLESHOOTING OF MACHINE
MONITOR SYSTEM
(M MODE)
Table of failure modes and causes (machine monitor system) ....................................................... 20-502
Electrical circuit diagrams for each system ........................................................................................ 20-504
M-1 No display is given on monitor panel when starting switch is turned to ON ..................... 20-506
M-2 When starting switch is turned to ON, all monitor panel lamps light up
and do not go out ........................................................................................................................ 20-506
M-3 Preheating display ( ) is abnormal ................................................................................... 20-507
SAP00526
20-501
(9)
2
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM
012406
20-504
7
2
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM
012406
20-505-1
(9)
012406 TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM
20-505-2
7
TROUBLESHOOTING M-3
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.
YES
Defective monitor panel Replace
1
Disconnection in wiring
Is voltage 3 YES harness between CN49 (6) Repair
between CN49 – CN31 (6) – CN20 (7) – or replace
(female) (6) and Is voltage between
YES heater relay output heater relay
chassis normal?
2 terminal and
• 4 – 30V chassis normal?
Is voltage between Defective heater relay Replace
• Turn starting NO
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
20-507
7
2
TROUBLESHOOTING M-3
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.
YES
Defective monitor panel Replace
1
Is voltage Disconnection in wiring
3 YES Repair
between CN49 harness between CN49 (6)
Is voltage between or replace
(female) (6) and – heater relay
YES heater relay output
chassis normal?
2 terminal and
• 4 – 30V chassis normal?
Is voltage between Defective heater relay Replace
• Turn starting NO
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
20-508-1
(9)
TROUBLESHOOTING M-3
012406
20-508-2
7
TROUBLESHOOTING M-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.
2 When it flashes
Start troubleshooting from the items marked ª in a).
20-509
7
2
TROUBLESHOOTING M-4
fl Check that the engine oil pressure is the specified value before starting troubleshooting.
012406
harness terminal of replace
Contact of chassis ground
engine oil pressure with wiring harness
sensor. Does 2 YES Repair
display go out? between CN49 (8) – CN20
Is there continuity (1) – engine oil pressure or replace
• Remove terminal between CN49 sensor
of engine oil NO (female) (8) and
pressure sensor. chassis ground?
Defective monitor panel Replace
• Start engine. • Turn starting NO
switch OFF.
• Remove terminal of
engine oil pressure
sensor.
20-510
7
2
TROUBLESHOOTING M-4
Cause Remedy
Carry out
sensor check
YES Defective coolant according to
2 temperature sensor STANDARD
VALUE TABLE,
YES Does flashing go replace
out when CN15
3 YES
is disconnected? Defective monitor panel Replace
1 Is voltage
• Disconnect between CN50 Wiring harness between
Is indicator of
coolant tempera- CN15. NO (1) and CN50 (4) CN50 (1) – CN31 (11) –
• Run engine at normal? CN17 (3), (2) – CN15 (1) – Repair
ture gauge above
border of red zone? half throttle or • Min. 2.5V NO coolant temperature or replace
above. • Start engine. sensor short circuiting
• Start engine. • Run engine at half throttle or above. with ground
• Run engine at • Disconnect CN15.
half throttle or Defective monitor panel Replace
NO
above.
012406
20-511
2
(9)
TROUBLESHOOTING M-4
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 (12) –
gauge below border Repair
half throttle or CN28 (1) – power train oil
of red zone? • Min. 2.5V NO or replace
above. temperature sensor short
• Start engine.
• Start engine. circuiting with ground
• Run engine at half throttle or above.
• Run engine at • Disconnect CN28.
half throttle or Defective monitor panel Replace
above. NO
012406
M-4. d) Related electrical circuit diagram
20-512
(9)
2
TROUBLESHOOTING M-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.
20-512-1
(9)
TROUBLESHOOTING M-4
fl Check that the engine oil pressure is the specified value before starting troubleshooting.
012406
harness terminal of replace
Contact of chassis ground
engine oil pressure with wiring harness
sensor. Does 2 YES Repair
display go out? between CN49 (8) – CN20
Is there continuity (1) – engine oil pressure or replace
• Remove terminal between CN49 sensor
of engine oil NO (female) (8) and
pressure sensor. chassis ground?
Defective monitor panel Replace
• Start engine. • Turn starting NO
switch OFF.
• Remove terminal of
engine oil pressure
sensor.
20-512-2
7
TROUBLESHOOTING M-4
Cause Remedy
Carry out
sensor check
YES Defective coolant according to
2 temperature sensor STANDARD
VALUE TABLE,
YES Does flashing go replace
out when CN15
3 YES
is disconnected? Defective monitor panel Replace
1 Is voltage
• Disconnect between CN50
Is indicator of Wiring harness between
coolant tempera- CN15. NO (1) and CN50 (4)
CN50 (1) – CN15 (1) –
• Run engine at normal? Repair
ture gauge above coolant temperature
border of red zone? half throttle or • Min. 2.5V NO sensor short circuiting or replace
above. • Start engine. with ground
• Start engine. • Run engine at half throttle or above.
• Run engine at • Disconnect CN15.
half throttle or Defective monitor panel Replace
NO
above.
012406
20-512-3
7
TROUBLESHOOTING M-4
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) – CN28 (1) –
gauge below border Repair
half throttle or power train oil
of red zone? • Min. 2.5V NO or replace
above. temperature sensor short
• Start engine.
• Start engine. circuiting with ground
• Run engine at half throttle or above.
• Run engine at • Disconnect CN28.
half throttle or Defective monitor panel Replace
above. NO
012406
M-4. d) Related electrical circuit diagram
20-512-4
7
TROUBLESHOOTING M-5
Cause Remedy
1 YES
Defective monitor panel Replace
When circuit bet-
ween CN50 (female)
(7) and chassis
Defective contact, or
ground is connected, disconnection in wiring
does buzzer sound? harness between fuse FB1 Repair
NO No. 1 - CN32 (4) - CN41 or replace
• Ground CN50
(1),(2) - buzzer - CN50 (7),
(female) (7) to chassis?
or defective buzzer
• Turn starting switch ON.
1 YES
Defective monitor panel Replace
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.
20-513
7
2
TROUBLESHOOTING M-6
Cause Remedy
Cause Remedy
012406
Defective monitor panel Replace
20-514
2
TROUBLESHOOTING M-7
Cause Remedy
20-515
7
2
TROUBLESHOOTING M-7
Cause Remedy
012406
20-515-1
(9)
TROUBLESHOOTING M-7
Cause Remedy
012406
Serial No.: 50201 and up
20-516
(9)
2
TROUBLESHOOTING M-7
20-517
(9)
2
TROUBLESHOOTING M-8
012406
Cause Remedy
1 YES
Go to M-4. a).
Does charge
abnormality
display flash?
Defective monitor panel Replace
• Start engine. NO
20-518
7
2
TROUBLESHOOTING M-9
M-9. Monitor panel lighting does not light up (front lamps are normal)
fl When a visual check shows that the bulb is not blown.
(If it is blown, replace the lamp bulb.)
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.
fl Before carrying out troubleshooting, check that fuse FB1, No. 1 is normal.
(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
Defective monitor panel Replace
Is voltage
between CN49
(7) and chassis Defective contact, or
ground normal? disconnection in wiring Repair
NO harness between CN49 (7) or replace
• 20 – 30V
– CN32 (3) – CN48 (3)
• Turn starting switch ON.
• Turn front lamp switch ON.
20-519
(9)
2
DISASSEMBLY AND ASSEMBLY RADIATEUR
012406
RECOIL SPRING
WORK EQUIPMENT
Disassembly ........................................... 30-129 Removal .................................................. 30-200
Assembly ................................................ 30-130 Installation .............................................. 30-201
IDLER Disassembly ........................................... 30-202
Disassembly ........................................... 30-131 Assembly ................................................ 30-205
Assembly ................................................ 30-132 HYDRAULIC TANK
TRACK ROLLER Removal .................................................. 30-208
Removal .................................................. 30-134 Installation .............................................. 30-208
Installation .............................................. 30-134 ROPS ROOF, GUARD
Disassembly ........................................... 30-135 Removal .................................................. 30-209
Assembly ................................................ 30-136 Installation .............................................. 30-209
CARRIER ROLLER CANOPY
Removal .................................................. 30-138 Removal .................................................. 30-210
Installation .............................................. 30-138 Installation .............................................. 30-210
Disassembly ........................................... 30-139 OPERATOR'S CAB
Assembly ................................................ 30-140 Removal .................................................. 30-211
TRACK SHOE Installation .......................................... 30-212-1
Removal .................................................. 30-142 OPERATOR'S CAB GLASS (STUCK GLASS)
Installation .............................................. 30-143 Removal ...............................................30-212-5
Overall disassembly .............................. 30-144 Installation .......................................... 30-212-6
Overall assembly ................................... 30-149
FLOOR FRAME
Press-fitting jig dimension table Removal .................................................. 30-213
for link press .......................................... 30-163 Installation .............................................. 30-217
ONE LINK AIR CONDITIONER COMPRESSOR
Field disassembly .................................. 30-164 Removal .................................................. 30-218
Field assembly ....................................... 30-166 Installation .............................................. 30-219
HYDRAULIC PUMP AIR CONDITIONER CONDENSER
Removal .................................................. 30-172 Removal .................................................. 30-220
Installation .............................................. 30-173 Installation .............................................. 30-221
30-2
(8)
DISASSEMBLY AND ASSEMBLY RADIATEUR
MONITOR
Removal .................................................. 30-222
Installation .............................................. 30-222
Removal, installation of
DT connector pins ............................... 30-223
Removal, installation of
HD connector pins ............................... 30-225
Repair procedure for wiring harness ....... 30-226
012406
30-2-1
(8)
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
Nominal number Plug Sleeve nut (elbow end) Use the two items below as a set
012406
02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
03 07376-50315 07221-20315 (Nut), 07222-00312 (Plug)
04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)
10 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)
Nominal number Flange (hose end) Sleeve head (tube end) Split flange
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Dimensions (mm)
Nominal number Part Number
D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15 Taper 1/8
øD
ød
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
L
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
DED01250
27 07049-02734 27 22.5 34
30-4
(9)
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
fl When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and
other hydraulic equipment removed for repair, always bleed the air as follows:
1. Start the engine and run at low idling.
2. Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times,
012406
30-5
(9)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
remodel
Sketch
Qty
New/
Component Symbol Part No. Part Name Nature of work, remarks
Removal, installation
3 790-331-1110 Wrench 1 Tightening of cylinder head
Removal, installation of round
Transmission 1 09003-06270 Wrench 1 nut
D
assemby Checking operation of clutch
2 799-301-1600 Oil leak tester 1 piston
1 790-337-1032 Lifting tool 1 Removal, installation of
final drive assembly
2 791T-427-1150 Bracket 1 N fi
1
Commercialy
3 available Shackle 1 SD type nominal diameter 14
4 01010-51640 Bolt 1
012406
790-101-2310 Block 1
790-101-2800 Puller 1
790-101-2390 Leg 2
790-434-1050 Screw 1
01643-32460 Washer 1
790-101-1102 Pump 1
790-101-2310 Block 1
790-101-2350 Leg 2
790-101-2360 Washer 4
6 Removal of shaft
02215-11622 Nut 2
790-101-2420 Adapter 2
790-201-2650 Plate 1
790-201-2750 Spacer 1
30-6
(9)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
remodel
Sketch
Qty
New/
Component Symbol Part No. Part Name Nature of work, remarks
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
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
791-635-3170 Nut 4
Disassembly, assembly of
791-635-3180 Screw 1
track (removal of link pin)
791-635-3190 Screw 1
791-630-3310 Adapter 1
791-630-3260 Pusher 1 Parts marked ª are used with
the track shoe assembly still
1 791-630-3530 Pusher 1
installed to the chassis when
791-635-3120 Support ª 1 removing or press fitting the
Track shoe
R link pin
assembly 791-635-3130 Nut ª 1
791-635-3140 Screw ª 1
791-635-3150 Hook ª 1
790-101-1102 Pump 1
30-7
7
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
remodel
Sketch
Qty
New/
Component Symbol Part No. Part Name Nature of work, remarks
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
791-635-3110 Frame 1 Remover & installer assembly
791-635-3160 Extension 1 791-630-3200
791-635-3170 Nut 4
791-635-3180 Screw 2
012406
Disassembly, assembly
04530-11018 Eyebolt 1
01580-01210 Nut 1
Track shoe
R
assembly 790-101-1102 Pump 1
790-101-1300 Cylinder (980kN {100ton}) 1
791-630-3220 Adapter 1
11
791-630-3250 Adapter 1
12 791-630-3290 Guide 1 Guide when press fitting link
791-635-3170 Nut 4
Press fitting of link pin
791-635-3180 Screw 2
791-635-3190 Screw 1
13 791-630-3310 Adapter 1
791-630-3210 Pin guide 1
791-630-3270 Guide 1
791-630-3280 Spacer 1
04530-11018 Eyebolt 1
01580-01210 Nut 1
30-8
3
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
remodel
Sketch
Qty
New/
Component Symbol Part No. Part Name Nature of work, remarks
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
Disassembly, assembly of
1
790-101-1102 Pump 1 hydraulic cylinder
1 790-720-1000 Expander 1
790-101-5021 Grip 1
Assembly Part No. 790-201-1702
01010-50816 Bolt 1
790-101-5021 Grip 1
Assembly Part No. 790-201-1500
01010-50816 Bolt 1
30-9
7
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
remodel
Sketch
Qty
New/
Component Symbol Part No. Part Name Nature of work, remarks
Contact size #20
799-601-7820 Remover 1
Removal of pin
(Tool color: Light blue)
Contact size #16 (Normal)
DT connector pin 799-601-7840 Remover 1 (Tool color: Blue)
1 Connector
HD connector pin Contact size #12 tool kit
X 799-601-7850 Remover 1 (Tool color: Yellow)
799-601-7800
Contact size #8
Wiring harness 799-601-7860 Remover 1 (Tool color Green)
Contact size #4
799-601-7870 Remover 1 (Tool color: White)
installation
799-703-1100 Vacuum pump (100V) 1
Removal,
Air conditioner Charging air conditioner
Y 799-703-1111 Vacuum pump (220V) 1
unit with gas
799-703-1121 Vacuum pump (240V) 1
012406
30-10
(9)
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
012406
J4
5
C0.5
P
10
R1
30
R0
.8
ø134+0.5
ø152.4
ø150-0.5
0
P(1:1)
(ø132.4)
220 CDD00505
791T-427-1160
30-12
(9)
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
L1-1
012406
L2-1
30-13
(9)
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
8
CED00011
A1
CED00012
30-17
(9)
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
10
CED00013
12
11
012406
CED00014
A2
CED00015
30-18
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
sor.
CED00012
30-18-1
(9)
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
10
CED00013
12
11
012406
CED00014
A2
CED00015
30-18-2
7
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY
• Carry out installation in the reverse order to
removal.
Tightening torque
Thread size Nm (kgm)
11.8 – 14.7
16 x 1.5 (1.2 – 1.5)
19.6 – 24.5
22 x 1.5 (2.0 – 2.5)
29.4 – 34.3
24 x 1.5
012406
(3.0 – 3.5)
30-19
(9)
DISASSEMBLY AND ASSEMBLY ENGINE HOOD
CDD00502
INSTALLATION OF ENGINE
HOOD ASSEMBLY
2
• Carry out installation in the reverse order to
removal.
CED00503
30-25
7
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
1. Drain coolant.
012406
2 3 CED00024
CED00026
30-26
7
DISASSEMBLY AND ASSEMBLY FUEL TANK
CED00053
CED00054
30-33
7
DISASSEMBLY AND ASSEMBLY RADIATOR, OIL COOLER
1. Drain coolant.
012406
CED00065
10
CED00067
30-34
7
DISASSEMBLY AND ASSEMBLY RADIATOR, OIL COOLER
11
CED00068
INSTALLATION OF RADIATOR,
OIL COOLER ASSEMBLY
• Carry out installation in the reverse order to
removal.
1
3 Radiator outlet hose clamp:
5.9 ± 0.49 Nm (0.6 ± 0.05 kgm)
13
• Refilling with water
CDD00069
Add water through water filler to the specified
level.
fl Run the engine to circulate the water
through the system. Then check the water
level again.
30-35
DISASSEMBLY AND ASSEMBLY HYDRAULIC COOLER
REMOVAL OF HYDRAULIC
COOLER
1. Remove grills (top, middle, bottom).
1
CED00099
INSTALLATION OF HYDRAULIC
COOLER
• Carry out installation in the reverse order to
removal.
012406
30-36
7
DISASSEMBLY AND ASSEMBLY ENGINE
REMOVAL OF ENGINE
ASSEMBLY
fl Although the engine stop solenoids on D41E-6
and D41P-6, Serial No. 50201 and up, are in- 1
stalled to positions different from this illustra-
2
tion, they can be removed and installed basi-
cally by the procedure explained here.
D41E-6 Serial No.: B20001 – B20980
D41P-6 Serial No.: B20001 – B20983
GUARD ASSEMBLY.
CED00071
30-37
(9)
DISASSEMBLY AND ASSEMBLY ENGINE
14
CED00074
19
012406
CED00075
30-38
7
No.: B20981 – B40000
No.: B20984 – B40000
DISASSEMBLY AND ASSEMBLY ENGINE
INSTALLATION OF ENGINE
ASSEMBLY
• Carry out installation in the reverse order to
removal.
Tightening torque
Thread size Nm (kgm)
11.8 – 14.7
16 x 1.5 (1.2 – 1.5)
19.6 – 24.5
22 x 1.5 (2.0 – 2.5)
29.4 – 34.3
24 x 1.5
012406
(3.0 – 3.5)
30-39
(9)
DISASSEMBLY AND ASSEMBLY RADIATOR, GUARD
REMOVAL OF RADIATOR,
GUARD ASSEMBLY
¤ Disconnect the cable from the negative (–) ter- 1
minal of the battery.
1. Drain coolant.
012406
CED00056
5 4
CED00057
12. Disconnect 2 window washer hoses (6) from
right side of radiator guard.
30-40
7
DISASSEMBLY AND ASSEMBLY TRANSMISSION
44 43
CDD00282
012406
CED00283
CED00284
30-56
(9)
DISASSEMBLY AND ASSEMBLY TRANSMISSION
58
012406
CED00286
CED00287 CED00288
CED00289
30-57
(9)
DISASSEMBLY AND ASSEMBLY TRANSMISSION
49
64 50 CED00290
66
012406
123
CED00291 CED00292
67
CED00293
70 69
70
72 71
70
CDD00294
30-58
(9)
DISASSEMBLY AND ASSEMBLY TRANSMISSION
CED00295 CED00296
CED00297
77
49
50 CED00298
78
CED00299
30-59
(9)
DISASSEMBLY AND ASSEMBLY TRANSMISSION
30. Collar
Remove collar (81).
CED00300 CED00301
012406
83
CED00302
85
CED00303
30-60
(9)
DISASSEMBLY AND ASSEMBLY TRANSMISSION
87
86A
CDD00304 CDD00305
91
012406
CED00306 CDD00307
63 120
94
CDD00308
95
CDD00309
30-61
(9)
DISASSEMBLY AND ASSEMBLY TRANSMISSION
CED00310
99
012406
64 CED00311
CDD00312
109
CDD00313
30-62
(9)
DISASSEMBLY AND ASSEMBLY TRANSMISSION
CDD00314
012406
30-62-1
(9)
DISASSEMBLY AND ASSEMBLY TRANSMISSION
ASSEMBLY OF
TRANSMISSION ASSEMBLY
fl Clean all parts, and check for dirt or damage.
Coat the sliding surfaces of all parts with en-
gine oil before installing.
fl Clean all the oil holes in the housing before
assembling.
fl The seal ring must be installed facing in the
correct direction, so install with the side receiv-
ing the pressure facing the housing as shown
in the diagram.
109
CDD00313
30-63
(8)
DISASSEMBLY AND ASSEMBLY TRANSMISSION
101
103
CDD00316
012406
102
CED00317 CED00318
99
64
CED00319
CED00310
30-64
(8)
DISASSEMBLY AND ASSEMBLY TRANSMISSION
95
CDD00309
CDD00322
30-65
(8)
DISASSEMBLY AND ASSEMBLY TRANSMISSION
012406
viii) Hold output shaft with press, then using
tool D1, tighten nut (85) and install col-
lar (124).
D1
2 Nut: Thread tightener (LT-2) 84
Nut: 269.7 ± 24.5 Nm
{27.5 ± 2.5 kgm}
ix) Install seal rings (84).
85
CED00325
30-66
(8)
DISASSEMBLY AND ASSEMBLY TRANSMISSION
4. Collar
Install collar (81).
CED00301 CED00300
6. Housing
Install housing (117).
117
7. Install No. 4 clutch ring gear (78).
fl Set with the face with the large cut on the
outside circumference facing up.
78
012406
CED00299
76
CED00327
30-67
(8)
DISASSEMBLY AND ASSEMBLY TRANSMISSION
CED00328 CED00295
72 71
012406
70
CDD00294
CED00293
30-68
(8)
DISASSEMBLY AND ASSEMBLY TRANSMISSION
CED00329
123 CED00330
64
49
012406
50
CED00331
CED00332
CED00333 CED00334
30-69
(8)
DISASSEMBLY AND ASSEMBLY TRANSMISSION
CED00335
18. No. 2 (F) clutch plates, discs, springs
D41E-6 Serial No.: B20001 – B35176
D41E-6 Serial No.: B35178 – B35179
D41E-6 Serial No.: B35185 – B35186
D41E-6 Serial No.: B35189
D41E-6 Serial No.: B35192
D41E-6 Serial No.: B35213 – B35215 49
D41E-6 Serial No.: B35222
D41E-6 Serial No.: B35224 – B35225
D41E-6 Serial No.: 50001 – 50312 54
D41P-6 Serial No.: B20001 – B35176 53
D41P-6 Serial No.: 50001 – 50305
1) Install plate (45), discs (49), and plates (50). 48
fl Discs: 5, plates (50): 5, plate (45): 1 50
2) Install springs (55) and (54), guide (48), and 55 45
washer (53).
012406
fl Free length of spring (large): 22.93 mm CED00336
(small): 18.65 mm
CED00337
30-70
(8)
(9)
DISASSEMBLY AND ASSEMBLY TRANSMISSION
49
48 46
CED00338
CDD00339
30-71
(8)
(9)
DISASSEMBLY AND ASSEMBLY TRANSMISSION
36 34
CDD00340
4) Input shaft
i) Using push tool, press fit bearing (32) to 32
input shaft (29), then install snap ring
(31). 30
ii) Install snap ring (30).
29
012406
31
CED00279
CDD00341
CED00277 CED00276
30-72
(8)
(9)
DISASSEMBLY AND ASSEMBLY TRANSMISSION
CED00342
CED00343
CED00274
30-73
(8)
(9)
DISASSEMBLY AND ASSEMBLY TRANSMISSION
10
CED00269
19
012406
CED00273
26. Coupling
1) Assemble spacer (17). 14 16
2) Install coupling (16).
17
2 Coupling bolt: Adhesive (LT-2)
Coupling bolt:
176.5 ± 19.6 Nm {18 ± 2 kgm}
3) Fit holder (15) and tighten bolt (14).
15
CED00272 CED00271
27. Strainer
1) Install strainer case (12). 11 12
2) Assemble strainer assembly (13) and spring
to strainer case (12), then install cover (11). 13
fl Clean the strainer assembly before as-
sembling it again.
CED00270
30-74
(8)
(9)
DISASSEMBLY AND ASSEMBLY TRANSMISSION
CED00268
8 CED00267
4
CED00266
3
1
CED00265
30-74-1
(9)
DISASSEMBLY AND ASSEMBLY STEERING CASE
20 CED00393
23
012406
CED00394
24
CED00395
29
CED00396
30-78
(9)
DISASSEMBLY AND ASSEMBLY STEERING CASE
ASSEMBLY OF STEERING
CASE ASSEMBLY
fl Clean all parts, and check for dirt or damage.
Coat the sliding surfaces of all parts with en-
gine oil before installing.
53
54
CED00409 CED00406
30-81
(8)
DISASSEMBLY AND ASSEMBLY STEERING CASE
40
41
012406
CED00411
CED00412
37
34
CED00413 CED00414
30-82
(8)
DISASSEMBLY AND ASSEMBLY STEERING CASE
CED00415
31
31
012406
CED00416
3. Adjusting preload
1) Adjust shim (32) so that starting torque at
32
tip of bevel gear is 13.7 – 22.6 N {1.4 – 2.3
kg}.
fl Do not mesh the bevel pinion when ad-
justing.
2) Adjust so that thickness of shim is more or 32
less equal on left and right.
fl There are three types of shim thickness:
0.2, 0.3. 1.0 mm
CED00417 CED00418
30-83
(8)
DISASSEMBLY AND ASSEMBLY STEERING CASE
012406
In addition, there should be no strong
contact at the addendum or dedendum
(tip or root of the gear teeth) or at the
big and small ends.
fl If the gears are adjusted to this pat-
tern, the tooth contact will be cor-
rect when load is applied.
Adjustment
If the result of the inspection shows that the
correct tooth contact is not being obtained,
adjust again as follows.
i) If bevel pinion is too far from center line
of bevel gear.
Contact is at the small end of the con-
vex tooth face of the bevel gear and at
the big end of the concave tooth face.
• Correct the tooth contact as follows.
Adjust the thickness of the shims at the
bevel pinion to move the bevel pinion
in direction A.
In addition, adjust the thickness of the
shims to move the bevel gear in direc- B
tion B, then check the tooth contact pat-
tern and backlash again.
30-84
(8)
DISASSEMBLY AND ASSEMBLY STEERING CASE
58
CED00426
29
CED00396
24
CED00427
30-85
(8)
DISASSEMBLY AND ASSEMBLY STEERING CASE
012406
20 CED00393
20 19
CED00392 CED00391
17
CED00430
30-86
(8)
DISASSEMBLY AND ASSEMBLY STEERING CASE
14 14
CED00389
18 18
chine. CED00388
6) Install washers (14).
8. Cover assembly
1) Using push tool, install bearings (13) to
cover.
11 11
CED00386
30-87
(8)
DISASSEMBLY AND ASSEMBLY STEERING CASE
CED00385
012406
9. Brake, clutch lever
Align match mark of shaft and install brake le- 9 9
vers (8) and clutch levers (9).
fl For details of the method for adjusting the
clearance between the lever and piston, see
TESTING AND ADJUSTING.
8
8
CED00384
7 6
CED00383
30-88
(8)
DISASSEMBLY AND ASSEMBLY STEERING CASE
5 2 3
CED00382
Steering case: 80 ¬
30-89
(8)
DISASSEMBLY AND ASSEMBLY BRAKE CONTROL VALVE
1 2
4 3
012406
5 8
6
9
7
10
18
11
19 21 20 22 17 16 14 15
CDD00358
30-94
(9)
DISASSEMBLY AND ASSEMBLY BRAKE CONTROL VALVE
CDD00359 CDD00360
7
012406
CDD00361
CDD00363
30-95
(9)
DISASSEMBLY AND ASSEMBLY BRAKE CONTROL VALVE
1 2
4 3
012406
5 8
6
9
7
10
18
11
19 21 20 22 17 16 14 15
CDD00358
30-96
(9)
DISASSEMBLY AND ASSEMBLY BRAKE CONTROL VALVE
5) Fit oil seal (11) to oil seal cap (10) and in- CDD00362
stall to valve body.
2 Lip of oil seal: Grease (G2-LI)
6) Tighten plug (13) to specified torque.
Plug (13): 68.6 ± 9.8 Nm (7 ± 1 kgm)
7
CDD00361
30-97
(9)
DISASSEMBLY AND ASSEMBLY BRAKE CONTROL VALVE
CDD00360 CDD00359
012406
30-98
DISASSEMBLY AND ASSEMBLY TRANSMISSION SHIFT VALVE
REMOVAL OF TRANSMISSION
SHIFT VALVE ASSEMBLY
1. Remove parking brake cylinder assembly.
For details, see REMOVAL OF PARKING BRAKE
CYLINDER ASSEMBLY.
CED00187
4
012406
CED00188
CED00189
INSTALLATION OF TRANS-
MISSION SHIFT VALVE
ASSEMBLY
• Carry out installation in the reverse order to
removal.
30-99
(9)
DISASSEMBLY AND ASSEMBLY TRANSMISSION SHIFT VALVE
012406
30-100
(9)
DISASSEMBLY AND ASSEMBLY TRANSMISSION SHIFT VALVE
30-101
(9)
DISASSEMBLY AND ASSEMBLY TRANSMISSION SHIFT VALVE
012406
30-102
(9)
DISASSEMBLY AND ASSEMBLY TRANSMISSION SHIFT VALVE
30-103
(9)
DISASSEMBLY AND ASSEMBLY TRANSMISSION SHIFT VALVE
012406
30-104
(9)
DISASSEMBLY AND ASSEMBLY TRANSMISSION PRESSURE VALVE
REMOVAL OF TRANSMISSION
PRESSURE VALVE ASSEMBLY
1. Remove side step (1) and side cover (2).
1
2
CED00070
012406
CED00098
INSTALLATION OF TRANSMISSION
PRESSURE VALVE ASSEMBLY
• Carry out installation in the reverse order to
removal.
Mounting bolt:
27.9±3.4Nm {2.85±0.35kgm}
30-108
(9)
DISASSEMBLY AND ASSEMBLY TRANSMISSION PRESSURE VALVE
012406
1. Covers
Remove covers (1) and (2).
3. Modulating valve
1) Remove stopper (6) by using a forcing-
bolt.
2) Remove valve (7).
3) Remove shims (8) from valve (7).
fl Check the thickness and number of
shims.
4) Remove springs (9) and (10).
5) Remove stopper (11).
6) Remove spool (12).
7) Remove valve (13), spring (14) and valve
(15) from spool (12).
30-110
(9)
DISASSEMBLY AND ASSEMBLY TRANSMISSION PRESSURE VALVE
1. Modulating valve
1) Install valve (15), spring (14) and valve (13)
to spool (12).
2) Install spool (12) to body (16).
3) Fit the O-ring, then install stopper (11).
2 O-ring: Grease (G2-LI)
4) Install springs (10) and (9).
5) Install shims (8) to valve (7).
fl Reuse the shims removed when disas-
sembled.
6) Install valve (7).
7) Fit the O-ring, then install stopper (6).
2 O-ring: Grease (G2-LI)
3. Covers
Install covers (2) and (1).
30-111
(9)
DISASSEMBLY AND ASSEMBLY STEERING PISTON
REMOVAL OF STEERING
PISTON ASSEMBLY (CLUTCH,
BRAKE PISTON) 6
5
1. Remove external cover under fuel tank assem-
bly. 1 7
2
2. Disconnect spring (1), pressure detection hoses 9
(2) and (3), brake hose (4), and clutch hose (5) 3 4 10
8
of right clutch and brake piston assembly.
012406
11
CED00446
INSTALLATION OF STEERING
PISTON ASSEMBLY (CLUTCH,
BRAKE PISTON)
• Carry out installation in the reverse order to
removal.
30-112
(9)
DISASSEMBLY AND ASSEMBLY STEERING PISTON
DISASSEMBLY OF STEERING
PISTON ASSEMBLY (CLUTCH,
BRAKE PISTON) 1 1
1. Blow in air from elbow (1) and push out pistons
(2) and (3).
2 3 q
¤ Put block [1] in contact with the tip of the
piston, and fill slowly with air.
4 8 10 9 5
012406
6 7
CED00381
ASSEMBLY OF STEERING
PISTON ASSEMBLY (CLUTCH,
BRAKE PISTON)
1. Install seals (9) and (8) to body (10).
30-113
(9)
DISASSEMBLY AND ASSEMBLY PARKING BRAKE CYLINDER
CDD00080
3 2
012406
CED00060
CED00123
6
7
CED00124
30-114
DISASSEMBLY AND ASSEMBLY PARKING BRAKE CYLINDER
CED00125
INSTALLATION OF PARKING
BRAKE CYLINDER ASSEMBLY
• Carry out installation in the reverse order to
removal.
1
fl Adjust the decelerator pedal.
For details, see Adjusting deceleration pedal.
012406
2
fl Adjust the inching and brake pedal.
For details, see Adjusting inching, brake
pedal linkage.
3
fl Release the parking brake.
For details, see TESTING AND ADJUSTING,
Procedure for releasing parking brake.
3 Parking brake cylinder nut:
51.5 ± 17.2 Nm (5.25 ± 1.75 kgm)
30-115
DISASSEMBLY AND ASSEMBLY PARKING BRAKE CYLINDER
d b
a c
1
q 2
CDD00436
012406
3. Loosen nuts (2) of guide bolts [1] in turn and
release tension of spring (3).
fl Installed dimension of spring (3): 190 mm
fl Free length of spring (3): 256 mm 7 6
30-116
(9)
DISASSEMBLY AND ASSEMBLY PARKING BRAKE CYLINDER
d b
a c
1
q 2
CDD00436
30-117
(9)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
012406
CED00130
30-118
(9)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
DISASSEMBLY OF FINAL
DRIVE ASSEMBLY
Serial No.: B20001 – B20500 2
4a
• Floating seal
3
1. Remove sprocket (2) from final drive assembly 4b
(1). 1
2. Remove cage (3), then remove floating seal (4a).
3. Remove floating seal (4b) from case.
CDD00235
q
q
012406
CDD00236
7
8
CED00237
CED00238
30-119
(9)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
J6
CED00239
012406
CDD00240
13
12
CED00241
13
9
CED00242
30-120
(9)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
15
CED00243
J3
16
012406
CED00244
• Pinion assembly 18 17
12. Remove cover (17), then remove oil seal and
bearing housing (18).
CDD00245
20
CDD00246
30-121
(9)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
CED00247
012406
CED00248
27
26
CDD00249
30-122
(9)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
27
26
CDD00249
• Pinion assembly
2. Assembly of pinion assembly
1) Press fit bearing inner race (23) and collar 24 23 22
(22) to pinion.
2 End portion of spline: LG-6
fl Press-fitting force for collar (22):
7.06 – 47.27kN {0.72 – 4.82ton}
2) Press fit bearing inner race (24) to pinion.
012406
CED00248
CDD00251
30-123
(9)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
012406
CDD00245
16
CDD00253 CED00254
13 9
CDD00255
30-124
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
CED00256 CED00257
CED00258
CDD00260
30-125
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
CED00261
012406
CDD00236
CDD00262
30-126
(9)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
4b
CDD00264
(1). CDD00235
30-127
3
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
DISASSEMBLY OF FINAL
DRIVE ASSEMBLY
Serial No.: B20501 – B40000, 50001and up
• Floating seal
1. Remove sprocket (2) from final drive assembly
(1).
2. Remove cage (3), then remove floating seal (4a).
3. Remove floating seal (4b) from case.
012406
• Drive shaft, gear
6. Remove bolt (7), then remove holder (8).
7
8
CED00237
CED00238
30-127-1
(9)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
J6
CED00239
13
12
CED00241
13
9
CED00242
30-127-2
(9)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
14
15
CED00243
J3
16
012406
CED00244
• Pinion assembly
12. Remove oil seal and bearing housing (18).
20
CDD00246
30-127-3
(9)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
CED00247
CED00248
30-127-4
(9)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
• Pinion assembly
2. Assembly of pinion assembly
1) Press fit bearing inner race (23) and collar 24 23 22
(22) to pinion.
2 End portion of spline: LG-6
fl Press-fitting force for collar (22):
7.06 – 47.27kN {0.72 – 4.82ton}
2) Press fit bearing inner race (24) to pinion.
012406
CED00248
30-127-5
(9)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
CED00254
CED00256 CED00257
30-127-6
(9)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
CED00258
012406
Thread tightener (LT-2)
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}
CED00261
30-127-7
(9)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
30-127-8
(9)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
012406
30-127-9
(9)
DISASSEMBLY AND ASSEMBLY IDLER, RECOIL SPRING
CED00140
012406
CDD00141
INSTALLATION OF IDLER,
RECOIL SPRING ASSEMBLY
• Carry out installation in the reverse order to
removal.
30-128
(9)
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
CED00375
30-129
(9)
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
012406
nut (6).
Nut (6): 328.5Nm {33.5kgm}
7) Remove recoil spring assembly (4) from tool.
3. Fill portion A inside cylinder (10) with at least
120 cc of grease to prevent air from accumulat-
ing.
4. Assemble yoke piston assembly (5) to recoil
spring assembly (4).
2 Sliding portion of yoke piston, wear ring:
Grease (G2-LI)
5. Fit valve (3) and seat (2), and secure with lock
plate (1).
fl Install the valve so that the fitting faces the
outside.
4 1 3
6 2
9 7
8
5 10
13 14
11 12
17
16 18
15
CED00375
30-130
(9)
DISASSEMBLY AND ASSEMBLY IDLER
DISASSEMBLY OF IDLER
ASSEMBLY
1. Remove dowel pin (1), then remove support
(2).
8
2. Remove floating seal (3) from support (2) and 6
idler (4).
7
3. Pull out idler (4) from shaft (5) and support
assembly (7).
fl It is filled with 150 cc. of oil, so drain the oil
at this point or lay a cloth to prevent the
area from becoming dirty.
2
012406
CED00190
4 6
6 7
CED00191
9,10 4 5
8
CED00192 CED00193
30-131
(9)
DISASSEMBLY AND ASSEMBLY IDLER
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
012406
CED00191
7 5
CED00197
L1-2
CED00198
30-132
(9)
DISASSEMBLY AND ASSEMBLY IDLER
CED00197
4
012406
CED00199
CED00200
8
6 L1-2
10 3
1
4 9
5
2
3
CED00202 CED00201
30-133
DISASSEMBLY AND ASSEMBLY TRACK SHOE
INSTALLATION OF TRACK
SHOE ASSEMBLY
• Carry out installation in the reverse order to
removal.
q e
fl Track shoe tension: 20 – 30mm
r w
Master link mounting bolt:
Initial torque: 196±19.6Nm {20±2kgm}
Tightening angle: 180±20°
CED00228
fl When winding on the track shoe, use a bar and
make sure that the link does not come off the
sprocket.
When winding on, keep the track shoe pulled
and do not let it become loose.
fl Check that there is no dirt or dust on the thread
or mating surface of the master link.
fl Tighten the shoe bolts in the order [1] – [4].
012406
30-143
(9)
DISASSEMBLY AND ASSEMBLY ONE LINK
6
CED00484
3 5
012406
CED00485
8. Vacuum test
Using tool R6, remove air from small plug hole
at end face of pins (1) and (2) and check sealing
performance.
fl Check that the airtightness is maintained for
5 seconds at a negative pressure of 695 ±
15 mmHg.
1 2 R6
CED00486
R7
CED00487
30-171
(9)
ONE LINK
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
R5
CED00488
REMOVAL OF HYDRAULIC
PUMP ASSEMBLY 1
¤ Lower the work equipment to the ground and
stop the engine. Release the remaining pres-
sure in the circuit. For details, see TESTING
AND ADJUSTING, RELEASING REMAINING
PRESSURE IN HYDRAULIC CIRCUIT. Then
loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank.
012406
CDD00080
1. Drain oil from hydraulic tank.
Hydraulic tank: 37 ¬
5 4
CED00081
30-172
(9)
DISASSEMBLY AND ASSEMBLY STEERING PPC VALVE
INSTALLATION OF STEERING
CED00171
PPC VALVE ASSEMBLY
• Carry out installation in the reverse order to
removal.
1
fl Adjust the steering lever linkage.
For details, see Adjusting steering lever link-
age.
30-189
7
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
fl Clean all parts, and check for dirt or damage.
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.
CED00179
012406
CED00180
11
12
13
9 10
CED00178
CED00181 CED00182
30-198
(9)
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
CED00177
CED00175
1,030±103
Blade angle {105±10.5}
932±93.2
Blade tilt {95±9.5}
CED00174
30-199
(9)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
REMOVAL OF WORK
EQUIPMENT ASSEMBLY
¤ Release the remaining pressure in the circuit.
For details, see TESTING AND ADJUSTING,
RELEASING REMAINING PRESSURE IN HY-
DRAULIC CIRCUIT. Then loosen the oil filler cap
slowly to release the pressure inside the hy-
draulic tank.
012406
CED00133
CED00134
CED00135
30-200
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
6
CDD00136
7
012406
8
CED00137
INSTALLATION OF WORK
EQUIPMENT ASSEMBLY
• Carry out installation in the reverse order to
removal.
• Greasing
fl After completion of the installation, carry
out greasing of the mounting pins that were
removed.
30-201
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
DISASSEMBLY OF WORK
EQUIPMENT ASSEMBLY
¤ Set blocks [1], [2], and [3] under the work equip-
ment frame, and secure the work equipment
assembly. q
w e
CED00154
1. Blade
1) Remove cover (1) and cover (2) of angle 1
cylinder assembly from blade.
012406
CED00155
3
CED00156
Blade: 650 kg
30-202
(9)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
Blade: 650 kg
012406
11
CED00159
30-203
(9)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
CED00160
4. Lever, rod
1) Sling lever (16), remove lock plates, then 18
16
remove pins (17) and (18), and lift off lever
(16).
Lever: 32 kg
17
2) Remove lock plate, and pull out pin (19),
then remove rod (20). 20
012406
19
CED00161
5. Hoses
1) Remove covers (21) and (22) from frame,
then remove hose (23).
24 25
2) Remove covers (24) and (25) from frame, 26
then remove hose (26).
23
21 22
CED00162
30-204
(8)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
ASSEMBLY OF WORK
EQUIPMENT ASSEMBLY
¤ Set blocks 1, 2, and 3 under the frame.
q
w
e
CED00163
1. Hoses, covers
1) Fit hose (26) to frame and install covers (25)
and (24). 24 25
2) Fit hose (23) to frame and install covers (22) 26
and (21).
23
012406
21 22
CED00162
240 120
Tilt cylinder
555
bottom side
Clip
CED00164
2. Lever, rod
1) Raise lever (16), align with frame, then in- 18
16
stall pin (18), and lock pin with lock plate.
4 Lever: 32 kg
19
CED00161
30-205
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
3. Tilt cylinder
1) Raise tilt cylinder assembly (12), then as-
semble to frame and install mounting pin
(15) at cylinder bottom end. 12
14 15
CED00165
11
012406
CED00166
4. Blade
1) Raise angle cylinder (3) and assemble bot-
tom end to frame, then install pin (10), and
3
lock pin with lock plate. 10
30-206
(9)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
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
6. Greasing
After assembly, apply grease (G2-LI) to all
mounting pins.
2
CED00155
30-207
(9)
DISASSEMBLY AND ASSEMBLY OPERATOR CAB
9
012406
CED00230
11
CED00232
30-211
(8)
DISASSEMBLY AND ASSEMBLY OPERATOR CAB
012406
12. Lift off cab assembly (14) slowly. 3
14
Cab assembly: 285 kg
CED00234
30-212
(8)
DISASSEMBLY AND ASSEMBLY OPERATOR CAB
INSTALLATION OF OPERATOR
CAB ASSEMBLY
• Carry out installation in the reverse order to
removal.
1
fl When connecting each connector, take care
not to mistake its No.
2
fl Note that the 2 bolts at the front part of the
operator's cab are different in length from
the other bolts.
1) Install and tighten the mounting bolts of
dashboard mounting bracket (10).
2) Measure the internal pressure and sealing
performance of the operator's cab. For de-
tails, see TESTING AND ADJUSTING OP-
ERATOR'S CAB.
fl If water enters the cab during the seal-
ing performance test, seal the cab with
012406
3
fl If the operator's cab is removed from the
floor frame, prepare the following sealant
to secure pressurizing performance and seal-
ing performance.
14X-911-2521 : 1 piece (Seal (B))
14X-911-5911 : 5 pieces (Seals (C) - (G))
198-Z11-3960 : Three bond (1207B)
: 1 pieces (Gasket sealant (A))
30-212-1
(8)
DISASSEMBLY AND ASSEMBLY OPERATOR CAB
012406
4) Fit seal (B) into the guide plate (33) of the
air conditioner box.
fl Pull seal (B) down and fit it, pressing
the gasket sealant applied in 2).
fl Fill the clearnce with adhesive (LT-1A)
between seal (B) and the floor frame
(Portion marked fl).
30-212-2
(8)
DISASSEMBLY AND ASSEMBLY OPERATOR CAB
30-212-3
(8)
REMOVAL AND INSTALLATION OF OPERATOR'S
DISASSEMBLY AND ASSEMBLY CAB GLASS (STUCK GLASS)
012406
∗ Among the panes off window glass of the opera- (1): Front window glass
tor's cab, the one panel of (1) is stuck. (2): Both-sided adhesive tape
In this section, the procedure for replacing the
stuck glass is explained.
30-212-4
(8)
REMOVAL AND INSTALLATION OF OPERATOR'S
DISASSEMBLY AND ASSEMBLY CAB GLASS (STUCK GLASS)
REMOVAL
30-212-5
(8)
REMOVAL AND INSTALLATION OF OPERATOR'S
DISASSEMBLY AND ASSEMBLY CAB GLASS (STUCK GLASS)
INSTALLATION
012406
3. Stick both-sided adhesive tape (3) along the in-
side edges of the front window glass sticking
section.
fl Do not remove the release tape of the both-
sided adhesive tape on the glass sticking
side before sticking the glass.
fl When sticking the both-sided adhesive tape,
do not touch the cleaned surface as long as
possible.
fl Take care that the both-sided adhesive tape
will not float at each corner of the window
frame.
fl Do not lap the finishing end of both-sided
adhesive tape (3) over the starting end but
make clearance a of about 5 mm between
them.
30-212-6
(8)
REMOVAL AND INSTALLATION OF OPERATOR'S
DISASSEMBLY AND ASSEMBLY CAB GLASS (STUCK GLASS)
5. Apply adhesive.
8 adhesive:
Sikaflex 256HV manufactured by
Sika Japan
fl Do not use prim7er.
fl The using limit of the adhesive is 6 months
after the date of manufacture. Do not use
the adhesive after this limit.
fl Keep the adhesive in a dark place where
the temperature is below 25°C.
fl Never heat the adhesive higher than 30°C.
fl When reusing the adhesive, remove the all
hardened part from the nozzle tip.
1) Break aluminum seal (6) of the outlet of
adhesive cartridge (5) and install the nozzle.
30-212-7
(8)
REMOVAL AND INSTALLATION OF OPERATOR'S
DISASSEMBLY AND ASSEMBLY CAB GLASS (STUCK GLASS)
012406
4) Remove release tape of the both-sided ad-
hesive tape (3a) on the glass side.
30-212-8
(8)
REMOVAL AND INSTALLATION OF OPERATOR'S
DISASSEMBLY AND ASSEMBLY CAB GLASS (STUCK GLASS)
30-212-9
(8)
REMOVAL AND INSTALLATION OF OPERATOR'S
DISASSEMBLY AND ASSEMBLY CAB GLASS (STUCK GLASS)
012406
30-212-10
(8)
REMOVAL AND INSTALLATION OF OPERATOR'S
DISASSEMBLY AND ASSEMBLY CAB GLASS (STUCK GLASS)
30-212-11
(8)
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
3. Drain coolant.
Operator’s seat: 45 kg
012406
floor frame.
30-213
(8)
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
15
CED00086
17
012406
CED00087
18
CED00089
CED00088
30-214
7
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
CDD00090
23 22
012406
CED00091
24
CED00092
25
26
CED00093
30-215
(9)
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
CED00094
012406
CED00095
CDD00096
CED00097
30-216
(9)
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
INSTALLATION OF FLOOR
FRAME ASSEMBLY
• Carry out installation in the reverse order to
removal.
30-217
(9)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
REMOVAL OF AIR
CONDITIONER COMPRESSOR
ASSEMBLY
¤ Disconnect the cable from the negative (–) ter- 1
minal of the battery.
¤ Bleed refrigerant gas from air conditioner. 2
012406
(7). 2
CED00044
30-218
(8)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
INSTALLATION OF AIR
CONDITIONER COMPRESSOR
ASSEMBLY
• Carry out installation in the reverse order to
removal.
Tightening torque
Thread size Nm (kgm)
11.8 – 14.7 Nm
16 x 1.5 (1.2 – 1.5 kgm)
19.6 – 24.5 Nm
22 x 1.5 (2.0 – 2.5 kgm)
012406
29.4 – 34.3 Nm
24 x 1.5 (3.0 – 3.5 kgm)
30-219
(9)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER
REMOVAL OF AIR
CONDITIONER CONDENSER
ASSEMBLY 1
¤ Disconnect the cable from the negative (–) ter-
minal of the battery.
¤ Bleed refrigerant gas from air conditioner.
1. Open cover (1).
012406
CED00047
3
5
CED00048
30-220
(8)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER
INSTALLATION OF AIR
CONDITIONER CONDENSER
ASSEMBLY
• Carry out installation in the reverse order to
removal.
Tightening torque
Thread size Nm (kgm)
11.8 – 14.7 Nm
16 x 1.5 (1.2 – 1.5 kgm)
19.6 – 24.5 Nm
22 x 1.5 (2.0 – 2.5 kgm)
012406
29.4 – 34.3 Nm
24 x 1.5 (3.0 – 3.5 kgm)
30-221
(9)
DISASSEMBLY AND ASSEMBLY MONITOR
REMOVAL OF MONITOR
ASSEMBLY
¤ Disconnect the cable from the negative (–) ter- 1
minal of the battery.
CED00121
INSTALLATION OF MONITOR
ASSEMBLY 1
• Carry out installation in the reverse order to 2
removal.
012406
CED00122
30-222
DISASSEMBLY AND ASSEMBLY DT CONNECTOR PIN
REMOVAL OF DT CONNECTOR
PIN
30-223
(9)
DISASSEMBLY AND ASSEMBLY DT CONNECTOR PIN
INSTALLATION OF DT
CONNECTOR PIN
012406
3. After inserting the all wires, install wedge (1).
30-224
(9)
DISASSEMBLY AND ASSEMBLY DT CONNECTOR PIN
REMOVAL OF HD CONNECTOR
PIN
INSTALLATION OF HD
CONNECTOR PIN
30-225
(9)
DISASSEMBLY AND ASSEMBLY REPAIR PROCEDURE FOR WIRING HARNESS
012406
4. Loosen locknut (3) and turn adjustment screw
(4).
30-226
(9)
MAINTENANCE STANDARD
40 MAINTENANCE STANDARD
40-1
(9)
MAINTENANCE STANDARD DAMPER, UNIVERSAL JOINT
3 66.2±7.4Nm
(6.75±0.75kgm)
012406
1
SDD00889
Unit: mm
Face runout, radial runout Face runout: Max. 1.0 (at ø115.06), Radial runout: Max. 1.5
— (When damper output shaft and transmission input shaft Adjust
of coupling are rotated at the same time)
40-2
MAINTENANCE STANDARD HYDRAULIC+POWER TRAIN PUMP
Unit: mm
40-3
(9)
MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION
(1/3)
Y
012406
3 24.5±4.9Nm
(2.5±0.5kgm)
A
Y
C C
A
3 277.0±31.9Nm
(28.25±3.25kgm) SDD00891
40-5
(9)
MAINTENANCE STANDARD TRANSMISSION
(2/3)
11 10 9 1 7
3 30.5±3.5Nm
(3.15±0.35kgm)
3 66.5±7.5Nm
(6.75±0.75kgm)
3
176.5±19.5Nm
(18±2kgm)
012406
64±5Nm
(6.5±0.5kgm)
3 269.5±24.5Nm
(27.5±2.5kgm)
2a 2b 12 3a 12 3b 4 13 14 5 15 6
8
C-C
SAD00892
40-6
(9)
MAINTENANCE STANDARD TRANSMISSION
Unit: mm
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
13 assembly thickness 18.6 ±0.24 17.0
(disc, plate: 3 each)
No. 4 clutch overall
14 assembly thickness 12.4 ±0.20 11.3
(disc, plate: 2 each)
No. 5 clutch overall
15 assembly thickness 21.8 ±0.26 20.2
(disc x 3, plate x 4)
40-7
MAINTENANCE STANDARD TRANSMISSION
(3/3)
012406
40-8
(9)
MAINTENANCE STANDARD TRANSMISSION
Unit: mm
–0.01 Replace
Width 4.0 3.60
Dimensions of –0.03
18
cage seal ring
012406
40-9
(9)
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
3 30.5±3.5Nm 3 30.5±3.5Nm
(3.15±0.35kgm) (3.15±0.35kgm)
D
D
012406
3 24.5±9.8Nm 3 30.5±3.5Nm
(2.5±1kgm) (3.15±0.35kgm)
C C
B B
3 14.7±4.9Nm
(1.5±0.5kgm)
A
3 30.5±3.5Nm
(3.15±0.35kgm)
SDD00894
40-11
(9)
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
(2/3)
2 8 9 3 7 4
10
A-A
6 11 5
012406
1
3 39.2±4.9Nm
(4.0±0.5kgm)
3 30.5±3.5Nm
(3.15±0.35kgm)
3 17.15±2.45Nm 1
(1.75±0.25kgm)
B-B SDD00895
40-12
(9)
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
Unit: mm
40-13
(9)
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
(3/3)
012406
40-14
(9)
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
Unit: mm
18 Standard shim thickness 1.0 (adjustment in pressure for each 0.5 mm shim:
at inching valve spring 35.0 KPa {0.357 kg/cm2})
Adjust shim
Standard shim thickness 1.0 (adjustment in pressure for each 0.5 mm shim:
20
at inching valve cover 18.3 KPa {0.187 kg/cm2})
40-15
(9)
MAINTENANCE STANDARD BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE
3 25.5±2.0Nm 3 66.2±7.4Nm
(2.6±0.2kgm) (6.75±0.75kgm)
1 2 7
012406
3 4 5 6 8
3 110.3±12.3Nm 3 66.2±7.4Nm
(11.25±1.25kgm) (6.75±0.75kgm)
SAD00897
40-16
(9)
MAINTENANCE STANDARD BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE
Unit: mm
Correct
Distortion of brake plate
Within 0.3 0.6 or replace
Clearance between
6 planetary pinion and 0.15 – 0.35 —
ring gear
40-17
1
MAINTENANCE STANDARD BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE
012406
40-2
40-17-1
(9)
MAINTENANCE STANDARD BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE
Unit: mm
Correct
Distortion of brake plate
Within 0.3 0.6 or replace
Clearance between
6 planetary pinion and 0.15 – 0.35 —
ring gear
40-3
40-17-2
(9)
MAINTENANCE STANDARD STEERING PPC VALVE
012406
Unit: mm
40-18
6
MAINTENANCE STANDARD STEERING PISTON
STEERING PISTON
012406
Unit: mm
40-19
(9)
MAINTENANCE STANDARD PRIORITY VALVE
PRIORITY VALVE
4 3 68.6±9.8Nm
(7±1kgm)
3 68.6±9.8Nm
(7±1kgm)
3 1 2 5
012406
SDD00900
Unit: mm
40-20
MAINTENANCE STANDARD BRAKE VALVE
BRAKE VALVE
012406
Unit: mm
48.2 N 46.1 N
39.55 36 38.4
(4.92 kg) (4.7 kg)
40-21
(9)
MAINTENANCE STANDARD PARKING BRAKE CYLINDER
3 71±17.2Nm
(7.25±1.75kgm)
012406
3 71±17.2Nm
(7.25±1.75kgm) 2 1 SDD00902
Unit: mm
4.88 KN 4.64 KN
256 190 248.3
{498 kg} {473 kg}
40-22
(9)
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
D41E, P-6 Serial No.: B20001 - B20500 fl The diagram shows the D41P-6.
012406
40-24
(9)
012406 MAINTENANCE STANDARD FINAL DRIVE
Unit: mm
40-25
1
MAINTENANCE STANDARD FINAL DRIVE
012406
40-4
40-25-1
(9)
012406 MAINTENANCE STANDARD FINAL DRIVE
Unit: mm
ª1 633.2 619
Wear of sprocket tooth 0
2
root diameter –5 Rebuild
ª2 628.8 614.5
or replace
Standard size Repair limit
Wear of sprocket tooth
3
tip width 40 32
40-5
40-25-2
6
MAINTENANCE STANDARD TRACK FRAME, RECOIL SPRING
012406
Unit: mm
40-26
(9)
MAINTENANCE STANDARD IDLER
IDLER
D41E-6 Serial No.: B20001–B20980
D41P-6 Serial No.: B20001–B20983
Unit: mm
40-27
(9)
MAINTENANCE STANDARD IDLER
IDLER
D41E-6 Serial No.: B20981 – B40000, 50001and up
D41P-6 Serial No.: B20984 – B40000, 50001and up
Unit: mm
40-27-2
40-7
(9)
MAINTENANCE STANDARD TRACK ROLLER
TRACK ROLLER
Serial No.: B20001 – B40000
Serial No.: 50001 – 50074
012406
Unit: mm
4 Width of flange 18 13
40-28
(9)
MAINTENANCE STANDARD TRACK SHOE
TRACK SHOE
LUBRICATED TRACK LINK (1/2)
SINGLE SHOE, SWAMP SHOE
Serial No.: B20001 – B40000
Serial No.: 50001 – 50200
012406
40-12
40-29-1
(9)
MAINTENANCE STANDARD MAIN CONTROL VALVE
(1/5)
3 66.2±7.4Nm
(6.75±0.75kgm)
C A D B
E E
J J
X
H H
012406
G
C A F F
D B
X SAD00908
40-30
(9)
MAINTENANCE STANDARD MAIN CONTROL VALVE
(2/5)
3 44.1±4.9Nm
(4.5±0.5kgm)
3 44.1±4.9Nm
(4.5±0.5kgm)
012406
3 147±9.8Nm A-A
(15±1kgm)
3 53.9±4.9Nm
(5.5±0.5kgm)
B-B
SAD00909
40-31
(9)
MAINTENANCE STANDARD MAIN CONTROL VALVE
(3/5)
3 139.7±22.1Nm
(14.25±2.25kgm)
2
3
3 139.7±22.1Nm
(14.25±2.25kgm)
C-C 3 39.2±4.9Nm
(4.0±0.5kgm)
3 29.4±4.9Nm
(3.0±0.5kgm) 3
39.2±4.9Nm
(4.0±0.5kgm)
012406
3 23.5±3.9Nm
(2.4±0.4kgm)
3 39.2±4.9Nm E-E
(4.0±0.5kgm) 3 39.2±4.9Nm
(4.0±0.5kgm)
D-D
SAD00910
Unit: mm
40-32
(9)
MAINTENANCE STANDARD MAIN CONTROL VALVE
(4/5)
3 98±9.8Nm
(10±1kgm)
3 39.2±4.9Nm
(4.0±0.5kgm)
3 9.8±2.0Nm
2 (1.0±0.2kgm)
3 1.5±0.2Nm 3 29.4±4.9Nm
(0.15±0.02kgm) (3.0±0.5kgm)
F-F
3 17.2±2.5Nm
4 3 (1.75±0.25kgm)
012406
3 34.5±4.9Nm
(3.5±0.5kgm)
3 168.2±24.0Nm
(17.15±2.45kgm)
G-G
SAD00911
Unit: mm
40-33
(9)
MAINTENANCE STANDARD MAIN CONTROL VALVE
(5/5)
3 17.2±2.5Nm
(1.75±0.25kgm)
3 17.2±2.5Nm
(1.75±0.25kgm)
H-H
012406
2
J-J
SAD00912
Unit: mm
40-34
(9)
MAINTENANCE STANDARD MAIN CONTROL VALVE
(1/5)
012406
40-22
40-35-1
(9)
MAINTENANCE STANDARD MAIN CONTROL VALVE
(2/5)
012406
40-23
40-35-2
(9)
MAINTENANCE STANDARD MAIN CONTROL VALVE
(3/5)
012406
Unit: mm
40-24
40-35-3
(9)
MAINTENANCE STANDARD MAIN CONTROL VALVE
(4/5)
012406
Unit: mm
98 ± 5.9 N 78.5 N
55.7 x 22.3 26.5 —
{10.0 ±0.6 kg} {8.0 kg}
40-25
40-35-4
(9)
MAINTENANCE STANDARD MAIN CONTROL VALVE
(5/5)
012406
Unit: mm
40-26
40-35-5
(9)
MAINTENANCE STANDARD WORK EQUIPMENT CYLINDER
012406
• BLADE ANGLE CYLINDER
40-36
(9)
012406 MAINTENANCE STANDARD WORK EQUIPMENT CYLINDER
Unit: mm
40-37
MAINTENANCE STANDARD WORK EQUIPMENT
WORK EQUIPMENT
POWER ANGLE TILTDOZER
012406
40-38
(9)
012406 MAINTENANCE STANDARD WORK EQUIPMENT
Unit: mm
40-39
(9)
MAINTENANCE STANDARD WORK EQUIPMENT
3 260±34Nm
(26.5±3.5kgm)
2 1
012406
3
SDD00918
Unit: mm
Replace
2 Height of end bit 160 110
40-40
STRUCTURE AND FUNCTION
90 OTHERS
With cab (2/2) (Serial No.: 50201 and up) .... 90-11-4
Without cab (Serial No.: B20001 – B40000,
50001 – 50200) ......................................... 90-13
Cab electrical circuit diagram
(Serial No.: B20001 – B40000,
50001 – 50200) ......................................... 90-15
Cab electrical circuit diagram
(Serial No.: 50201 and up)...................... 90-17
90-1
(9)
OTHERS ACTUAL ELECTRIC WIRING DIAGRAM
90-9-1
(9)
ELECTRICAL CIRCUIT DIAGRAM
WITH CAB
Serial No.: B20001 – B40000
Serial No.: 50001 – 50200 *1. Serial N0.: B20501 – B40000
012406
90-11
(9)
ELECTRICAL CIRCUIT DIAGRAM
WITHOUT CAB
Serial No.: B20001 – B40000
Serial No.: 50001 – 50200 *1. Serial No.: B20501 – B40000
012406
90-13
(9)
OTHERS ELECTRICAL CIRCUIT DIAGRAM
90-15
(9)