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SEBMOOI 007

Shop
Manual

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BULLDOZERS

This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or
disciosed except in accordance with written authorization from Komatsu America lntemational Company.

It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or add improvements at any time wlthout Incurring any obligation to install such changes on products sold
previously.

Due to this continuous program of research and development, periodic revisions may be made to this publication.
It is recommended that customers contact their distributor for information on the latest revision.

May 1997 Copyright 1997 Komatsu America International Company


oo&
CONTENTS

No. of page
01 GENERAL . . . . ..~................................................................. 01-l

10 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-I

20 TESTING AND ADJUSTING . ... ... ... .. . ... .. .. .. . .. .. ... .. .. ... . ... . 20-I

30 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . ..*.........*m....... 30-I

40 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . ..n....m.........m..... 40-I

%
:
0
90 OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-I
LIST OF REVISED PAGES

The affected pages are indicated by the use of the


following marks. It is requested that necessary actions Mark Indication Action required
be taken to these pages according to the table below.
0 Page to be newly added Add

a Page to be replaced Replace

Page to be deleted Discard


( 1

Pages having no marks are those previously revised


or made additions.

LIST OF REVISED PAGE

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IO-56 @ 20-11 @ 20-33-2 20-72-3 @ 20-98

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IO-72 @ 20-23-l @ 20-57 20-80 0 30- 9-5

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10-74 @ 20-24 @ 20-59 20-82 0 30-10-I

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20- 2 @ 20-27 @ 20-62 20-85 0 30-12

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00-J-2
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30-19-3 30-51 0 30-87 C 30-115-I 0 40-17

30-19-4 30-52 0 30-88 ^


L/ 30-115-2 @ 40-18

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30-21 30-54 0 30-88-2 n


i/ 30-115-4 @ 40-20

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30-21-4 30-58 30-92 30-117 @ 40-24-I @

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30-23-3 0 30-61-I 30-97 30-122 @ 40-29 @

30-24 0 30-61-2 30-98 30-123 @ 40-29-I @

30-25 0 30-61-3 30-99 30-124 @ 40-29-2 @

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90-l 3 90-57

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00-J-4
SAFETY SAFETY NOTICE

SAFETY
SAFETY NOTICE

IMPORTANT SAFETY NOTICE

Proper service and repair is extremely important for safe machine operation. The
service and repair techniques recommended by Komatsu and described in this manual
are both effective and safe. Some of these techniques require the use of tools specially
designed by Komatsu for the specific purpose.

To prevent injury to workers, the symbol A is used to mark safety precautions in this
manual. The cautions accompanying these symbols should always be followed care-
fully. If any dangerous situation arises or may possibly arise, first consider safety, and
take the necessary actions to deal with the situation.

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to


keep tools and removed parts. Always keep
Mistakes in operation are extremely dangerous. the tools and parts in their correct places.
Read the Operation and Maintenance Manual Always keep the work area clean and make
carefully BEFORE operating the machine. sure that there is no dirt or oil on the floor.
1. Before carrying out any greasing or repairs, Smoke only in the areas provided for smok-
read all the precautions given on the decals ing. Never smoke while working.
which are fixed to the machine.

2. When carrying out any operation, always PREPARATIONS FOR WORK


wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs,
missing. park the machine on hard, level ground, and
. Always wear safety glasses when hitting block the wheels or tracks to prevent the
parts with a hammer. machine from moving.
. Always wear safety glasses when grind-
%. Before starting work, lower blade, ripper,
ing parts with a grinder, etc.
bucket or any other work equipment to the
3. If welding repairs are needed, always have a ground. If this is not possible, insert the
trained, experienced welder carry out the safety pin or use blocks to prevent the work
work. When carrying out welding work, al- equipment from falling. In addition, be sure
ways wear welding gloves, apron, hand to lock all the control levers and hang warn-
shield, cap and other clothes suited for weld- ing signs on them.
ing work.
9. When disassembling or assembling, support
4. When carrying out any operation with two the machine with blocks, jacks or stands
or more workers, always agree on the oper- before starting work.
ating procedure before starting. Always in-
IO. Remove all mud and oil from the steps or
form your fellow workers before starting any
other places used to get on and off the ma-
step of the operation. Before starting work,
chine. Always use the handrails, ladders or
hang UNDER REPAIR signs on the controls
steps when getting on or off the machine.
in the operator’s compartment.
Never jump on or off the machine. If it is
5. Keep all tools in good condition and learn impossible to use the handrails, ladders or
the correct way to use them. steps, use a stand to provide safe footing.

00-3
SAFETY SAFETY NOTICE

PRECAUTIONS DURING WORK 19. Be sure to assemble all parts again in their
original places.
11 When removing the oil filler cap, drain plug Replace any damaged parts with new parts.
or hydraulic pressure measuring plugs, . When installing hoses and wires, be sure
loosen them slowly to prevent the oil from that they will not be damaged by contact
spurting out. with other parts when the machine is be-
Before disconnecting or removing compo- ing operated.
nents of the oil, water or air circuits, first
20. When installing high pressure hoses, make
remove the pressure completely from the
sure that they are not twisted. Damaged
circuit.
tubes are dangerous, so be extremely care-
12. The water and oil in the circuits are hot ful when installing tubes for high pressure
when the engine is stopped, so be careful circuits. Also, check that connecting parts
not to get burned. are correctly installed.
Wait for the oil and water to cool before
21 When assembling or installing parts, always
carrying out any work on the oil or water
use the specified tightening torques. When
circuits.
installing protective parts such as guards,
13. Before starting work, remove the leads from or parts which vibrate violently or rotate at
the battery. Always remove the lead from high speed, be particularly careful to check
the negative (-1 terminal first. that they are installed correctly.

14. When raising heavy components, use a hoist 22. When aligning two holes, never insert your
or crane. fingers or hand. Be careful not to get your
Check that the wire rope, chains and hooks fingers caught in a hole.
are free from damage.
23. When measuring hydraulic pressure, check
Always use lifting equipment which has
that the measuring tool is correctly assem-
ample capacity.
bled before taking any measurements.
Install the lifting equipment at the correct
places. Use a hoist or crane and operate
24. Take care when removing or installing the
slowly to prevent the component from hit-
tracks of track-type machines.
ting any other part. Do not work with any
When removing the track, the track sepa-
part still raised by the hoist or crane.
rates suddenly, so never let anyone stand at
15. When removing covers which are under in- either end of the track.
ternal pressure or under pressure from a
spring, always leave two bolts in position
on opposite sides. Slowly release the pres-
sure, 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 mini-
mum 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 judgements. 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 further divided into the each main group of components.

STRUCTURE AND FUNCTION


This section explains the structure and function of each component. It serves not only to give
an understanding of the structure, but also serves as reference material for troubleshooting.

TESTING AND ADJUSTING


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

DISASSEMBLY AND ASSEMBLY


This section explains the order to be followed when removing, installing, disassembling or
assembling each component, as well as precautions to be taken for these operations.

MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.

NOTICE
The specifications contained in this shop manual are subject to change at any
time and without any advance notice. Use the specifications given in the book
with the latest date.

00-5
FOREWORD HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

VOLUMES REVISED EDITION MARK

Shop manuals are issued as a guide to carrying When a manual is revised, an edition mark
out repairs. They are divided as follows: (@@@...J is recorded on the bottom of the
Chassis volume: Issued for every machine model pages.
Engine volume: Issued for each engine series
Electrical volume: Each issued as one
Attachments volume: volume to cover all REVISIONS
I models
Revised pages are shown in the LIST OF RE-
These various volumes are designed to avoid VISED PAGES next to the CONTENTS page.
duplicating the same information. Therefore, to
deal with all repairs for any model , it is neces-
sary that chassis, engine, electrical and attach-
SYMBOLS
ment volumes be available.
So that the shop manual can be of ample prac-
DISTRIBUTION AND UPDATING tical use, important safety and quality portions
are marked with the following symbols.
Any additions, amendments or other changes
will be sent to KOMATSU distributors. Get the
most up-to-date information before you start any
work.

FILING METHOD
1. See the page number on the bottom of the Symbol Item Remarks
page. File the pages in correct order.
Special safety precautions are
2. Following examples
page number.
show how to read the

Example 1 (Chassis volume):


a Safety necessary when performing
the work.

Special technical precautions


10 -3
or other precautions for pre-
* Caution serving standards are neces-
Item number (IO. Structure sary when performing the
and Function) work.
Consecutive page number for
Weight of parts of systems.
each item.

el
Caution necessary when se-
Weight lecting hoisting wire, or when
kg
Example 2 (Engine volume): working posture is important,
etc.

Places that require special at-


ighteninc I
Unit number (1. Engine) tention for the tightening
torque torque during assembly.
Item number (2. Testing and
Adjusting) Places to be coated with ad-
Consecutive page number for Coat
hesives and lubricants, etc.
each item.
Places where oil, water or fuel
Xl, water must be added, and the ca-
3. Additional pages: Additional pages are indi- pacity.
cated by a hyphen (-1 and number after the
Places where oil or water
page number. File as in the example. Drain must be drained, and quan-
Example: tity to be drained.

IO-4 12-203
10-4-I -
> Added pages -c~f~~~~~~
1O-4-2
IO-5 12-204

00-6
FOREWORD HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS

HOISTING
Slinging near the edge of the hook may
Heavy parts (25 kg or more) must be cause the rope to slip off the hook during
lifted with a hoist, etc. In the DISAS- hoisting, and a serious accident can re-
SEMBLY AND ASSEMBLY section, sult. Hooks have maximum strength at
every part weighing 25 kg or more is the middle portion.
indicated clearly with the symbol &

. If a part cannot be smoothly removed from


the machine by hoisting, the following checks
should be made:
I) Check for removal of all bolts fastening 100% 88% 79% 71% 41%
the part to the relative parts. SAW0479
2) Check for existence of another part caus- 3) Do not sling a heavy load with one rope
ing interference with the part to be re- alone, but sling with two or more ropes
moved. symmetrically wound onto the load.

A Slinging with one rope may cause


turning of the load during hoisting,
untwisting of the rope, or slipping of
WIRE ROPES
the rope from its original winding
1) Use adequate ropes depending on the
position on the load, which can re-
weight of parts to be hoisted, referring to
sult in a dangerous accident.
the table below:

Wire ropes 4) Do not sling a heavy load with ropes form-


(Standard “Z” or “S” twist ropes ing a wide hanging angle from the hook.
without galvanizing) When hoisting a load with two or more
ropes, the force subjected to each rope
Rope diameter T Allowable load will increase with the hanging angles. The
table below shows the variation of allow-
mm kN tons
able load kN {kg} when hoisting is made
10 9.8 1.0 with two ropes, each of which is allowed
11.2 13.7 1.4 to sling up to 9.8 kN (1000 kg) vertically,
at various hanging angles.
12.5 15.7 1.6
When two ropes sling a load vertically, up
14 21.6 2.2
to 19.6 kN (2000 kg} of total weight can be
16 27.5 2.8 suspended. This weight becomes 9.8 kN
18 35.3 3.6 11000 kg) when two ropes make a 120”

20 43.1 4.4 hanging angle. On the other hand, two


ropes are subjected to an excessive force
22.4 54.9 5.6
as large as 39.2 kN (4000 kg) if they sling
30 98.1 10.0
a 19.6 kN {2000 kg) load at a lifting angle
40 176.5 18.0

50 274.6 28.0

60 392.2 40.0

* The allowable load value is estimated to


be one-sixth or one-seventh of the break-
ing strength of the rope used.

2) Sling wire ropes from the middle portion


30 60 90 120 150
of the hook. Lifting anole (deoree) SAD00480

00-7
FOREWORD COATING MATERIALS

COATING MATERIALS
Sr 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 :omatsu code Part No. Q’tY Container Main applications, features

l Used to prevent rubber gaskets, rubber


LT-IA 790-129-9030 150 g Tube
cushions, and cock plug from coming out.

l Used in places requiring an immediately


effective, strong adhesive. Used for plas-
790-129-9050 20 9 ?olyethylem
LT-1 B tics (except polyethylene, polyprophylene,
(2 pes.) container
tetrafluoroethlene and vinyl chloride), rub-
ber, metal and non-metal.

l Features: Resistance to heat and chemi-


Jolyethylen~ cals
LT-2 09940-00030 50 g container l Used for anti-loosening and sealant pur-
pose for bolts and plugs.

790-129-9060 Adhesive: l Used as adhesive or sealant for metal, glass


(Set of adhe- 1 kg and plastic.
LT-3 sive and iardeninc Can
hardening agent:
agent) 500 g
Adhesives
‘olyethylem Used as sealant for machined holes.
LT-4 790-129-9040 250 g l

container

Holtz l Used as heat-resisting sealant for repair-


790-12fs9120 75 g Tube
MH 705 ing engine.

l Quick hardening type adhesive


Three bond ‘olyethylene l Cure time: within 5 sec. to 3 min.
1735 790-129-9140 50 g Used mainly for adhesion of metals, rub-
container l

bers, plastics and woods.

l Quick hardening type adhesive


l Quick cure type (max. strength after 30 min-
Aron-alpha ‘olyethylene
790-129-9130 29 utes)
201 container
l Used mainly for adhesion of rubbers, plas-
tics and metals.

l Features: Resistance to heat, chemicals


Loctite ‘olyethylene
‘9A-129-9 110 50 cc l Used at joint portions subject to high tem-
648-50 container
peratures.

l Used as adhesive or sealant for gaskets


LG-1 790-129-9010 200 g Tube
and packing of power train case, etc.

Features: Resistance to heat


Used as sealant for flange surfaces and
Gasket bolts at high temperature locations, used
sealant LG-3 790-129-9070 Can to prevent seizure.
1 kg
Used as sealant for heat resistance gasket
for high temperature locations such as en-
gine precombustion chamber, exhaust
pipe, etc.

00-8
FOREWORD COATING MATERIALS

Category Komatsu code 1 Part No. i Q’ty Container Main applications, features

l Features: Resistance to water, oil


l Used as sealant for flange surface, thread.
LG-4 200 g Tube l Also possible to use as sealant for flanges
790-129-9020
with large clearance.
l Used as sealant for mating surfaces of fi-
nal drive case, transmission case.
I I

l Used as sealant for various threads, pipe


Polyethylene joints, flanges.
LG-5 790-129-9080 1 kg container l Used as sealant for tapered plugs, elbows,
nipples of hydraulic piping.

l Features: Silicon based, resistance to heat,


Gasket cold
sealant LG-6 09940-00011 250 g Tube l Used as sealant for flange surface, tread.
l Used as sealant for oil pan, final drive case,
etc.

l Features: Silicon based, quick hardening


type
LG-7 09920-00150 150 g Tube l Used as sealant for flywheel housing, in-
take manifold, oil an, thermostat housing,
etc.

Used as heat-resisting sealant for repairing


Thr;;,b,ond 790-129-9090 loo g 1 Tube I* engine.

l Used as lubricant for sliding portion (to pre-


LM-G
Molybde- IO~~~O-OOO~I1 60g 1 can I vent from squeaking).
num
disulphide l Used to prevent seizure or scuffling of the
lubricant LM-P 09940-00040 200 g Tube thread when press fitting or shrink fitting.
l Used as lubricant for linkage, bearings, etc.

SYG2-400LI l General purpose type


SYG2-350LI
G2-LI SYG2-4OOLI-A Various Various
SYG2-160LI
SYGA-16OCNLI

l Used for normal temperature, light load


SYG2-400CA bearing at places in contact with water or
Grease
SYG2-350CA steam.
GP-CA SYGP-4OOCA-A Various Various
SYG2-16OCA
SYGA-16OCNCA

Molybdenum 400 g l Used for places with heavy load


disulphide SYG2-400M (10 per Belows type
lubricant case)

00-9
FOREWORD STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUES OF BOLTS AND NUTS


Use these torques for metric bolts and nuts. (Always use torque wrench).

Thread diameter Width


of bolt across flats

mm I mm I Nm I kcm
6 10 13.251.4 1.35f0.15
8 13 31f3 3.2f0.3
10 17 66+7 6.7f0.7
12 19 113flO 11.5+1
14 22 177+19 18f2

16 24 279f30 28.5+3
18 27 382+39 39f4
20 30 549k59 56f6
22 32 745k83 76+8.5
24 36 927k103 94.5f10.5

1320+140 135f15
172Ok190 175+20
2210+240 225f25

Thread diameter Width


of bolt across flats

mm mm Nm bm
6 10 7.85f 1.95 0.8f0.2
8 13 18.6k4.9 1.9f0.5
10 14 40.2k5.9 4.1kO.6
12 27 82.35f7.85 8.4f0.8

TIGHTENING TORQUE OF HOSE NUTS


Use these torques for hose nuts.
Thread diameter Width across flat Tightening torque
Nominal No.
mm mm Nm kgm
02 14 19 24.5k 4.9 2.5+0.5
03 18 24 49+ 19.6 5+2
04 22 27 78.5k 19.6 8+2
05 24 32 137.3+ 29.4 14+3
06 30 36 176.5rt29.4 18f3
10 33 41 196.1*49 20f5
12 36 46 245.2+ 49 2555
14 42 55 294.2f 49 30*5

TIGHTENING TORQUE OF SPLIT FLANGE BOLTS


Use these torques for split flange bolts.
Thread diameter Width across flat Tightening torque

mm mm Nm bm
10 14 65.7k6.8 6.7k0.7
12 17 112k9.8 11.5*1
16 22 279f29 28.5+3

00-l0
FOREWORD STANDARD TIGHTENING TORQUE

TIGHTENING TORQUE OF O-RING BOSS CONNECTOR


Use these torques for O-ring boss connector

Thread diameter Width across flat Tightening torque


Nominal No.
mm mm Nm kgm
02 14 34.3f 4.9 3.5kO.5
03,04 20 Varies depending on 93.1+9.8 9.5fl
05,06 24 type of connector. 142.1f19.6 14.51t2
IO,12 33 421.4rt58.8 43f6
14 42 877.1k132.3 89.5f13.5

TIGHTENING TORQUE OF O-RING BOSS CONNECTOR


Use these torques for O-ring boss connector

Thread diameter Width across flat Tightening 1 torque


Nominal No.
mm mm Nm Mm
08 8 14 7.35f1.47 0.75+0.15
10 10 17 11.27f 1.47 1.15+0.15
12 12 19 17.64f1.96 1.8f 0.2
14 14 22 22.54f1.96 2.3+ 0.2
16 16 24 29.4* 4.9 3kO.5
18 18 27 39.2k 4.9 4f0.5
20 20 30 49k4.9 5f0.5
24 24 32 68.6k9.8 7kl
30 30 32 107.8f14.7 11+1.5
33 33 - 127.4k19.6 13f2
36 36 36 151.9f24.5 15.5f 2.5
42 42 - 210.7f29.4 21.5f3
52 52 - 323.4k44.1 33f4.5
-

,Sealingsurface

TIGHTENING TORQUES OF FLARE NUT


SAD00483
Use these torques for O-ring boss connector

Thread diameter Width across flat Tightening torque

mm mm Nm Mm
14 19 24.5f4.9 2.5f0.5
18 24 49+ 19.6 5+2
22 27 78.5+ 19.6 8f2
24 32 137.3f29.4 14f3
30 36 176.5f29.4 18f3
33 41 196.1f49 20+5
36 46 245.2f49 25+5
42 55 294.2*49 30f5

00-l 1
FOREWORD STANDARD TIGHTENING TORQUE

TIGHTENING TORQUE FOR 102 SERIES ENGINE (BOLT AND NUTS)


Use these torques for metric bolts and nuts of 102 Series Engine.

Thread diameter Tightening torque


mm Nm kgm
6 10 +2 1.02 f 0.20
8 24 f 4 2.45 f 0.41
10 43 f 6 4.38 f 0.61
12 77 f 12 7.85 f 1.22

TIGHTENING TORQUE FOR 102 SERIES ENGINE (EYE JOINTS)


Use these torques for metric eye joints of 102 Series Engine.

Thread diameter Tiahtenina toraue


mm Nm kgm
6 8f2 0.81 + 0.20
8 10 f2 1.02 + 0.20
10 12 f2 1.22 f 0.20
12 24 f 4 2.45 + 0.41
14 36 f 5 3.67 f 0.51

TIGHTENING TORQUE FOR 102 SERIES ENGINE (TAPERED SCREWS)


Use these torques for inches tapered screws of 102 Series Engine.

Thread diameter Tightening torque


inches Nm kam
1 / 16 3fl 0.31 IL0.10
I/8 8f2 0.81 f 0.20
114 12 f2 1.22 f 0.20
318 15f2 1.53 + 0.41
l/2 24 f 4 2.45 + 0.41
314 36 f 5 3.67 f 0.51
1 60 f 9 6.12 f 0.92

00-12
FOREWORD ELECTRIC WIRE CODE

ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates.a cable having a nominal number 5 and white coating with black stripe.

CLASSIFICATION BY THICKNESS

Applicable circuit

100 217 0.80 109.1 17.6 230 Starting

CLASSIFICATION BY COLOR AND CODE


FOREWORD CONVERSION TABLE

CONVERSION TABLE

METHOD OF USING THE CONVERSION TABLE


The Conversion Table in this section is provided to enable simple conversion of figures. For
details of the method of using the Conversion Table, see the example given below.

EXAMPLE
. Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(I) Locate the number 50 in the vertical column at the left side, take this as @, then draw a horizontal
line from @.
(2) Locate the number 5 in the row across the top, take this as @I, then draw a perpendicular line
down from @.
(3) Take the point where the two lines cross as 0. This point 0 gives the value when converting
from millimeters to inches. Therefore, 55 mm = 2.165 inches.

2. Convert 550 mm into inches.


(I) 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.

Millimeters to inches 1 mm = 0.03937 in

0 1 2 3 4 5; 6 7 8 9

0 0 0.039 0.079 0.118 0.157 0.197; 0.236 0.276 0.315 0.354


10 0.394 0.433 0.472 0.512 0.551 0.591 ; 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 i 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 -t 1.378; 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772; 1.811 1.850 1.890 1.929

. . .50
. .. . . . . . . .1.969
. . . . .. .. . .. . . .2.008
.. . . . .. . . . .2.047
. . . . . . .. . . . 2.087
. . .. . . . . .. .2.126
... ....... ‘pi 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 3.07 1 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

00-l 4
FOREWORD CONVERSIONTABLE

Millimeters to Inches
1 mm = 0.03937 in
l-

0 1 2 3 4 5 6 7 8 9

0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748

20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142

30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536

40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323

60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717

70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110

80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504

90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

- - -

Kilogram to Pound
1 kg = 2.2046 lb

0 1 2 3 4 5 6 7 8 9

0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89

20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93

30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98

40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03

50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07

60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12

70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17

80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21

90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

00-15
FOREWORD CONVERSIONTABLE

Literto U.S. Gallon


l! = 0.2642 U.S. Gal

0 1 2 3 4 5 6 7 8 9
\

0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019

20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661

30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303

40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944

50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586

60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228

70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870

80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511

90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153

Liter to U.K. Gallon


It = 0.21997 U.K. Gal

\\I 0

10
0
0

2.200
1

0.220

2.420
2

0.440

2.640
3

0.660

2.860
4

0.880

3.080
5

1.100

3.300
6

1.320

3.520
7

1.540

3.740
8

1.760

3.950
9

1.980

4.179

20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379

30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579

40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778

50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978

60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178

70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378

80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577

90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777

00-16
FOREWORD CONVERSIONTABLE

kgm to ft. lb
1 kgm = 7.233 ft. lb

0 1 2 3 4 5 6 7 8 9
\

0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4

20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8

30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1

40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4

50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8

60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1

70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4

80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7

90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1

100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4

110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7

120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1

130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4

140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0

160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4

170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7

180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0

190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

00-17
FOREWORD CONVERSIONTABLE

kg/cm* to lb/in*
1kg/cm* = 14.2233 lb/in*

0 1 2 3 4 5 6 7 8 9
\

0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2

20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5

30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7

40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9

50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2

60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4

70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124

80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266

90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408

100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550

110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693

120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835

130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977

140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119

150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262

160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404

170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546

180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688

190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830

200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973

210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115

220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257

230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399

240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542

00-l 8
FOREWORD CONVERSION TABLE

Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade tempera-
ture reading or vice versa is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values,
and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8”F

“C “F “C “F “C “F “C “F

-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8


-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0

-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8


-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0

-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8


-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0

-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8


-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0

-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0


-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0

-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0


-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0

-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0


-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0

00-19
01 GENERAL

Specification drawings ................................ Ol- 2


Specifications.. .............................................. 01-I 4
Weight table ................................................. 01-38
Fuel, coolant and lubricants.. ..................... .Ol-50
GENERAL SPECIFICATION DRAWINGS

SPECIFICATION DRAWINGS
Unit: mm
D31E-20 Serial No.: 42001 - 42713

n-t-
SOP

Lb

.
c
+--xc--
SL9Z

Il4F02185

01-2
0
GENERAL SPECIFICATION DRAWINGS

Unit: mm
D31P-20 Serial No.: 45001 - 47616
D31PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652

z7iB ___ (
OFP
+ !SZbE;(SPZE)
'XPZ41P!M IleJaAO ’

Il4FO2186

Note: The values given are the values for D31P-20.


( 1: Values for D31PL-20
[ I: Values for D31PLL-20
In cases where there are no values given in ( ) or [ I, the values are the same as for D31P-20.

01-3
0
GENERAL SPECIFICATION DRAWINGS

Unit: mm
D31P-20A Serial No.: 45001 - 47616

. .
oszz
.
OS91

I-
0911 * OEPI

Il4FO2187

01-4
0
GENERAL SPECIFICATION DRAWINGS

Unit: mm
D31S-20 Serial No.: 41001 - 41183
D31Q-20 Serial No.: 41001 - 41183

I
OW’06Ll
.
,0~9I:o~Pl

Il4FO2188

Note: The values given are the values for D31S-20.


( ): Values for D31Q-20
In cases where there are no values given in ( ), the values are the same as for D31S-20.

01-5
0
GENERAL SPECIFICATION DRAWINGS

Unit: mm
D37E-5 Serial No.: 3001 - 3730

I
0611

I- -
I -
9% OLZI SL9Z

Il4FO2189

01-6
GENERAL SPECIFICATION DRAWINGS

Unit: mm
D37P-5A Serial No.: 3001 - 3660

I
S69Z

Il4FO2190

01-7
0
GENERAL SPECIFICATION DRAWINGS

D31E-20 Serial No.: 42714 and up Unit: mm

0611

I_ _I
956 OLZl
GENERAL SPECIFICATION DRAWINGS

D31P-20 Serial No.: 47617 and up Unit: mm


D31PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up

[O!XZl(O~6Z)0407

[LiZPEl GPZE)SFPZ
4695

Note: The values given are the values for D31 P-20.
( 1: Values for D31PL-20
[ I: Values for D31PLL-20
In cases where there are no values given in ( ) or [ 1,the values are the same as for D31P-20.
GENERAL SPECIFICATION DRAWINGS

D31P-20A Serial No.: 47617 and up Unit: mm

i- oszz
049 I

-
7 , f-

SBD02174

01&l0
GENERAL SPECIFICATION DRAWINGS

D31S-20 Serial No.: 41184 and up Unit: mm


D31Q-20 Serial No.: 41184 and up

IO09I
OFF

[oz9zlozPz
[oP9zloP9z
[9LlEl40lE
I
[410P]ci91P

Note: The values given are the values for D31 S-20.
( ): Values for D31Q-20 SBD02175
In cases where there are no values given in ( 1, the values are the same as for D31S-20.
GENERAL SPECIFICATION DRAWINGS

D37E-5 Serial No.: 3731 and up Unit: mm

I-
06Ll
09PI

SED02176

01612
GENERAL SPECIFICATION DRAWINGS

D37P-5A Serial No.: 3661 and up Unit: mm

0991

- 7

l-t
OZP

- I SEDO2 177
GENERAL SPECIFICATIONS

SPECIFICATIONS
D31E, P-20
D3 1 P-20A
D3 1 PL, PLL-20

Machine model D31 E-20 D3 1 P-20 D31 P-2Ok 4 ID31 PL-20 331 PLL-20
-~
42001 - 45001 - 45001 - 45001 - 45001 -
Serial No.
42713 47616 47616 47616 47652

Operating weight
l Bare tractor kg 5,060 5,750 5,720 6,130 6,610

l With dozer kg 6,090 6,700 6,800 7,050 7,550

Blade capacity m3 1.7 1.52 1.52 1.02 1.02

Min. turning radius m 2.2 2.5 2.6 3.2 3.3

Gradeability dw 30 30 30 30 30

Stability de9 35 35 35 35 35

Forward 1st km/h 2.2 2.2 2.2 2.2 2.2

Forward 2nd km/h 3.9 3.9 3.9 3.9 3.9

Forward 3rd km/h 6.5 6.5 6.5 6.5 6.5

Reverse 1 st km/h 2.4 2.2 2.4 2.4 2.4 %


z
0
Reverse 2nd km/h 4.3 3.9 4.3 4.3 4.3

Reverse 3nd km/h 7.1 7.1 7.1 7.1 7.1


kPa
Bare tractor
kg/cm? IO.2 iO.41) 21.6 to.221 !I .6 10.22) I ’
12.7 (0.13) 11.8 IO.121
kPa
With dozer kg/cm21 18.1 (0.49) 25.5 IO.261 !5.5 lO.26) i 14.7 10.15) 13.7 {0.14}

Bare tractor mm 2,910 3,035 3,035 3,025 3,410

With dozer mm 3,840 3,845 3,940 3,875 4,300

Bare tractor mm 1,790 2,050 2,250 2,950 2,950

With dozer mm 2,415 2,435 2,875 3,425 3,425

To top of canopy mm - 2,735 2,735 2,735 2,735


i!
.G?
i! To tip of exhaust pipe mm 2,675 2,695 2,695 2,695 2,695

.-i To top of operator’s compartment mm 1,955 2,045 2,045 2,045 2,045


n
Track gauge mm 1,450 1,450 1,650 1,900 1,900

Length of track on ground mm 1,880 2,185 2,185 2,185 2,570

Width of track shoe (standard) mm 330 600 600 1,050 1,050

Min. ground clearance


mm 315 380 380 380 380
(to drain port of steering case)
-
GENERAL SPECIFICATIONS

Machine model D31 E-20 D31 P-20 D31 P-20A D31 PL-20 D31 PLL-20

42001 - 45001 - 45001 - 45001 - 45001 -


Serial No.
42713 47616 47616 47616 47652

Name 6D95L-1

Type 4-cycle, water-cooled, in-line vertical type, direct injection

No. of cylinders - bore x stroke mm 6-95x 115

Piston displacement e WA 4.89 (4,890)

Rated horsepower kW/rpm IHP/rprr 52.2/2,350 {70/2,350}

Max. torque Nmlrpmlkgmhpn 264.8/1,400 {27/l ,400)


.-F
z
Lu
High idling rpm 2,580

Low idling rpm 700

Min. fuel consumption ratio g/kWh {g/HPt 217 (162)

Starting motor 24 V, 5.5 kW

Alternator 24 V, 15 A

Battery 12 V, 70 Ah x 2

Radiator core type D-4 type


-
Damper Wet type, spring friction type

Planetary gear type, hydraulically actuated, lubrication


HYDROSHIFT transmission
pump force feed type, forward 3 speed, reverse 3 speed
_
Bevel gear shaft Spiral bevel gear, splash lubrication type
-
Dry type, multiple disc clutch, spring boosted,
Steering clutch I
manually operated, PPC actuated
-
Steering brake IrY type, band type, PPC actuated, interconnected with clutch
-
Final drive I jpur gear type, l-stage reduction gear, splash type lubrication
-

Suspension Rigid

Carrier roller (each side) 1 1 1 1 2


I

Track roller (each side)


1 516/61618
GENERAL SPECIFICATIONS

Machine model D31 E-20 D31 P-20 D31P-20A D31 PL-20 D31 PLL-20

42001 - 45001 - 45001 - 45001 - 45001 -

---r
Serial No.
42713 47616 47616 47616 47652
Sealed and
[ Dry, assembly Sealed and Sealed and
$ assemb’y lubricated,
t assembly type type lubricated type lubricated type

Single Arc shoe Arc shoe Arc shoe Arc shoe


Track shoe .37 on each 41 on each 41 on each 41 on each 46 on each
<;ide side side side side

F‘itch: 154mm Pitch: 154mm Pitch: 154mm Pitch: 154mm Pitch: 154mm

\iWidth: 330mm Width: 600mm Width: 600mm Width: 1,050mmWidth: 1,050mm

MPa
Max. pressure 17.2 I1751 j 17.2 11751 17.2 II751 17.2 11751 17.2 (1751
:g/cm2 1

Gear type (SAL(2)-036)

Urnin
90.1

Main control valve 2-spool valve

i
Type Double-acting, piston type
7
0
Cylinder bore mm 90 70 90 70 70

Outside diameter of piston rod mm 40 45 40 45 45

Piston stroke mm 393 850 393 850 850

Max. distance between pins mm 1,109 1,350 1,109 1,350 1,350

Min. distance between pins mm 716 500 716 500 500

Cylinder bore mm 90 90 90 90 90

Outside diameter of piston rod mm 40 40 40 40 40

Piston stroke mm 145 120 145 120 120

Max. distance between pins mm 613 790 613 790 790

Min. distance between pins mm 468 670 468 670 670

Cylinder bore mm 90 - 90 - -

Outside diameter of piston rod mm 40 - 40 - -

Piston stroke mm 393 - 393 - -

Max. distance between pins mm 1,109 - 1,109 - -

Min. distance between pins mm 716 - 716 - -

Hydraulic tank Externally mounted control valve


GENERAL SPECIFICATIONS

Machine model D31 E-20 D31 P-20 D31 P-20A D31 PL-20 131 PLL-20

42001 - 45001 - 45001 - 45001 - 45001 -


Serial No.
42713 47616 47616 47616 47652

iydraulic type iydraulic type ! iydraulic type


t iydraulic type iydraulic type
Type angle tiltdozer iltdozer aangle tiltdozer iltdozer iltdozer

.eft side: .eft side: .eft side:


iydraulic iydraulic hydraulic
iydraulic ylinder type iydraulic
t
ylinder type ylinder type
Blade support method
ylinder type Cylinder type
light side: light side: light side:
{race type lrace type brace type

Max. lifting height (from ground) mm 865 875 935 825 1,035

Max. lowering depth (from ground) mm 370 325 300 345 430

Max. tilt mm 350 355 420 415 450

Angle of blade 25 - 25 - -
dag

Blade cutting angle dag 57 55 60 55 55

Blade width mm 2,415 2,435 2,875 3,425 3,425

Blade height mm 840 790 790 540 545


GENERAL SPECIFICATIONS

D31S, Q-20

Machine model D31 S-20 D31 Q-20

Serial No. 41001 - 41183 41001 - 41183

Operating weight kg 6,700 6,700

Bucket capacity m3 0.8 0.8

Max. load kN {kg1 I 5.7 (1,600I 15.7 (1,600)

Min. turning radius m 2.2 2.4

Gradeability deg 30 30

Forward deg 30 31

Stability Reverse deg 35 35

(Right/Left) 26 28
deg
-
Forward 1st km/h 2.2 2.2

Forward 2nd km/h 3.9 3.9


L
P Forward 3rd km/h 6.5 6.5
2
-0
8
Reverse 1 st km/h 2.4 2.4
&.f Reverse
,
2nd km/h 4.3 4.3

Reverse 3rd km/h 7.1 7.1


-
kPa
Ground pressure 52.9 IO.541 30.4 IO.311
kg/cm*)

Overall length mm 4,220 4,120

Overall width mm 1,790 2,250

Bucket width mm 1,905 2,300

5 To top of canopy mm 2,705 2,735


r”
F To tip of exhaust pipe mm 2,665 2,695

8 To top of operator’s compartment mm 2,015 2,045

Track gauge mm 1,450 1,650

Length of track on ground mm 1,880 1,880

Width of track shoe (standard) mm 330 600

Min. ground clearance


(to drain port of steering case) mm 315 380

O&l8
GENERAL SPECIFICATIONS

T
Machine model D31 S-20 D31 Q-20

Serial No. 41001 - 41183 41001 - 41183

Name 6D95L-1

Type 4-cycle, water-cooled, in-line vertical type, direct injection

No. of cylinders - bore x stroke mm 6-95x 115

Piston displacement e bd 4.89 {4,890}

Rated horsepower kW/rpm {HP/rpn 52.2/2,350 {70/2,3501

Max. torque Nmhpm {kgmlrpr 264.8/l ,400 (27/l ,400)

High idling vm 2,580

Low idling rpm 700

Min. fuel consumption ratio g/kWh (g/HPt 217 {162}

Starting motor 24 V, 5.5 kW

Alternator 24V, l5A

Battery 12 V, 70 Ah x 2

Radiator core type D-4 type

Damper Wet type, spring friction type

Planetary gear type, hydraulically actuated, lubrication


HYDROSHIFT transmission
pump force feed type, forward 3 speed, reverse 3 speed

Bevel gear shaft Spiral bevel gear, splash lubrication type

Wet type, multiple disc clutch, spring boosted,


Steering clutch
foot operated, PPC actuated

Steering brake Net type, band type, PPC actuated, interconnected with clutch

Final drive spur gear type, l-stage reduction gear, splash type lubrication

Suspension Rigid

Carrier roller (each side) 1


I 1
I
Track roller (each side) 5 I 5 I
GENERAL SPECIFICATIONS

Machine model D31 S-20 D31 Q-20

Serial No. 41001 - 41183 41001 - 41183

ntegrated rubber
lry, assembly type
:rawler

iemi-double grouser Arc shoe

Track shoe 37 on each side 37 on each side

Pitch: 154 mm Pitch: 154 mm

Width: 330 mm Width: 600 mm


MPa
Max. pressure (g/cm* 17.2 (1751 17.2 I1751

Gear type Gear type


(SAL(2)-036) (SAL(2k036)
Umin
90.1 90.1

2-spool valve 2-spool valve

Double-acting, piston type

Cylinder bore mm 100 100

Outside diameter of piston rod mm 50 50

Piston stroke mm 650 650

Max. distance between pins mm 1,710 1,710

Min. distance between pins mm 1,060 1,060

Cylinder bore mm 80 80

Outside diameter of piston rod mm 45 45

Piston stroke mm 595 595

Max. distance between pins mm 1,880 1,880

Min. distance between pins mm 1,285 1,285

Hydraulic tank Externally mounted control valve

01&O
GENERAL SPECIFICATIONS

Machine model D31 S-20 D31 Q-20

Serial No. 41001 - 41183 41001 - 41183

-ink type
T Single type

shape of bucket edge With teeth (6) With teeth (7)

Bucket hinge pin height mm 3,105 3,175

Dumping clearance mm 2,540 2,640

(Tip of teeth) mm (2,420) (2,520)

Dumping reach
l Hinge pin max. position mm 810 750

(Tip of teeth) mm (885) (825)

Dumping reach
l Hinge pin min. position mm - -

(Tip of teeth) mm - -

Bucket tilt reverse angle deg 43 43


(Bucket on ground)

Bucket tilt forward angle deg 50 50


(Bucket max. raise)

Bucket digging depth

(IO” forward) mm 260 185

(Tip of teeth) mm (310) (235)


GENERAL SPECIFICATIONS

D37E-5
D37 P-5A

Machine model D37E-5 D37 P-5A

Serial No. 3001 - 3730 3001 - 3660


-

E
! 5,200 5,890
p
6,290 7,020

Blade capacity m3 2.13 2.30

Min. turning radius m 2.3 2.6

Gradeability deg 30 30

Stability deg 35 35

Forward 1st km/h 2.3 2.3

4.1 4.1

6.9 6.9

2.5 2.5

4.5 4.5

Reverse 3nd km/h 7.5 7.5

oE kPa
cX Bare tractor 35.3 (0.36} 21.6 IO.22)
{kg/cm?
;Z
kPa
5$ With dozer 43.2 (0.44) 26.5 IO.271
{kg/cm?

mm 2,995 3,035

mm 3,950 3,940

;= Bare tractor mm 1,790 2,250


5%
5.2 With dozer mm 2,415 2,875

To top of canopy mm - 2,735


,Z
5.~ To tip of exhaust pipe mm 2,675 2,695
>a,
I-c
To top of operator’s compartment mm 1,955 2,045

Track gauge mm 1,450 1,650

2,185 2,185

330 600

315 380

01622
GENERAL SPECIFICATIONS

Machine model D37E-5 D37P-5A

Serial No. 3001 - 3730 3001 - 3660

Name 6D95L-1

Type 4-cycle, water-cooled, in-line vertical type, direct injection

No. of cylinders - bore x stroke mm 6-95x 115

Piston displacement e ICC} 4.89 14,890)

Rated horsepower kW/rpm {HP/rpn 59.6/2,500 I79.912,5001

Max. torque \m/rpm {kgmirpn 269.7/1,400 {27.5/1,400}

High idling rpm 2,700

Low idling rpm 700

Min. fuel consumption ratio g/kWh {g/HPt 217 (162)

Starting motor 24 V, 5.5 kW

Alternator 24 V, 15 A

Battery 12 V, 70 Ah x 2

Radiator core type D-4 type


_
Damper Wet type, spring friction type

Planetary gear type, hydraulically actuated, lubrication


HYDROSHIFT transmission
pump force feed type, forward 3 speed, reverse 3 speed

Bevel gear shaft Spiral bevel gear, splash lubrication type

Dry type, multiple disc clutch, spring boosted,


Steering clutch
manually operated, PPC actuated

Steering brake Dry type, band type, PPC actuated, interconnected with clutch

Final drive Spur gear type, l-stage reduction gear, splash type lubrication

Suspension Rigid

Carrier roller (each side) 1 1

Track roller (each side) 6 6


I I
GENERAL SPECIFICATIONS

Machine model D37E-5 D37P-5A

Serial No. 3001 - 3730 3001 - 3660


f

In/, assembly typl e IDry, assembly type

Single Arc shoe

Track shoe 41 on each side 41 on each side

Pitch: 154 mm Pitch: 154 mm

Width: 400 mm Width: 600 mm

MPa
Max. pressure 17.2 I1751 17.2 {175}
(g/cm,

Gear type (SAL(2)-036)

k!/min
95.5

Vlain control valve 2-spool valve

Type Double-acting, piston type


0
Cylinder bore mm 90 90

Outside diameter of piston rod mm 40 40

Piston stroke mm 393 393

Max. distance between pins mm 1,109 1,109

Min. distance between pins mm 716 716

Cylinder bore mm 90 90

Outside diameter of piston rod mm 40 40

Piston stroke mm 145 145

Max. distance between pins mm 613 613

Min. distance between pins mm 468 468


I
Cylinder bore mm 90 90

Outside diameter of piston rod mm 40 40

Piston stroke mm 393 393

Max. distance between pins mm 1,109 1,109

Min. distance between pins mm 716 716

Hydraulic tank Externally mounted control valve


GENERAL SPECIFICATIONS

Machine model D37E-5 D37P-5A

Serial No. 3001 - 3730 3001 - 3660


f
Hydraulic type Hydraulic type
Type angle tiltdozer angle tiltdozer

Hydraulic cylinder Hydraulic cylinder


Blade support method
type type

Max. lifting height (from ground) mm 865 935

Max. lowering depth (from ground) mm 370 300

Max. tilt mm 350 420

Angle of blade deg 25 25

Blade cutting angle deg 57 60

Blade width mm 2,415 2,875

% Blade height mm 940 895


z -
0
GENERAL SPECIFICATIONS

D31E, P-20
D3 1 P-20A
D31 PL, PLL-20

Machine model D31E-20 D31 P-20 D31 P-20A D31 PL-20 131 PLL-20

42714 47617 47617 47617 47653


Serial No.
f and up and up and up and up and up

Operating weight
l Bare tractor kg 5,240 5,890 5,850 6,270 6,760

l With dozer kg 6,270 6,840 6,930 7,190 7,700

Blade capacity m3 1.7 1.52 1.52 1.02 1.02

Min. turning radius m 2.2 2.5 2.6 3.2 3.3

Gradeability deg 30 30 30 30 30

Stability deg 35 35 35 35 35

Forward 1st km/h 2.2 2.2 2.2 2.2 2.2

Forward 2nd km/h 3.9 3.9 3.9 3.9 3.9

Forward 3rd km/h 6.5 6.5 6.5 6.5 6.5

Reverse 1 st km/h 2.4 2.2 2.4 2.4 2.4


%
Reverse 2nd km/h 4.3 3.9 4.3 4.3 4.3 7
0

Reverse 3nd km/h 7.1 7.1 7.1 7.1 7.1


kPa
Bare tractor kg/cm21 41.2 {0.42} Z2.6 IO.231 !1.6 IO.22) 13.7 (0.14) 12.7 (0.131
kPa
With dozer kg/cm2 50.0 10.51) 25.5 IO.261 25.5 IO.261 15.7 (0.161 13.7 io.141

Bare tractor mm 2,910 3,035 3,035 3,025 3,410

With dozer mm 3,840 3,845 3,940 3,875 4,300

Bare tractor mm 1,790 2,050 2,250 2,950 2,950

With dozer mm 2,415 2,435 2,875 3,425 3,425

To top of canopy mm - 2,735 2,735 2,735 2,735

To tip of exhaust pipe mm 2,675 2,695 2,695 2,695 2,695

To top of operator’s compartment mm 1,955 2,045 2,045 2,045 2,045

Track gauge mm 1,450 1,450 1,650 1,900 1,900

Length of track on ground mm 1,880 2,185 2,185 2,185 2,570

Width of track shoe (standard) mm 330 600 600 1,050 1,050

Min. ground clearance


mm 315 380 380 380 380
(to drain port of steering case)

01626
GENERAL SPECIFICATIONS

Machine model D31 E-20 D31 P-20 D31 P-20A D31 PL-20 D31 PLL-20

42714 47617 47617 47617 47653


Serial No.
f and up and up and up and up and UD
Name S4D102-1

4-cycle, water-cooled, in-line vertical type, direct injection,


Type with turbocharger

No. of cylinders - bore x stroke mm 4 - 102 x 120

Piston displacement e ICC} 3.92 {3,9201

Rated horsepower W/rpm IHP/rpn 52.2/2,350 I70/2,350}

Max. torque lm/rpmIkgmirpn 294/l ,400 {30/l ,400)

High idling rpm 2,470

Low idling rpm 800

Min. fuel consumption ratio j/kWh {g/I-K? 217 {I621

Starting motor 24 V, 4.5 kW

Alternator 24 V, 25 A

Battery 12 V, 70 Ah x 2

Radiator core type D-4 type

Damper Wet type, spring friction type

Planetary gear type, hydraulically actuated, lubrication


HYDROSHIFT transmission
pump force feed type, forward 3 speed, reverse 3 speed

Bevel gear shaft Spiral bevel gear, splash lubrication type

Dry type, multiple disc clutch, spring boosted,


Steering clutch
manually operated, PPC actuated

Steering brake >ry type, band type, PPC actuated, interconnected with clutch

Final drive ipur gear type, l-stage reduction gear, splash type lubrication

Suspension Rigid

Carrier roller (each side) 1 1 1 1 2

Track roller (each side) 5 6 6 6 8


GENERAL SPECIFICATIONS

Machine model D31 E-20 D31 P-20 D31 P-20A D31 PL-20 D31 PLL-20

42714 47617 47617 47617 47653


Serial No.
f and up and up and up and up and up
Sealed and
Dry, assembly Sealed and Sealed and
$; assembly lubricated,
assembly type tVpe lubricated type lubricated type

Single Arc shoe Arc shoe Arc shoe Arc shoe


Track shoe 37 on each 41 on each 41 on each 41 on each 46 on each
side side side side side

‘itch: 154mm Pitch: 154mm Pitch: 154mm Pitch: 154mm Pitch: 154mm

Nidth: 330mm Width: 600mm Width: 600mm Width: 1,050mmWidth: 1,050mm

MPa
Vlax. pressure 17.2 (175) 17.2 11751 17.2 I1751 17.2 {I751 17.2 (175}
kg/cm:
I
Gear type (SAR(2)-045)

Umin
90.1

3-spool 2-spool S-spool P-spool 2-spool


Vlain control valve
valve valve valve valve valve
0

Type Double-acting, piston type


2
F
0
Cylinder bore mm 90 70 90 70 70

Outside diameter of piston rod mm 40 45 40 45 45

Piston stroke mm 393 850 393 850 850

Max. distance between pins mm 1,109 1,350 1,109 1,350 1,350

Min. distance between pins mm 716 500 716 500 500

Cylinder bore mm 90 90 90 90 90

Outside diameter of piston rod mm 40 40 40 40 40

Piston stroke mm 145 120 145 120 120

Max. distance between pins mm 613 790 613 790 790

Min. distance between pins mm 468 670 468 670 670

Cylinder bore mm 90 - 90 - -

Outside diameter of piston rod mm 40 - 40 - -

Piston stroke mm 393 - 393 - -

Max. distance between pins mm 1,109 - 1,109 - -

Min. distance between pins mm 716 - 716 - -

tiydraulic tank Externally mounted control valve


GENERAL SPECIFICATIONS

Machine model D31 E-20 D31 P-20 D31 P-20A D31 PL-20 131 PLL-20

42714 47617 47617 47617 47653


Serial No.
and up and up and up and up and up

hydraulictype iydraulic type iydraulic type iydraulictype iydraulic type


Type angle tiltdozer iltdozer angle tiltdozer iltdozer iltdozer
.eft side: .eft side: .eft side:
iydraulic iydraulic iydraulic
iydraulic :ylinder type iydraulic :ylinder type ylinder type
Blade support method
:ylinder type :ylinder type
tight side: light side: light side:
kace type {race type lrace type

Max. lifting height (from ground) mm 865 875 935 825 1,035

Max. lowering depth (from ground) mm 370 325 300 345 430

Max. tilt mm 350 355 420 415 450

25 - 25 - -
Angle of blade deg

Blade cutting angle deg 57 55 60 55 55

Blade width mm 2,415 2,435 2,875 3,425 3,425

Blade height mm 840 790 790 540 545


GENERAL SPECIFICATIONS

D31S. Q-20

Machine model D31 S-20 D31 Q-20

Serial No. 41184 and up 41184 and up

D
Operating weight kg 6,810 7,110

Bucket capacity m3 0.8 0.8

Max. load kN {kg1 15.7 {I,6001 15.7 {I ,600I

Min. turning radius m 2.2 2.4

Gradeability deg 30 30

Forward deg 30 31

Stability Reverse deg 35 35

(Right/Left) 26 28
deg

Forward 1st km/h 2.2 2.2

2 Forward 2nd km/h 3.9 3.9


g
(II Forward 3rd km/h 6.5 6.5
L

p Reverse 1st km/h


x
* Reverse 2nd km/h

Reverse 3rd km/h 7.1 I 7.1 I


kPa
Ground pressure 53.9 IO.551 31.4 IO.321
11
kg/cm*}

Overall length mm 4,220 4,120

Overall width mm 1,790 2,250

Bucket width mm 1,905 2,300

5 To top of canopy mm 2,690 2,735


2
;; To tip of exhaust pipe mm 2,650 2,695
&
2 To top of operator’s compartment mm 2,020 2,035

Track gauge mm 1,450 1,650

Length of track on ground mm 1,880 1,880

Width of track shoe (standard) mm 330 600

Min. ground clearance


(to drain port of steering case) mm 315 380

01630
GENERAL SPECIFICATIONS

Machine model D31S-20 D31 Q-20

Serial No. 41184 and up 41184 and up

Name S4D102-1

4-cycle, water-cooled, in-line vertical type, direct injection,


Type with turbocharger

No. of cylinders - bore x stroke mm 4 - 102 x 120

Piston displacement e ICC} 3.92 13,920)

Rated horsepower kW/rpm {HP/rpn 52.2/2,360 {70/2,350}

Max. torque Nmirpm{kgmlrpn 29411,400 {30/l ,400)

High idling rpm 2,470

Low idling rpm 800

Min. fuel consumption ratio gikWh Ig/HPt 217 {162}

Starting motor 24 V, 4.5 kW

Alternator 24 V, 25 A

Battery 12 V, 70 Ah x 2

Radiator core type D-4 type

Damper Wet type, spring friction type

Planetary gear type, hydraulically actuated, lubrication


HYDROSHIFT transmission
pump force feed type, forward 3 speed, reverse 3 speed

Bevel gear shaft Spiral bevel gear, splash lubrication type

Wet type, multiple disc clutch, spring boosted,


Steering clutch
foot operated, PPC actuated

Steering brake Wet type, band type, PPC actuated, interconnected with clutch

Final drive Spur gear type, l-stage reduction gear, splash type lubrication

Suspension Rigid

Carrier roller (each side)


I 1
I 1
I
Track roller (each side) 5 5
GENERAL SPECIFICATIONS

-r

Machine model D31 S-20 D31 Q-20

Serial No. f 41184 and up 41184 and up

In/, assembly type Integrated rubber


crawler
Semi-double grouser Arc shoe

Track shoe 37 on each side 37 on each side

Pitch: 154 mm Pitch: 154 mm

Width: 330 mm Width: 600 mm


MPa
Max. pressure kg/cm’ 17.2 (1751 17.2 11751

Gear type Gear type


(SAR(2)-045) (SAR(2)-045)
elmin
90.1 90.1

Main control valve 2-spool valve 2-spool valve

Type Double-acting, piston type

Cylinder bore mm 100 100

Outside diameter of piston rod mm 50 50

Piston stroke mm 650 650

Max. distance between pins mm 1,710 1,710

Min. distance between pins mm 1,060 1,060

Cylinder bore mm 80 80

Outside diameter of piston rod mm 45 45

Piston stroke mm 595 595

Max. distance between pins mm 1,880 1,880

Min. distance between pins mm 1,285 1,285

Hydraulic tank Externally mounted control valve

0122
GENERAL SPECIFICATIONS

Machine model

Serial No.
f

Link type Single type

shape of bucket edge With teeth (6) With teeth (7)

Bucket hinge pin height mm 3,105 3,175

Dumping clearance mm 2,540 2,640

(Tip of teeth) mm (2,420) (2,520)

Dumping reach
l Hinge pin max. position mm 810 750

(Tip of teeth) mm (885) (825)

Dumping reach
lHinge pin min. position mm - -

(Tip of teeth) mm - -

Bucket tilt reverse angle deg 43 43


(Bucket on ground)

Bucket tilt forward angle deg 50 50


(Bucket max. raise)

Bucket digging depth

(IO’ forward) mm 260 185

(Tip of teeth) mm (310) (235)


GENERAL SPECIFICATIONS

D37E-5
D37P-5A

Machine model D37E-5 D37P-5A

Serial No. 3731 and up 3661 and up

z Operating weight
.‘$ l Bare tractor kg 5,400 5,890
3 With dozer 6,490 7,020
l
kg

Blade capacity m3 2.13 2.30

Min. turning radius m 2.3 2.6

Gradeability deg 30 30

Stability deg 35 35

2.3 2.3

4.1 4.1

6.9 6.9

Reverse 1st km/h 2.5 2.5

Reverse 2nd km/h 4.5 4.5

Reverse 3nd km/h 7.5 7.5

kPa
Bare tractor 36.3 IO.371 21.6 IO.221
{kg/cm21
kPa
With dozer 44.1 IO.451 26.5 10.27)
Iko/cm2

2,995 3,035

3,950 3,940

1,790 2,250

2,415 2,875

To top of canopy mm - 2,735

To tip of exhaust pipe mm 2,675 2,695

To top of operator’s compartment mm 1,955 2,045

Track gauge mm 1,450 1,650

Length of track on ground mm 2,185 2,185

Width of track shoe (standard) mm 330 600

Min. ground clearance


mm 315 380
(to drain port of steering case)

0124
GENERAL SPECIFICATIONS

I I
Machine model D37E-5 D37P-5A

Serial No. 3731 and up 3661 and up

Name S4D102-1
4-cycle, water-cooled, in-line vertical type, direct injection,
Type with turbocharger
No. of cylinders - bore x stroke mm 4 - 102 x 120

Piston displacement e {cc} 4.89 (4,890)

Rated horsepower W/rpm IHP/rprr 59.612.500 {79.9/2,500}

Max. torque lmhpm {kgmirpn 294/l ,400 {30/l ,400}

High idling wm 2,625

Low idling vm 800

Min. fuel consumption ratio I/kWh {g/HI?- 217 1162)

Starting motor 24 V, 4.5 kW

Alternator 24 V, 25 A

Battery 12 V, 70 Ah x 2

Radiator core type D-4 type


I
Damper Wet type, spring friction type

Planetary gear type, hydraulically actuated, lubrication


HYDROSHIFT transmission
pump force feed type, forward 3 speed, reverse 3 speed

Bevel gear shaft Spiral bevel gear, splash lubrication type

Dry type, multiple disc clutch, spring boosted,


Steering clutch
manually operated, PPC actuated

Steering brake Dry type, band type, PPC actuated, interconnected with clutch

Final drive Spur gear type, l-stage reduction gear, splash type lubrication

Suspension

Carrier roller (each side)

Track roller (each side) 6 6


GENERAL SPECIFICATIONS

Machine model D37E-5 D37P-5A

Serial No. 3731 and up 3661 and up

Dry, assembly type Dry, assembly type

Single Arc shoe

Track shoe 41 on each side 41 on each side

Pitch: 154 mm Pitch: 154 mm

Width: 400 mm Width: 600 mm

MPa
Max. pressure 17.2 (1751 17.2 {175}
kg/cm

Gear type (SAR(2)-045)

Q/min
95.5

Main control valve 3-spool valve

Double-acting, piston type

Cylinder bore mm 90 90

Outside diameter of piston rod mm 40 40

Piston stroke mm 393 398

Max. distance between pins mm 1,109 1,109

Min. distance between pins mm 716 716

Cylinder bore mm 90 90

Outside diameter of piston rod mm 40 40

Piston stroke mm 145 145

Max. distance between pins mm 613 613

Min. distance between pins mm 468 468

Cylinder bore mm 90 90

Outside diameter of piston rod mm 40 40

Piston stroke mm 393 393

Max. distance between pins mm 1,109 1,109

Min. distance between pins mm 716 716

Hydraulic tank Externally mounted control valve


GENERAL SPECIFICATIONS

Machine model D37E-5 D37 P-5A

Serial No. 3731 and up 3661 and up

Hydraulic type Hydraulic type


Type angle tiltdozer angle tiltdozer

Blade support method Hydraulic cylinder Hydraulic cylinder


type type

Max. lifting height (from ground) mm 865 935

Max. lowering depth (from ground) mm 370 300

Max. tilt mm 350 420

Angle of blade deg 25 25

Blade cutting angle deg 57 60

Blade width mm 2,415 2,875

% Blade height mm 940 895


z -
0
GENERAL WEIGHT TABLE

WEIGHT TABLE
D31E, P, PL, PLL-20
D3 1 P-20A

Ah This weight table is a guide for use when transporting or handling components.

Unit: kg

Machine model D31E-20 D31P-20 D31P-20A D31PL-20 C131PLL-20

42001 - 45001 - 45001 - 45001 - 45001 -


Serial No.
42713 47616 47616 47616 47652

Engine and damper assembly 460 469 469 469 469

l Engine assembly 430 439 439 439 439

l Damper assembly 27 27 27 27 27

Radiator assembly 40 40 37 40 40

Fuel tank assembly (with fuel) 195 195 175 195 195

HYDROSHIFT transmission assembly 232 232 232 232 232

- Modulating valve assembly 6 6 6 6 6

l Speed and inching valve assembly 8 8 8 8 8

Bevel gear shaft and steering clutch assembly 140 140 140 140 140

l Steering clutch assembly (each side) 48 48 48 48 48 %


l Brake band assembly (each side) 9 9 9 9 9 z
0

l Bevelgearshaft 9 9 9 9 9

l Bevel gear 15 15 15 15 15

PPC valve assembly 6 6 6 6 6

Final drive case (each side) 45 53 45 69 69

Sprocket (each side) 41 41 41 41 41

Main frame assembly 690 670 690 720 720

l Main frame and steering case 623 596 624 624 624

l Sprocket shaft (each side) 32 37 32 45 45

Track group assembly (each side) 478 523 530 530 665

l Track frame (each side) 106 127 132 132 163

l Idler assembly (each side) 95 95 95 95 95

l Track roller assembly (each) 27 27 27 27 27

l Carrier roller assembly (each) 20 20 20 20 20

Track shoe assembly (each side) 890 1,340 1,340 1,610 1,800

Cross bar 106 132 107 134 134

Ob38
GENERAL WEIGHT TABLE

Unit: kg

Machine model D31 E-20 D31 P-20 D31 P-201 D31 PL-20 D31 PLL-20

42001 - 45001 - 45001 - ~ 45001 - 45001 -


Serial No.
42713 47616 47616 47616 47652

Hydraulic tank assembly 87 I 87 87 87 87


Hydaulic control valve assembly 20 20 20 20 20
Blade lift cylinder assembly (each side) 24 24 34 34 34
Blade tilt cylinder assembly 17 17 22 22 22
Blade angle cylinder assembly (each side) 23 23 - - -

Power angle and tiltdozer assembly 726 787

l Blade 360 412 - - -

l U-frame 261 261

Straight tiltdozer assembly 678 638 677


l Blade 349 273 276
%
Z l Straight frame (each side) - - 82 82 89
0
l Blade tilt cylinder assembly 22 22 22

l Tilt brace 14 14 14

Radiator guard 56 56 176 176 207


Engine underguard 42 42 42 42 42

Transmission underguard 36 39 39 39 39

Hood 27 28 28 28 ~ 28
Loader frame 120 120 103 103 103

Operator’s seat assembly 21 11 11 11 11

Canopy assembly 50 50 50 50 50
GENERAL WEIGHT TABLE

D31S, Q-20

Machine model D31 S-20 D31 Q-20

Serial No. 41001 - 41183 41001 - 41183

Engine and damper assembly 469 469

l Engine assembly 439 439

l Damper assembly 27 27

Radiator assembly 40 40

Fuel tank assembly (with fuel) 195 195

HYDROSHIFT transmission assembly 232 232

l Modulating valve assembly 6 6


l Speed and inching valve assembly 8 8

Bevel gear shaft and steering clutch assembly 140 140


l Steering clutch assembly (each side) 48 48
l Brake band assembly (each side) 9 9

l Bevel gear shaft 9 9

l Bevel gear 15 15

PPC valve assembly 6 6

Final drive case (each side) 45 53

Sprocket (each side) 41 41

Main frame assembly 680 680


l Main frame and steering case 612 612

l Sprocket shaft (each side) 32 37

Track group assembly (each side) 478 478

l Track frame (each side) 106 106

l Idler assembly (each side) 95 95


l Track roller assembly (each) 27 27 *

- Carrier roller assembly (each) 20 20

Track shoe assembly (each side) 980 1,210


Cross bar 107 127

Ol-&IO
GENERAL WEIGHT TABLE

Unit: kg

Machine model D31 S-20 D31 Q-20

Serial No. 41001 - 41183 41001 - 41183


I

Hydraulic tank assembly 87 70

Hydaulic control valve assembly 20 20

Bucket lift cylinder assembly (each side) 43 43

Bucket dump cylinder assembly (each side) 33 33

Lift arm assembly 487 487

Bucket dump lever (Inside) 23 23

Bucket dump lever (Outside) 26 26

Bucket assembly (with tooth) 357 384

Radiator guard 56 51

Engine underguard 42 42

% Transmission underguard 36 36
z
0 Hood 28 28

Loader frame 282 282

Operator’s seat assembly 11 11

Canopy assembly 50 50
GENERAL WEIGHT TABLE

D37E-5
D37P-5A

Unit: kg

Machine model D37E-5 D37P-5A

Serial No. 3001 - 3730 3001 - 3660

Engine and damper assembly 460 469

l Engine assembly 430 439

l Damper assembly 27 27

Radiator assembly 40 40

Fuel tank assembly (with fuel) 195 195

HYDROSHIFT transmission assembly 232 232

l Modulating valve assembly 6 I 6

l Speed and inching valve assembly 8 8

Bevel gear shaft and steering clutch assembly 140 140

l Steering clutch assembly (each side) 48 48

l Brake band assembly (each side) 9 9

l Bevel gear shaft 9 9

l Bevel gear 15 15
I
PPC valve assembly 6 6

Final drive case (each side) 45 53

Sprocket (each side) 41 41

Main frame assembly 660 670

l Main frame and steering case 596 596

l Sprocket shaft (each side) 32 37

Track group assembly (each side) 523 663

l Track frame (each side) 127 197

l Idler assembly (each side) 95 95

l Track roller assembly (each) 27 27

l Carrier roller assembly (each) 20 20

Track shoe assembly (each side) 990 1,340

Cross bar 106 132


GENERAL WEIGHT TABLE

Unit: kg

Machine model D37E-5 D37P-5A


I

Serial No. 3001 - 3730 3001 - 3660


I

Hydraulic tank assembly 70 70


Hydaulic control valve assembly 20 20
Blade lift cylinder assembly (each side) 24 24
Blade tilt cylinder assembly 18 18
Blade angle cylinder assembly (each side) 19 19

Blade pitch cylinder assembly 19 19

Power angle and tiltdozer assembly 787 787


I
l Blade 412 412
l U-frame 261 261

Radiator guard 56 56
%
z Engine underguard 42 42
0
Transmission underguard 39 39

Hood 26 26

Loader frame 120 120

Operator’s seat assembly 21 11

Canopy assembly - 50

01-.&43
GENERAL WEIGHT TABLE

D31E, P, PL, PLL-20


D3 1 P-20A

Unit: kg

Machine model D31 E-20 D31 P-20 D31 P-20A D31 PL-20 131 PLL-20

42714 47617 47617 47617 47653


Serial No.
and up and up and up and up and up

Engine and damper assembly 410 469 469 469 469


l Engine assembly 360 439 439 439 439
l Damper assembly 27 27 27 27 27

Radiator assembly 40 40 37 40 40

Fuel tank assembly (with fuel) 195 195 175 195 195

HYDROSHIFT transmission assembly 232 232 232 232 232

l Modulating valve assembly 6 6 6 6 6

l Speed and inching valve assembly 8 8 8 8 8

Bevel gear shaft and steering clutch assembly 140 140 140 140 140

Steering clutch assembly (each side) 48 48 48 48 48 %


l

l Brake band assembly (each side) 9 9 9 9 9 z


0

9 Bevel gear shaft 9 9 9 9 9

l Bevel gear 15 15 15 15 15

PPC valve assembly 6 6 6 6 6'

Final drive case (each side) 45 53 45 69 69

Sprocket (each side) 41 41 41 41 41

Main frame assembly 690 670 690 720 720

l Main frame and steering case 623 596 624 624 624

l Sprocket shaft (each side) 32 37 32 45 45

Track group assembly (each side) 557 615 628 628 771

l Track frame (each side) 185 219 230 230 269

l Idler assembly (each side) 95 95 95 95 95

l Track roller assembly (each) 27 27 27 27 27

l Carrier roller assembly (each) 20 20 20 20 20

Track shoe assembly (each side) 890 1,340 1,340 1,610 1,800

Cross bar 106 132 107 134 134

01544
GENERAL WEIGHT TABLE

Unit: kg

Machine model D31 E-20 D31 P-20 D31 P-2OP D31 PL-20 C131 PLL-20

42714 47617 47617 47617 47653


Serial No.
and up and up and up and up and up

Hydraulic tank assembly 87 87 87 87 87

Hydaulic control valve assembly 25 25 20 20 20

Blade lift cylinder assembly (each side) 24 24 34 34 34

Blade tilt cylinder assembly 17 17 22 22 22

Blade angle cylinder assembly (each side) 23 23 - - -

Power angle and tiltdozer assembly 726 787

l Blade 360 412 - - -


l U-frame 261 261

Straight tiltdozer assembly 678 638 677

l Blade 349 273 276


%
F l Straight frame (each side) - - 82 82 89
0
l Blade tilt cylinder assembly 22 22 22

l Tilt brace 14 14 14

Radiator guard 56 56 176 176 207

Engine underguard 42 42 42 42 42

Transmission underguard 36 39 39 39 39

Hood 27 28 28 28 28

Loader frame 120 120 103 103 103

Operator’s seat assembly 21 11 11 11 11

Canopy, assembly 50 50 50 50 50
GENERAL WEIGHT TABLE

D31S, Q-20

Unit: kg

Machine model D3 1S-20 D31 Q-20

Serial No. 41184 and up 41184 and up

Engine and damper assembly 419 419

l Engine assembly 389 389

l Damper assembly 27 27

Radiator assembly 40 40

Fuel tank assembly (with fuel) 195 195

HYDROSHIFT transmission assembly 232 232


l Modulating valve assembly 6 6
l Speed and inching valve assembly 8 8

Bevel gear shaft and steering clutch assembly 140 140


Steering clutch assembly (each side) 48 48
l
%
l Brake band assembly (each side) 9 9 ;;
l Bevel gear shaft 9 9

l Bevel gear 15 15

PPC valve assembly 6 6

Final drive case (each side) 45 53

Sprocket (each side) 41 41

Main frame assembly 680 680

l Main frame and steering case 612 612

l Sprocket shaft (each side) 32 37

Track group assembly (each side) 557 557

l Track frame (each side) 185 185

l Idler assembly (each side) 95 95

l Track roller assembly (each) 27 27

l Carrier roller assembly (each) 20 20

Track shoe assembly (each side) 980 1,210

Cross bar 107 127

01-&a
GENERAL WEIGHT TABLE

Unit: kg

Machine model D31 S-20 D31 Q-20

Serial No. 41184 and up 41184 and up

Hydraulic tank assembly 87 70

Hydaulic control valve assembly 20 20

Bucket lift cylinder assembly (each side) 43 43

Bucket dump cylinder assembly (each side) 33 33

Lift arm assembly 487 487

Bucket dump lever (Inside) 23 23

Bucket dump lever (Outside) 26 26

Bucket assembly (with tooth) 357 384

Radiator guard 56 51

Engine underguard 42 42

% Transmission underguard 36 36
z
0 Hood 28 28

Loader frame 282 282

Operator’s seat assembly 11 11

Canopy assembly 50 50
GENERAL WEIGHT TABLE

D37E-5
D37P-5A

Unit: kg

Machine model D37E-5 D37P-5A

Serial No. 3731 and up 3661 and up

Engine and damper assembly 410 419

l Engine assembly 380 389


l Damper assembly 27 27

Radiator assembly 40 40
Fuel tank assembly (with fuel) 195 195

HYDROSHIFT transmission assembly 232 232


l Modulating valve assembly 6 6
l Speed and inching valve assembly 8 8

Bevel gear shaft and steering clutch assembly 140 140


l Steering clutch assembly (each side) 48 48 %
v
Brake band assembly (each side) 9 9
l
;5
l Bevel gear shaft 9 9
l Bevel gear 15 15

PPC valve assembly 6 6


Final drive case (each side) 45 53
Sprocket (each side) 41 4;

Main frame assembly 660


l Main frame and steering case 596 596

l Sprocket shaft (each side) 32 37

Track group assembly (each side) 615 685


l Track frame (each side) 219 219
l Idler assembly (each side) 95 95
l Track roller assembly (each) 27 27
l Carrier roller assembly (each) 20 20

Track shoe assembly (each side) 990 1,340


Cross bar 106 132

0128
GENERAL WEIGHT TABLE

Unit: kg
I
Machine model D37E-5 D37P-5A
I I

Serial No. 3731 and up 3661 and up


I

Hydraulic tank assembly 70 70

Hydaulic control valve assembly 20 20

Blade lift cylinder assembly (each side) 24 24

Blade tilt cylinder assembly 18 18

Blade angle cylinder assembly (each side) 19 19

Blade pitch cylinder assembly 19 19

Power angle and tiltdozer assembly 787 787

* Blade 412 412

U-frame 261 261


l
I
Radiator guard 56 56
%
c Engine underguard 42 42
z
Transmission underguard 39 39

Hood 26 26

Loader frame 120 120

Operator’s seat assembly 21 11

Canopy assembly - 50
GENERAL LIST OF LUBRICANT AND WATER

LIST OF LUBRICANT AND WATER


D31P-20 Serial No.: 45001 - 47616
D31PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652

AMBIENT TEMPERATURE CAPACITY (.b?,


KIND OF
RESERVOIR -22 -4 14 32 50 68 86 104T
FLUID Soecified Refill

Engine oil pan 11

Damper case 0.7

Transmission case 16 13

Transfer case
17
(incl. bevel gear case)

Steering clutch case 30


Engine oil

Final drive case (each)


(D31: 9.5) (D3.l.: 9.5)

Hydraulic system 33

Idler (each) 0.15

Track roller (each) 0.15

Carrier roller (each) 0.115

Fuel tank Iiesel fue 118 -

Cooling system Coolant Add antifreeze -

01-&50
GENERAL LIST OF LUBRICANT AND WATER

D31E-20 Serial No.: 42001 - 42713


D31P-20A Serial No.: 45001 - 47616
D31S, Q-20 Serial No.: 41001 - 41183
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660

T
AMBIENT TEMPERATURE CAPACITY (e)
KIND OF
RESERVOIR -. I
FLUID Specified ~ Refill
-.

Engine oil pan 13 11

Damper case

Transmission case

Transfer case
(incl. bevel gear case)

Steering clutch case


!ngine oil

%
z
0 Final drive case (each)
D3&: 9.5) ,,,I,,;,‘,: 9.5)

Hydraulic system

Idler (each)

Track roller (each)

Carrier roller (each)

Fuel tank Xesel fuel

Cooling system Coolant 9dd antifreeze


GENERAL LIST OF LUBRICANT AND WATER

D31P-20 Serial No.: 47617 and up


D31PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up

KIND OF
AMBIENT TEMPERATURE I CAPACITY (e,
RESERVOIR
FLUID -22 -4 14 32 50 36 104°F
Af 1°C Specified r Refill

Engine oil pan

Damper case

Transmission

Transfer case
case
c
L=
15.2

1.5

16
14

1.5

13

F
17.5 17
(incl. bevel gear case)

Steering clutch case 30 30


ingine oi

Final drive case (each)


(D31: 9.5)

Hydraulic system 45 33

Idler (each) 0.15 0.15

Track roller (each) 0.15 0.15

Carrier roller (each) 0.115 0.115

Fuel tank Iiesel fue 118

Cooling system Coolant Add antifreeze 22

og2
GENERAL LIST OF LUBRICANT AND WATER

D31 E-20 Serial No.: 42714 and up


D31P-20A Serial No.: 47617 and up
D31S, Q-20 Serial No.: 41184 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up

T
AMBIENT TEMPERATURE CAPACITY (8)
RESERVOIR KIND OF
FLUID -22 -4 14 32 50 68 86 104"
Specified Refill
-

Engine oil pan 15.2 14

Damper case 1.5 1.5

Transmission case 16 13

Transfer case
17.5 17
(incl. bevel gear case)

Steering clutch case 30 30


ingine oil

%
z
0 Final drive case (each)
D3lE,&: 9.5) (D3&: 9.5)

Hydraulic system 49 33

Idler (each) 0.15 0.15

Track roller (each) 0.15

Carrier roller (each)

Fuel tank liesel fuel 118

Cooling system Coolant


GENERAL FUEL, COOLANT AND LUBRICANTS

NOTE:
(I) When fuel sulphur content is less than 0.5%,
change oil in the oil pan every periodic main-
tenance hours described in this manual.
Change oil according to the following table
if fuel sulphur content is above 0.5%.

Change interval of oil in


Fuel sulphur content
engine oil pan

(2) When starting the engine in an atmospheric


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

ASTM: American Society of Testing and Material


SAE: Society of Automotive Engineers
API: American Petroleum Institute

Specified capacity: Total amount of oil includ-


ing oil for components and
oil in piping.
Refill capacity: Amount of oil needed to refill
system during normal inspection
and maintenance.

01-54
0
10 STRUCTURE AND FUNCTION

Power train system .............. .I.. ...... IO- 2


Power train skeleton ................. ...... IO- 3
Power train hydraulic piping .......... ...... IO- 4
Power train hydraulic circuit diagram . ...... IO- 6
Power train hydraulic .........
system ...... IO- 7
Damper and universal joint ........... ...... IO- 8
Transmission control ................. ....... IO- 9
Transmission pump .................. ...... IO-12
HYDROSHIFT transmission ........... ...... IO-14
Transmission control valve ........... ...... 1 o-22
Steering control ...................... ...... 1 O-28
Steering cylinder ..................... ...... 1 O-30
Brake cylinder ....................... ...... 1 o-31
PPC valve ............................ ...... 1 O-32
Bevel gear shaft and steering clutch .. ...... 1 O-38
Steering brake ....................... ...... 1 O-40
Final drive ........................... ...... 1 O-42
Track frame ......................... ...... 1 o-43
Main frame and suspension .......... ...... 1 o-45
Hydraulic piping ..................... ...... 1 o-47
Hydraulic circuit diagram ............. ...... 1 O-50
Hydraulic circuit system .............. ...... 1 o-51
Hydraulic control ..................... ...... 1 O-56
Hydraulic tank and filter .............. ...... 1 o-57
Hydraulic control valve ............... ...... 1 O-58
Angle selector valve ................. ...... 1 O-62
Suction safety valve .................. ...... 1 O-65
Work equipment ..................... ...... 1 O-66
Electrical circuit diagram ............. ...... 1 O-69
Engine control ....................... ...... 1 O-70
Monitor system ...................... ...... 1 o-71
Sensors ............................. ...... 1 O-72
STRUCTURE AND FUNCTION POWER TRAIN SYSTEM

POWER TRAIN SYSTEM

SBOO2 169

OUTLINE . Steering clutches (9) is installed at both ends of


. Motive power generated by diesel engine (2) is the bevel gear shaft make and break the flow of
transmitted to damper (3) which is fixed on the power from the bevel gear shaft to the final drive
engine flywheel. (IO), and are used to change the direction of the
After vibration is absorbed by the damper, the machine.
power from the engine passes from the output . The direction of the machine is changed by oper-
shaft through universal joint (4) to the input shaft ating the steering lever in order to cut off power
of HYDROSHIFT transmission (6). In accordance from the clutch at the side of the machine to
with changes in load, transmission control valve which it is to be steered. The size of the turning
which is mounted at the top of the transmission radius is varied by means of steering brake (8)
case is operated to select an appropriate speed which is mounted on the periphery of the brake
stage. The power which is selected by the make drum of the steering clutch.
and break action of the speed change clutch in- . Power from the steering clutch is transmitted to
side the transmission passes through the output the final drive flange where speed reduction takes
gear of transfer to bevel pinion. place through pinion + gear prior to rotating
. The power which is transmitted from the engine sprocket (11).
--f damper + transmission at the rear of the ma- . The rotation of the sprocket (11) drives track (12)
chine is then diverted into the left and right direc- of the undercarriage, causing the machine to
tions by means of the bevel pinion and bevel travel.
gear (7) on the bevel gear shaft.
STRUCTURE AND FUNCTION POWER TRAIN SKELETON

POWER TRAIN SKELETON


D31 E-20 Serial No. 42001 - 42713
D31P-20A Serial No. 45001 - 47616
D31P, PL-20 Serial No. 45001 - 47616
D31PLL-20 Serial No. 45001 - 47653
D31S, Q-20 Serial No. 41001 - 41183
D37E-5 Serial No. 3001 - 3730
D37P-5A Serial No. 3001 - 3660

SAD02137

1. Hydraulic pump (SAR(2)-036) 7. Bevel gear


2. Engine (6D95L-1) 8. Steering brake
3. Damper 9. Steering clutch
4. Universal joint 10. Final drive
5. Transmission pump 11. Sprocket
6. HYDROSHIFT transmission 12. Track shoe
STRUCTURE AND FUNCTION POWER TRAIN SKELETON

D31E-20 Serial No. 42714 and up


D31P-20A Serial No. 47617 and up
D31P. PL-20 Serial No. 47617 and up
D31PLL-20 Serial No. 47654 and up
D31S. Q-20 Serial No. 41184 and up
D37E-5 Serial No. 3731 and up
D37P-5A Serial No. 3661 and up

-r - I-

SAD02138

1. Hydraulic pump (SAR(2)-045) 7. Bevel gear


2. Engine (S4D102-1) 8. Steering brake
3. Damper 9. Steering clutch
4. Universal joint 10. Final drive
5. Transmission pump 11. Sprocket
6. HYDROSHIFT transmission 12. Track shoe
POWER TRAIN HYDRAULIC PIPING
D3 1 E-20 Serial No. 42001 - 42198
D31 P-20A Serial No. 45001 - 45784
D31P, PL, PLL-20 Serial No. 45001 - 45784
D31S, Q-20 Serial No. 41001 - 41054
D37E-5 Serial No. 3001 - 3234
D37P-5A Serial No. 3001 - 3152

6
114FO2002

1. Oil cooler 7. R.H. steering cylinder


2. Transmission pump 8. R.H. brake cylinder
3. Oil cooler bypass valve 9. L.H. brake cylinder
4. Transmission modulating valve 10. L.H. steering cylinder
5. Check valve 11. PPC valve
6. Tansmission case 12. Oil filter

OUTLINE
l Oil in transmission case (6) is sucked up by pump tion circuit when clogging of the oil cooler circuit
(2) installed to the transmission. It passes through causes the pressure to go above specified press-
modulating valve (4). pushes open check valve (5), ure.
and is sent to PPC valve (11). The check valve is in the circuit between the
. PPC valve (11) switches the flow of the oil ac- transmission hydraulic circuit and the steering hy-
cording to the operation of the left and right draulic circuit. It prevents the oil in the trans-
steering levers, and sends it to one of left or right mission hydraulic circuit from flowing back.
cylinder (7) or (IO) to disengage the steering In other words, if the gear is shifted when the
clutch. steering clutch is disengaged, the modulating
l The modulating valve sets the pressure in the cir- valve acts to make the pressure in the circuit 0 Pa
cuit to specified pressure. Oil relieved by the main (0 kg/cm*), so it becomes impossible to disengage
relief valve passes through bypass valve (3), and the clutch.
is then sent to oil cooler (I), where it is cooled When this happens, the check valve shuts off the
before being sent to lubricate the transmission. two circuits and keeps the pressure in the steering
. The oil cooler bypass valve acts to protect the oil circuit high, so it remains possible to disengage
cooler from damage. It sends the oil directly from the steering clutch.
the modulating valve to the transmission lubrica-

1o-4
0
D31E-20 Serial No. 42199 and up
D31 P-20A Serial No. 45785 and up
D31P, PL, PLL-20 Serial No. 45785 and up
D31S, Q-20 Serial No. 41055 and up
D37E-5 Serial No. 3235 and up
D37P-5A Serial No. 3153 and up

0
SBD01175

1. Oil cooler 7. R.H. steering cylinder


2. Transmission pump 8. R.H. brake cylinder
3. Oil cooler bypass valve 9. L.H. brake cylinder
4. Transmission modulating valve 10. L.H. steering cylinder
5. Check valve 11. PPC valve
6. Tansmission case 12. Oil filter

OUTLINE
l Oil in transmission case (6) is sucked up by pump tion circuit when clogging of the oil cooler circuit
(2) installed to the transmission. It passes through causes the pressure to go above specified press-
modulating valve (4), pushes open check valve (5), ure.
and is sent to PPC valve (11). . The check valve is in the circuit between the
l PPC valve (11) switches the flow of the oil ac- transmission hydraulic circuit and the steering hy-
cording to the operation of the left and right draulic circuit. It prevents the oil in the trans-
steering levers, and sends it to one of left or right mission hydraulic circuit from flowing back.
cylinder (7) or (IO) to disengage the steering In other words, if the gear is shifted when the
clutch. steering clutch is disengaged, the modulating
l The modulating valve sets the pressure in the cir- valve acts to make the pressure in the circuit 0 Pa
cuit to specified pressure. Oil relieved by the main (0 kg/cm2), so it becomes impossible to disengage
relief valve passes through bypass valve (3), and the clutch.
is then sent to oil cooler (I), where it is cooled When this happens, the check valve shuts off the
before being sent to lubricate the transmission. two circuits and keeps the pressure in the steering
l The oil cooler bypass valve acts to protect the oil circuit high, so it remains possible to disengage
cooler from damage. It sends the oil directly from the steering clutch.
the modulating valve to the transmission lubrica-
STRUCTURE AND FUNCTION POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM

POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM

/iiC
$$-q /
P2 P PI P3 P4

L
21
. c
I!
22

18

ti )(

II

L-. - I

1
I
. r
/
I I-
I -
I
!_
SAD02168

1. Transmission case 16. Transmission lubrication


2. Transmission pump 17. Reverse clutch lubrication
3. Modulating valve 18. Check valve
Set pressure: 2.1 +~~2sMPa {21.5’~kg/cm2} 19. Oil filter
4. Quick return valve 20. PPC valve
5. Speed valve 20A. Brake valve
6. 1st clutch 20B. Steering valve
7. 2nd clutch 20C. Oil filter
8. 3rd clutch 21. Right steering cylinder
9. Inching valve 22. Left steering cylinder
IO. Direction valve 23. Right brake cylinder
11. Forward clutch 24. Left brake cylinder
12. Reverse clutch
13. Oil cooler PI. Main relief pressure pickup port
14. Oil cooler bypass valve P4. Inching valve pressure pickup port
Set pressure: 0.98 MPa {IO kg/cm*}
15. Transmission lubrication valve
Set pressure: 0.29 MPa 13 kg/cm*}
POWER TRAIN HYDRAULIC SYSTEM

(Engine at low idling, steering and directional lever at neutral)

-mm
r
3rd 2nd

I
I

It
SBDOI 176
DAMPER AND UNIVERSAL JOINT

Il3FI8008

OUTLINE

1. Output shaft l The damper acts as a cushion to prevent the vi-


2. Flywheel bration of the engine from being transmitted
3. Damper directly to the transmission.
4. Oil filler plug l The power from the engine is transmitted to
5. Cover damper (3) through flywheel (2). The power is
6. Output coupling absorbed the engine vibration by damper (31,
7. Universal joint and is transmitted to shaft (1) and universal joint
8. Transmission input coupling (7). and then is transmitted to the transmission.
9. Oil level plug

1 O-8
TRANSMISSION CONTROL *
D3 1 E-20 Serial No. 42001 - 42086
D3 1 P-20A Serial No. 45001 - 45420
D3 1 P-20 Serial No. 45001 - 45420
D31PL, PLL-20 Serial No. 45001 - 45609 0
D31 S, Q-20 Serial No. 41001 - 41025 (
D37E-5 Serial No. 3001 - 3085 /
D37P-5A Serial No. 3001 - 3048

I SBDDt177

1. Gear shift lever OUTLINE


2. Steering and directional lever l Gear shift lever (I) and steering and directional
3. Lock lever lever (2) in the oberator’s compartment are inter-
4. Speed, directional, inching valve assembly connected with each spool of the speed, direc-
5. Inching pedal tional, and inching valve assembly (4) on top of
the steering case.
Lever, pedal position Inching pedal (5) is also interconnected with the
0: Forward inching valve spool in the same way.
0: Neutral
0: Reverse l When steering and directional lever (2) is oper-
0: 1st ated, the directional valve spool is actuated, and
0: 2nd when gear shift lever (1) is operated, the speed
0: 3rd valve spool is actuated at the same time. A set of
0: Free 2 clutches inside the transmission is engaged and
8: Lock the machine travels.
0: Inching When inching ,pedal (5) is operated, the inching
valve spool is actuated, and the forward or
reverse clutch inside the transmission is partially
or fully disengaged to make fine adjustment of the
travel speed or to make the machine stop.
SAFETY MECHANISM WHEN SHIFTING TRANSMISSION

I I4FO.2006

1. Steering and directional lever


2. Gear shift lever
3. Intermediate lever
4. Rod
5. Lever
OUTLINE
l This mechanism ensures safety and protects the
transmission by using a link motion that prevents
the machine from starting in 3rd gear either for-
ward or in reverse.
l Lever (5) is fixed to the bracket at point C, and
lever (5) and rod (4) are joined with a pin at free
point B.
Rod (4) and intermediate lever (3) are joined with
a pin at point A.
l At the boss portion of intermediate lever (3) and
gear shift lever (2), the notches are each meshed.

OPERATION

L
When steering and directional lever is at N;
The gear shift lever will enter 1st or 2nd position,
I 14FO2007
but will not enter 3rd position.
When steering and directional lever (1) is at N,
points A, B, and C are in a straight line.
When gear shift lever (2) is at 2nd position, faces
D and E of intermediate lever (3) are in contact,
so if it is attempted to move gear shift lever (2)
to the 3rd position, points A, B, and C are in a
straight line. Because of this, the moment does
not move, and the force acts on point C to pre-
vent gear shift lever (2) from being operated.
(Point B is at the dead point.)
When gear shift lever (2) is moved from 2nd posi-
tion to 1st position, there is clearance “a” at faces
F and G, so the operation is possible without
3’ I 14FO2008
moving intermediate lever (3).

10-10
2. When steering and directional lever is at F or R;
The gear shift lever can be moved to Ist, 2nd or
3rd positions.
l When gear shift lever (2) is at 2nd, if steering and
directional lever (1) are operated to F or R, inter-
mediate lever (3) rotates in the direction of the
arrow. Clearance “b” is formed in both directions
at the meshing portion of the boss, so gear shift
lever (2) can be operated in both directions (1st
- 3rd). -3

1 I I 14F0200E

3rd

I14F02010

3. When gear shift lever is at 3rd, and steering and


directional lever is moved to N;
The gear shift lever is shifted down to 2nd.
. When gear shift lever (2) is at 3rd, the meshing
portion of the boss is at the position shown in the
diagram. In this condition, if steering and direc-
tional lever (1) is operated F + N (- R) or R + N
(- F), steering and directional lever (1) passes
through the N position when it is shifted.
l At the N position, points A, B, and C come into a
straight line, and intermediate lever (3) moves in
the direction of the arrow, so face D at the mesh-
I I B Il4FO201 I
ing portion of the boss pushes face E, and gear
shift lever (2) is returned to 2nd position.
3rd
2nd \

Il4FO2Oli
STRUCTURE AND FUNCTION TRANSMISSION CONTROL

D31E-20 Serial No. 42087 - 42713


D31P-20A Serial No. 45421 - 47616
D3 1 P-20 Serial No. 45421 - 47616
D31 PL-20 Serial No. 45610 - 47616
D31PLL-20 Serial No. 45610 - 47653
D31S, Q-20 Serial No. 41026 - 41183
D37E-5 Serial No. 3086 - 3730
D37P-5A Serial No. 3049 - 3660

1. Gear shift lever OUTLINE


2. Steering and directional lever Gear shift lever (1) and steering and directional
3. Lock lever lever (2) in the oyjerator’s compartment are inter-
4. Speed, directional, inching valve assembly connected with each spool of the speed, direc-
5. Inching pedal tional, and inching valve assembly (4) on top of
the steering case.
Lever, pedal position Inching pedal (5) is also interconnected with the
0: Forward inching valve spool in the same way.
0: Neutral
0: Reverse When steering and directional lever (2) is oper-
0: 1st ated, the directional valve spool is actuated, and
0: 2nd when gear shift lever (1) is operated, the speed
@: 3rd valve spool is actuated at the same time. A set of
0: Free 2 clutches inside the transmission is engaged and
@I: Lock the machine travels.
0: Inching When inching ,pedal (5) is operated, the inching
valve spool is actuated, and the forward or
reverse clutch inside the transmission is partially
or fully disengaged to make fine adjustment of the
travel speed or to make the machine stop.

lo-~‘-’
STRUCTURE AND FUNCTION TRANSMISSION CONTROL

D31E-20 Serial No. 42714 and up


D31P-20A Serial No. 47617 and up
D31P, PL-20 Serial No. 47617 and up
D31PLL-20 Serial No. 47654 and up
D31S, Q-20 Serial No. 42184 and up
D37E-5 Serial No. 3731 and up
D37P-5A Serial No. 3661 and up

1. Steering, directional, gear shift lever OUTLINE


2. Lock lever . Steering, directional, gear shift lever (1) in the
3. Speed, directional, inching valve assembly operator’s compartment is interconnected with
4. Inching pedal each spool of the speed, directional, and inching
5. Steering PPC valve valve assembly (3) on top of the steering case.
Inching pedal (4) is also interconnected with the
Lever, pedal position inching valve spool in the same way.
0: Neutral
0: Forward . When steering, directional, gear shift lever (1) is
0: Reverse operated, the directional valve spool and the
0: Swing left speed valve spool is actuated at the same time. A
0: Swing right set of 2 clutches inside the transmission is en-
0: 1st gaged and the machine travels.
Q): 2nd When inching pedal (4) is operated, the inching
@: 3rd valve spool is actuated, and the forward or re-
0: Free verse clutch inside the transmission is partially
@: Lock or fully disengaged to make fine adjustment of
0: Inching the travel speed or to make the machine stop.

’O-g
-*
TRANSMISSION PUMP

%
6

A-A

Il3FI8012

OUTLINE
1. Transmission input coupling l The transmission pump is assembled to the
2. Transmission input shaft transmission input shaft.
3. Cover l The oil in the transmission case passes through
4. Drive gear the strainer, is sucked in at port A and discharged
5. Gear case from port B.
6. Bracket It then flows to the transmission control valve
7. Driven gear and the steering control valve.
A. From transmission case
B. To transmission control valve

10-12
HYDROSHIFT TRANSMISSION

\ \ I

A-A

I13F18009

1. Input coupling
2. Sleeve
A. To 1 st speed clutch 3. Cover
6. To forward clutch 4. Transmission pump
C. To reverse clutch 5. Transmission case
D. To 2nd speed clutch 6. Transfer case
E. To 3rd speed clutch 7. Breather
F. From modulation valve 8. Oil strainer

10-14
POWER TRAIN OF TRANSMISSION

FIRST FORWARD SPEED

FI 1318007

No.2 and No.5 clutches engaged and No.2 ring gear


fixed, No.4 carrier and No.5 ring gear are engaged.

With No.2 and No.5 clutches engaged, No.2 ring Since No.4 carrier (39) and No.5 ring gear (26) are
gear (16) is fixed and No.4 carrier (39) and No.5 ring engaged, sun gear (20). ring gear (22). No.4 carrier
gear (26) are engaged. When No.2 ring gear (16) is (391, No.5 ring gear (26) and No.5 piston housing
fixed, the rotation of the engine is transmitted to (38) are all engaged as a unit.
No.2, 3 carrier (41) with reduced turning speed The rotation of No.2, 3 carrier (41) is then transmit-
through input shaft (9) and No.2 sun gear (15). No.2, ted to output shaft (27) in the same direction and at
3 carrier (411, then, rotates in the same direction as the same speed.
input shaft (9). The rotation of output shaft (27) is tramsitted to
bevel pinion (33) with reduced turning speed through
tranfer drive gear (32) and trasfer driven gear (34).
Bevel pinion (33) then rotates in the opposite direc-
tion to output shaft (27).

10-17
SECOND FORWARD SPEED

Nn!i 22 24 27 32

ii i4 3’3 FI 1318008

No.2 and No.4 clutches engaged and No.2 and No.4


ring gears fixed.

With No.2 and No.4 clutches engaged, No.2 and Sine No.4 ring gear (24) is fixed, the rotation of No.2,
No.4 ring gears (I 6),and (24) are fixed. 3 carrier (41) is transmitted to output shaft (27) at an
When No.2 ring gear (I 6) is fixed, the rotation of the increased turning speed through No.3 ring gear (22)
engine is transmitted to No.2, 3 carrier (41) with re- and No.4 carrier (391, and No.4 sun gear (25) in that
duced turning speed and in the same direction as in order.
the case of first forward speed. (Besides, the rotation is transmitted from No.3 sun
gear (20) to output shaft (271.)
Output shaft (27) rotates in the same direction as
input shaft (9).
The rotation of output shaft (27) is transmitted to
bevel pinion (33) with reduced turning speed through
transfer drive gear (32) and transfer driven gear (34).
Bevel pinion (33) then rotates in the opposite direc-
tion to output shaft (27).

lo-18
THIRD FORWARD SPEED

9 12 14 16 No.3 22 24
\ \ \ Nod' No.2
F 1 3rd No.4
2nd No.5
1st / /

2'5 3'9 2% 3‘8 3'4 3'3


FI 1318009

No.2 and No.3 clutches engaged and No.2 and No.3


ring gears fixed.

With No.2 and No.3 clutches engaged, No.2 and Since No.3 ring gear (22) is fixed, the rotation of
No.3 ring gears (I 6) and (22) are fixed. No.2, 3 carrier (41) is transmitted to output shaft
When No.2 ring gear (16) is fixed, the rotation of the (27) at an increased turning speed thorgh No.3 sun
engine is transmitted to No.2, 3 carrier (41) with re- gear (20) in that order.
duced turning speed and in the same direction as in Output shaft (27) rotates in the same direction as
the case of first forward speed. input shaft (9).
The rotation of output shaft (27) is transmitted to
bevel pinion (33) with reduced turning speed through
transfer drive gear (32) and transfer driven gear (34).
Bevel pinion (33) then rotates in the opposite direc-
tion to output shaft (27).

10-19
FIRST REVERSE SPEED

i i i
25 39 26 38 34 33
FI 1318010

No.1 and No.5 clutches engaged and No.1 ring gear


fixed, No.4 carrier and No.5 ring gear are engaged.

With No.1 and No.5 clutches engaged, No.1 ring Since ring gear (I I) is meshed with No.2, 3 carrier
gear (I 2) is fixed and No.4 carrier (39) and No.5 ring (411, the rotation is transmitted to No.2, 3 carrier
gear (26) are engaged. When No.1 ring gear (I 2) is (41).
fixed, No.1 carrier (49) meshed with No.1 ring gear The rotation of No.2, 3 carrier (41) is transmitted to
(I 2) is also fixed. output shaft (27) in the same way as in first forward
The rotation of the engine is transmitted to ring gear speed.
(14) through input shaft (9) and No.1 sun gear (1 I) Output shaft (27) rotates in the opposite direction to
in the opposite direction and at a reduced turning input shaft (9).
speed. The rotation of output shaft (27) is transmitted to
bevel pinion (33) with reduced turning speed through
transfer drive gear (32) and transfer driven gear (34).
Bevel pinion (33) then rotates in the opposite direc-
tion to output shaft (27).

1O-20
TRANSMISSION CONTROL VALVE

P4
\

114FO2016

A. From transmission pump


B. To steering circuit
C. To oil cooler
PI Plug for modulating valve
P4 Plug for inching valve pressure

1o-22
1. Valve body
2. Detent
3. Plug
4. F-R spool
5. Speed spool
6. Plug
7. Piston
8. Spring
9. Piston
10. Inching valve
1 1. Spring
12. Piston
13. Spring
14. Sleeve
15. Cover
\
A-A 5 16. Inching valve spool
17. Cover
18. Stopper
19. Load piston
20. Valve body
21. Spring
22. Spring
23. Modulating valve
24. Piston
25. Spring
26. Piston
27. Stopper
28. Quick return valve
29. Stopper
B-B
30. Cover
31. Detent
A. From transmission pump

17 18 19 20 21 22 c 23 24 25 26 27

31

D-D

114FO2017

1 O-23
MODULATING VALVE

OUTLINE

The modulating valve consists of a modulating l Modulating graph


relief valve and a quick return valve, and acts to
MPa
modulates the pressure.
(kg/en?) Modulating time
When the gear shift lever is operated to shift
iA- - C : Build-up time
gear, the clutch is pushed into close contact by B : Filling time ,
D
the piston. However, if high pressure is suddenly
applied, the piston will suddenly engage the
clutch. This will make the machine suddenly
2
start, and it will receive an excessive shock. 2
To prevent this, the modulating valve is installed. :
h
When the gear shift lever is operated to shift
5
gear, the pressure on the piston gradually rises
to the set pressure and the clutch is engaged
smoothly. This allows the machine to start with-
out any shock, thereby improving the durability
of the power train and at the same time providing 0 > (sec.)
0
a comfortable ride for the operator. Time
The figure on the right shows the relationship be-
114FO2018
tween the time and the increase in the hydraulic
pressure of the modulating valve.
For example, when the gear is shifted from Fl to
F2, the oil from the pump passes through the
speed valve spool, flows to the second 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”,
and the oil pressure during this time is 0 kg/cm2.
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 pres-
sure is called the “build-up time”. The filling time
and build-up time toghther are called the
“modulating time”.

1 O-24
OPERATION 19 21 22 To oil cooler
23 ?S

1. While traveling
(Range A and D in Fig. 114FO2018)
The oil from the transmission pump enters port
A and chamber B.
The oil passes through orifice b and goes from
chamber F through the speed valve and F-R
To speed
valve to fill the two sets of clutch piston ports. valve
The pressure in this circuit is always set by the ‘a
action of modulating valve (23) to specified press-
ure.
When the pressure inside the circuit becomes
higher, the modulating valve moves to the left. It
opens the passage between chambers B and E, I b
so the oil from the pump is relieved to chamber E. From pump :9
If the pressure inside the circuit drops because F I0306027
of leakage of oil from the clutch piston or valve,
the modulating valve moves to the right. This
closes the passage between chambers B and E, 19 21 22 To oil cooler 23 ?S
so the oil from the pump all flows from port A
into the circuit to the clutch piston port.

2. Immediately after shifting gear shift lever

ZJ (Range B in Fig. 114FO2018)


* When the gear shift lever is moved, the circuit
6 from the transmission pump to the piston port of
the clutch after gear shifting is opened and oil
flows to the clutch piston port.
When this happens, a difference in pressure is
generated between port A and chamber F be-
cause the oil is restricted by orifice b. Because of
the pressure at port A, quick return valve (28)
moves to the right. This connects chamber D
and drain port G and relieves the back pressure
on load piston (19). F 10306028

When this happens, modulating valve (23) is


moved to the right by the tension of springs (21)
and (22), and load piston (19) is returned to the
left.

To speed
valve

2’8 pump 29
F I0306029

1o-25
3. While clutch pressure is rising 19 21 22 Tooil,cooler 23 26
(Range C in Fig. F10406016)
When the oil sent under pressure from the pump
fills the circuit from port A to the clutch piston
port, the oil pressure starts to rise.
When this happens, the difference in pressure
on both sides of orifice b is removed. Quick
return valve (28) moves to the left and the
To speed
passage between chamber D and drain port G is valve

closed.
The oil flows through orifice a to chamber C and
pushes piston (26). The reaction to this makes
modulating valve (23) compress springs (21)
and (22) and move to the left. This opens the
passage from chamber B to chamber E.
At the same time, the oil passing from orifice c
Pump 29
through the chamber in the center of quick
F I 0306030
return valve (28) then passes through orifice d
and enters chamber D. The oil becomes the back
19 21 22 To oil,cooler 23 26
pressure of load piston (I 9), compresses springs
(21) and (22) and move the load piston to the
right to the passage between close chambers B
and E.
This operation is repeated continuously to in-
crease the load on springs (21) and (22). In this
way, the hydraulic pressure inside the circuit
gradually rises and finally load piston (19) comes To speed
valve
into contact with the valve body and cannot
move any further. .a
When this happens, modulating valve (23) stops
in a position where the passage between cham-
bers B and E is open, and the rise in pressure is
completed.
The hydraulic pressure at this point is specified
pressure. The oil relieved from chamber B to pump
chamber E flows from chamber E into the oil
F I 030603 I
cooler circuit.

21 22 Tooil cooler 23 26

F 10306032

1 O-26
OUTLINE

l The inching valve is in the circuit between the


speed valve and F-R valve. The amount that the
inching pedal is operated adjusts the amount of
oil (oil pressure) sent from the speed valve to the
F-R valve. This changes the contact force of the
FORWARD or REVERSE clutches to partially dis-
engage the clutches and allow fine control of the
travel speed; or it completely disengages the
clutches to make it possible to stop the machine.

OPERATION

1. Inching pedal not operated


Spool (16) is interconnected with the inching
pedal, so when the inching pedal is not being To F-R valve
operated, it is at the end of its stroke on the right.
As a result, valve (10) is pushed to the right by
sleeve (14) together with the spool.
The oil sent under pressure from the pump
passes through the modulating valve and speed
valve and enters ports A and B. It then passes
through the F-R valve and flows to the FOR-
WARD or REVERSE clutch piston port.
The oil passing through orifice a and entering /if b Cc
chamber C becomes the force trying to move
Fromspeedvalve
valve (10) to the left because of the reaction
pushing piston (7). F I0306033

However, valve (IO) is in contact with sleeve


(141, so it cannot move to the left. Therefore,
passage b between port A and B is kept fully
open.
As a result, the oil from the speed valve gradually
increases in pressure because of the action of
the modulating valve. It enters clutch piston port
and fully engages the clutch.

1 O-27
2. Fine operation of inching pedal
To F-R valve
When the inching pedal is partially depressed,
spool (16) moves to the left by an amount which
corresponds to the amount the pedal is de-
pressed. When this happens, sleeve (14) moves
out of contact with valve (10) and determines
the tension of spring (1 1). In this case, if the oil
from the speed valve fills the circuit to the clutch
piston port, the oil pressure gradually rises.
When this happens, the oil pressure in chamber A ~
C gradually moves valve (I 0) to the left to a posi- t
tion where it is in balance with the tension of From speed valve
spring (11). Passage b is restricted, so the pres- F I 0306034

sure in the circuit from port B to the clutch port


does not rise any more.
To F-R valve
As a result, the clutch is partially disengaged and
the machine travel speed drops.

From speed valve


F 10306035

3. Inching pedal fully depressed


To F-R valve
When the inching pedal is fully depressed, spool
(16) moves to the left from the condition in Step
2, and the tension of spring (11) becomes the
minimum.
In this condition, the oil pressure in the circuit
from port B to the clutch piston port rises slight-
ly, and valve (10) is moved by the oil pressure in
chamber C to close passage b.
Therefore, the clutch is disengaged and the ma-
chine stops. If the oil pressure in the circuit
beyond B drops because of oil leakage in the cir- From speed valve
F I0306036
cuit beyond port B, the balance between the hy-
draulic pressure in chamber C and the tension of
spring (1 1) is lost. The tension of spring (I 1)
then moves valve (10) back to the right to open
passage b and supply oil.
This operation is repeated to maintain the hy-
draulic pressure in the circuit beyond port B to a
fixed level.

1 O-28
D3 1 E-20 Serial No. 42001 - 42198
D3 1 P-20A Serial No. 45001 - 45784
D31P, PL, PLL-20 Serial No. 45001 - 45784
D31S, Q-20 Serial No. 41001 - 41054
D37E-5 Serial No. 3001 - 3234
D37P-5A Serial No. 3001 - 3152

114FO2019

1. Brake lock lever OUTLINE


2. Brake pedal l Steering and directional lever (6) on the left side
3.. Right brake of the operator’s compartment is interconnected
4. Right brake cylinder with PPC valve (7), and uses hydraulic pressure to
5. Right steering cylinder actuate the steering and brakes.
6. Steering and directional lever Brake pedal (2) is interconnected only with the
7. PPC valve brake lever.
8. Left brake . If the steering and directional lever is moved
9. Left steering cylinder slightly to the left, the left steering clutch is par-
10. Left brake cylidner tially disengaged and the machine turns slowly to
the left.
Lever, pedal positions . If the steering and directional lever is moved fully
@I: Left steering clutch disengaged to the left, the left steering clutch is completely
0: Left steering brake applied disengaged, and left steering brake (8) is also ap-
0: Right steering clutch disengaged plied to make the machine turn sharply to the left.
0: Right steering brake applied
0: Steering brake applied
0: Brake locked

10-29-l
0
STRUCTURE AND FUNCTION STEERING CONTROL

D31 E-20 Serial No. 42199 - 42713


D31P-20A Serial No. 45785 - 47616
D31P, PL-20 Serial No. 45785 - 47616
D31PLL-20 Serial No. 45785 - 47653
D31S, Q-20 Serial No. 41055 - 41183
D37E-5 Serial No. 3235 - 3730
D37 P-5A Serial No. 3153 - 3660

1. Brake lock lever OUTLINE


2. Brake pedal . Steering and directional lever (6) on the left side
3. Right brake of the operator’s compartment is interconnected
4. Right brake cylinder with PPC valve (7), and uses hydraulic pressure
5. Right steering cylinder to actuate the steering and brakes.
6. Steering and directional lever Brake pedal (2) is interconnected only with the
7. PPC valve brake lever.
8. Left brake . If the steering and directional lever is moved
9. Left steering cylinder slightly to the left, the left steering clutch is par-
10. Left brake cylinder tially disengaged and the machine turns slowly
to the left.
Lever, pedal positions . If the steering and directional lever is moved fully
0: Neutral to the left, the left steering clutch is completely
0: Left steering clutch disengaged disengaged, and left steering brake (8) is also
0: Left steering brake applied applied to make the machine turn sharply to the
0: Right steering clutch disengaged left.
0: Right steering brake applied
8: Steering brake applied
0: Brake locked

’O-i9-*
STRUCTURE AND FUNCTION STEERING CONTROL

D3 1 E-20 Serial No. 42714 and up


D31P-20A Serial No. 47617 and up
D31P, PL-20 Serial No. 47617 and up
D31PLL-20 Serial No. 47654 and up
D31S, Q-20 Serial No. 41184 and up
D37E-5 Serial No. 3731 and up
D37P-5A Serial No. 3661 and up

SE002140

1. Brake lock lever OUTLINE


2. Brake pedal . Steering, directional, gear shift lever (6) on the
3. Right brake left side of the operator’s compartment is inter-
4. Right brake cylinder connected with PPC valve (71, and uses hydraulic
5. Right steering cylinder pressure to actuate the steering and brakes.
6. Steering, directional, gear shift lever Brake pedal (2) is interconnected only with the
7. PPC valve brake lever.
8. Left brake . If the steering, directional gear shift lever is moved
9. Left steering cylinder slightly to the left, the left steering clutch is par-
10. Left brake cylinder tially disengaged and the machine turns slowly
to the left.
Lever, pedal positions . If the steering and directional lever is moved fully
0: Neutral to the left, the left steering clutch is completely
0: Left steering clutch disengaged disengaged, and left steering brake (8) is also
0: Left steering brake applied applied to make the machine turn sharply to the
0: Right steering clutch disengaged left.
0: Right steering brake applied
@: Steering brake applied
0: Brake locked

’o-k9-3
STEERING CYLINDER

+
Z
Y Z
A

1
2

3
I I

u-u i-u
A-A

114FO2020

1. Steering cylinder OUTLINE


2. Spring l The steering cylinder is installed on the steering
3. Piston case. It is actuated by the oil pressure from the
PPC valve and operates the release yoke of the
steering clutch.

1O-30
BRAKE CYLINDER

I
C F

x-x 114FO2021

1. Right brake cylinder A. From PPC valve (port PI)


2. Left brake cylinder B. To left brake cylinder port F
3. Cylinder C. To left brake cylinder port E
4. Spring D. From PPC valve (port P2)
5. Piston E. To right brake cylinde port C
6. Plug F. To right brake cylinder port B

10-31
PPC VALVE

FOR STEERING CLUTCH AND BRAKE

D31 E-20 Serial No. 42001 - 42198


D3 1 P-20A Serial No. 45001 - 45784
D31P, PL, PLL-20 Serial No. 45001 - 45784
D31S. Q-20 Serial No. 41001 - 41054
D37E-5 Serial No. 3001 - 3234
D37P-5A Serial No. 3001 - 3152

2OSF3098

a. P port (from charging pump)


b. T port (to tank)
c. P2 port (brake valve: to left brake cylinder)
d. P4 port (steering valve: to right steering cylinder)
e. PI port (brake valve: to right brake cylinder)
f. P3 port (steering valve: to left steering
cylinder)

1 O-32
0
A-A B-B

I I4FO2022
c-c

1. Lever 7. Retainer
2. Disc 8. Metering spring
3. Joint 9. Valve
4. Piston IO. Body
5. Plate 11. Centering spring
6. Collar

1o-33
PPC VALVE FOR STEERING CLUTCH CYLINDER

OPERATION
1) At neutral
Ports A and B of the steering clutch cylinder
and ports P3 and P4 of the PPC valve are con-
nected to drain chamber D through fine control
hole f in spool (1). (Fig. 1)

2) During fine control (neutral + fine control)


When piston (4) starts to be pushed by disc (5),
retainer (9) is pushed; spool (1) is also pushed E
(Fig. 1) 114FO2023 d
by metering spring (2), and moves down.
When this happens, fine control hole f is shut ‘;
off from drain chamber D, and at almost the
same time, it is connected to pump pressure
chamber PP, so pilot pressure oil from the
charging pump passes through fine control hole
f and goes from port P3 to port A.
When the pressure at port P3 becomes higher,
spool (1) is pushed back and fine control hole f
is shut off from pump pressure chamber PP.
At almost the same time, it is connected to
drain chamber D to release the pressure at port
P3.
When this happens, spool (1) moves up or
down so that the force of metering spring (2) is
balanced with the pressure at port P3. The rela-
tionship in the position of spool (I) and body
(10) (fine control hole f is at a point midway
between drain hole D and pump pressure
chamber PP) does not change until retainer (9)
contacts spool (1).
Therefore, metering spring (2) is compressed
proportionally to the amount of movement of
the control lever, so the pressure at port P3
also rises in proportion to the travel of the con-
trol lever. In this way, the steering cylinder pis-
ton moves to a position where the pressure in
chamber A (the same as the pressure at port
P3) and the force of the return spring are bal-
anced. (Fig. 2) (Fig. 2) 114FO2024

1o-34
0
3) During fine control
(where control lever is returned)
When disc (5) starts to be returned, spool (I) is
pushed up
and the pressure
When this
by the

happens,
force
at port P3.
fine
of centering

control hole
spring

f is con-
(3)
Qk!xl n
nected to drain chamber D and the pressure oil
at port P3 is released.
If the pressure at port P3 drops too far, spool
(1) is pushed down by metering spring (Z), and
fine control hole f is shut off from drain cham-
ber D. At almost the same time, it is connected
to pump pressure chamber PP, and the pump
pressure is supplied until the pressure at port
P3 recovers to a pressure that corresponds to
the lever position. (Fig. 3)

(Fig. 3)
114FO2025

4) At full stroke
When disc (5) pushes down piston (4), and re-
tainer (9) pushes down spool (I), fine control
hole f is shut off from drain chamber D, and is
connected with pump pressure chamber PP.
Therefore, the pilot pressure oil from the charg-
ing pump passes through fine control hole f
and flows to chamber A from port P3, and
pushes the steering clutch cylinder piston.
(Fig. 4)

(Fig. 4) 114FO2026

1o-35
0
PPC VALVE FOR BRAKE CYLINDER

* The output pressure for the brake is generated


when the output pressure for the steering clutch
has almost reached 100% (when the clutch is
completely disengaged), so the stroke is slower
than for the steering clutch.

OPERATION
1) At neutral
Ports A and B of brake cylinder and ports PI and
P2 of the PPC valve are connected to drain cham-
ber D through fine control hole f in spool (1). (Fig.
1)

2) During fine control (neutral -+ fine control) s


d
When piston (4) starts to be pushed by disc (5),
(Fig. 1) 114FO2027 =
retainer (9) is pushed; spool (I) is also pushed by 0
metering spring (2), and moves down.
When this happens, fine control hole f is shut off
from drain chamber D, and at almost the same
time, it is connected to pump pressure chamber
PP, so pilot pressure oil from the charging pump
passes through fine control hole f and goes from
port PI to port A.
When the pressure at port Pi becomes higher,
spool (I) is pushed back and fine control hole f is
shut off from pump pressure chamber PP.
At almost the same time, it is connected to drain
chamber D to release the pressure at port PI.
When this happens, spool (1) moves up or down
so that the force of metering spring (2) is bal- f’

anced with the pressure at port PI. The relation-


ship in the position of spool (1) and body (10) PP
I
(fine control hole f is at a point midway between
drain hole D and pump pressure chamber PP)
does not change until retainer (9) contacts spool
(1).
Therefore, metering spring (2) is compressed pro-
portionally to the amount of movement of the
control lever, so the pressure at port PI also rises
in proportion to the travel of the control lever. In
this way, the brake cylinder piston moves to a po-
sition where the pressure in chamber A (the same
as the pressure at port PI) and the force of the
return spring are balanced. (Fig. 2) (Fig. 2) 114FO2028

1 O-36
3) During fine control
(where control lever is returned)
When disc (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3)
and the pressure at port PI.
When this happens, fine control hole f is con-
nected to drain chamber D and the pressure oil at
port PI is released.
If the pressure at port Pi drops too far, spool (1)
is pushed down by metering spring (2), and fine
control hole f is shut off from drain chamber D.
At almost the same time, it is connected to pump
pressure chamber PP, and the pump pressure is
supplied until the pressure at port PI recovers to
a pressure that corresponds to the lever position.
When the brake cylinder piston returns, oil in
drain chamber D flows in from fine control hole f
in the valve on the side that is not working. The
oil passes through port P2, and enters chamber B
to fill the chamber with oil (Fig. 3)

(Fig. 3) 114FO2029

4) At full stroke
When disc (5) pushes down piston (4), and re-
tainer (9) pushes down spool (I), fine control hole
f is shut off from drain chamber D, and is con-
nected with pump pressure chamber PP. There-
fore, the pilot pressure oil from the charging
pump passes through fine control hole f and flows
to chamber A from port PI, and pushes the brake
cylinder piston.
The oil returning from chamber B passes from
port P2 through fine control hole f’ and flows to
drain chamber D. (Fig. 4)

(Fig. 4) 114FO2030

1o-37
PPC VALVE

FOR STEERING CLUTCH AND BRAKE


D31 E-20 Serial No. 42199 and up
D3 1 P-20A Serial No. 45785 and up
D31P. PL, PLL-20 Serial No. 45785 and up
D31S, Q-20 Serial No. 41055 and up
D37E-5 Serial No. 3235 and up
D37P-5A Serial No. 3153 and up

0 A

C a d

f b e

SAD01 179

a. P port (from power train pump)


b. T port (to hydraulic tank)
c. P2 port (brake valve: to L.H. brake cylinder)
d. P4 port (steering valve: to R.H. steering cylinder)
e. PI port (brake valve: to R.H. brake cylinder)
f. P3 port (steering valve: to L.H. steering cylinder)

1o-37- 1
0
A-A B-B

F-F

SAD01 180

1. Spool 6. Nut (for lever connection)


2. Metering spring 7. Joint
3. Centering spring 8. Plate
4. Piston 9. Retainer
5. Disc 10. Body

1 O-37-2
Co
PPC VALVE FOR STEERING CLUTCH CYLINDER

OPERATION
1) At neutral
Ports A and B of the steering clutch cylinder (1)
and ports P3 and P4 of the PPC valve are con-
nected to drain chamber D. (Fig. 1)

2) During fine control (neutral + fine control)


SADOI
181
When piston (4) starts to be pushed by disc (5),
(Fig. 1)
retainer (9) is pushed; spool (1) is also pushed
by metering spring (2), and moves down.
When this happens, port P3 is shut off from drain
chamber D, and at almost the same time, it is
connected to pump pressure chamber PP, so pi-
lot pressure oil from the charging pump goes
from port P3 to port A.
When the pressure at port P3 becomes higher,
spool (1) is pushed back and port p3 is shut off
from pump pressure chamber PP.
At almot the same time, it is connected to drain
chamber D to release the pressure at port P3.
When the happens, spool (1) moves up or down
so that the force of metering spring (2) is bal-
anced with the pressure at port P3. The relation-
ship in the position of spool (1) and body (IO)
does not change until retainer (9) contacts spool
(1).
Therefore, metering spring (2) is compressed
proportionally to the amount of movement of
the control lever, so the pressure at port P3
also rises in proportion to the travel of the con-
trol lever. In this way, the piston of steering cy-
linder (11) moves to a position where the
pressure in chamber A (the same as the press-
ure at port P3) and the force of the piston of
steering cylinder pushed by steering clutch re-
turn spring are balanced. (Fig. 2) (Fig. 2)

’o-i7-3
3) During fine control
(where control lever is returned)
When disc (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3)
and the pressure at port P3.
When this happens, port P3 is connected to drain
chamber D and the pressure oil at port p3 is
released.
If the pressure at port P3 drops too far, spool (1)
is pushed down by metering spring (21, and port
P3 is shut off from drain chamber D. At almost
the same time, it is connected to pump pressure
chamber PP, and the pump pressure is supplied
until the pressure at port p3 recovers to a pres-
sure that corresponds to the lever position. (Fig.
3)

4) At full stroke
When disc (5) pushes down piston (4). and re-
tainer (9) pushes down spool (I), port p3 is shut
off from drain chamber D, and is connected with
pump pressure chamber PP. Therefore, the pilot
pressure oil from the charging pump flows to
chamber A from port P3, and pushes the piston
of steering clutch cylinder (11). (Fig. 4)

(Fig. 4)
PPC VALVE FOR BRAKE CYLINDER

OPERATION
1) At neutral
Ports A and B of brake cylinder (11) and ports
PI and P2 of the PPC valve are connected to
drain chamber D. (Fig. 1)

SAD01185
2) During fine control (neutral -fine control) (Fig. 1)
When piston (4) starts to be pushed by disc (5),
retainer (9) is pushed; spool (1) is also pushed
by metering spring (2), and moves down.
When this happens, port P1 is shut off from drain
chamber D, and at almost the same time, it is
connected to pump pressure chamber PP, so pi-
lot pressure oil from the charging pump goes
from port PI to port A.
When the pressure at port PI becomes higher,
spool (1) is pushed back and port Pl is shut off
from pump pressure chamber PP.
At almot the same time, it is connected to drain
chamber D to release the pressure at port PI.
When this happens, spool (1) moves up or down
so that the force of metering spring (2) is bal-
anced with the pressure at port Pl. The relation-
ship in the position of spool (1) and body (IO)
does not change until retainer (9) contacts spool
(1).
Therefore, metering spring (2) is compressed
proportionally to the amount of movement of
the control lever, so the pressure at port PI
also rises in proportion to the travel of the con- > I1
trol lever. In this way, the piston of brake cylin-
der (11) moves to a position where the press-
ure in chamber A (the same as the pressure at
port PI) and the force of the return spring are SAD01
I 86
balanced. (Fig. 2) (Fig. 2)

1o-37-5
0
3) During fine control
(where control lever is returned)
When disc (5) starts to be returned, spool (I) is
pushed up by the force of centering spring (3)
and the pressure at port PI.
When this happens, port PI is connected to drain
chamber D and the pressure oil at port PI is
released.
If the pressure at port PI drops too far, spool (I)
is pushed down by metering spring (2). and port
PI is shut off from drain chamber D. At almost
the same time, it is connected to pump pressure
chamber PP, and the pump pressure is supplied
until the pressure at port Pi recovers to a pres-
sure that corresponds to the lever position.
When the piston of brake cylinder (11) returns,
oil in drain chamber D flows in from port PI in
the valve on the side that is not working. The oil
passes through port P2, and enters chamber B to
fill the chamber with oil (Fig. 3)

(Fig. 3)

4) At full stroke
When disc (5) pushes down piston (4). and re-
tainer (9) pushes down spool (I), port PI is shut
off from drain chamber D, and is connected with
pump pressure chamber PP. Therefore, the pilot
pressure oil from the charging pump flows to
chamber A from port PI, and pushes the piston
of brake cylinder (II).
The oil returning from chamber B passes from
port P2 and flows to drain chamber D. (Fig. 4)

(Fig. 4)

1 O-37-6
@
BEVEL GEAR SHAFT AND STEERING CLUTCH

17 16 15
Il3Fl8014

1. Final drive flange OUTLINE


2. Outer drum (Brake drum)
3. Pressure plate l The steering clutch is a wet type, multiple disc,
4. Collar spring-boosted clutch.
5. Clutch spring l There are steering clutches installed on the left
6. Clutch spring and right at both ends of the bevel gear shaft, be-
7. Inner drum tween the bevel gear shaft and the final drive.
8. Bevel gear shaft hub The steering clutches transmit or cut the trans-
9. Release yoke mission of motive force from the bevel gear
10. Bearing cage shaft to the final drive to change the direction of
11. Bearing cage the machine.
12. Adjustment nut
13. Bevel gear
14. Bevel gear shaft
15. Retainer
16. Clutch disc
17. Clutch plate

1 O-38
1. L.H. steeting clutch ENGAGED
When the left steering lever is not being pulled,
no oil enters steering booster cylinder (18) from
the steering control valve.
As a result, release yoke (9) is not actuated, and
the tension of clutch springs (5) and (6) makes
pressure plate (3) push clutch disc (16) and
clutch plate !I 7) into close contact with inner
drum (7).
In this condition, the motive force from bevel
gear shaft (13) is transmitted from inner drum
(7) through the clutch disc and clutch plate to
outer drum (2). It is then transmitted to final drive
from flange (I), which forms one unit with the
outer drum.
Therefore, if the right steering clutch is also en-
gaged, the machine will travel in a straight line.

-r,--g
77-T”
17 16 15 FI 1318012

2. L.H. steetring DISENGAGED 1 2 3 5 6 7 9 1813


When the left steering lever is pulled, the steering
control valve is actuated and oil enters steering
booster cylinder (I 8).
As a result, release yoke (9) is pushed to the left,
and retainer (I 5) and pressure plate (3) move to
the left as one unit.
When this happens, the close contact between
clutch disc (16) and clutch plate (I 7). and inner
drum (7) is released.
In this condition, the motive force from bevel
gear shaft (13) -is transmitted only as far as inner
drum (7). It is not transmitted to outer drum (2).
L
Therefore, if the right steering clutch is engaged,
the machine will turn to the left.

17 16 15 FI 1318013

10-39
8 7 5 13 8

A-A

B-B
Il3Fl8017

1. Steering case cover OUTLINE


2. Lever
3. Lever l The steering brake is an anchor type contracting
4. Yoke band brake which is tightened on the outside cir-
5. Lever cumference of the brake drum (steering clutch
6. Rod outer drum).
7. Anchor l The steering brake has two functions: sharp
8. Adjustment nut turning and stopping. It is used to stop the ma-
9. Spring chine when the brake pedal is depressed, and to
10. End steer the machine when the steering lever is
11. Brake band pulled to move lever (3).
12. Lining When parking the machine, depress the brake
13. Pin pedal and apply the brake lock lever to hold the
14. Pin pedal in position.

10-40
. When steering to the left, pull the left steering
lever and the left steering clutch is disengaged;
when steering to the right, pull the right steering
lever and the right steering clutch is disengaged.
However, the motive force passing through the
steering clutch is not completely cut, so there is
dragging for a short time and the machine turns
in a wide circle.
To adjust the radius of the turn, depress the
brake pedal on the side to which the machine is
turning. This will tighten the brake band on the
outer drum (brake drum) and prevent the ‘A
dragging.

1. Operation of brake when traveling forward


When the brake pedal is depressed, lever (2)
moves up and pulls up lever (5) to contract both
ends of the brake band to the inside.
When this happens, the outer drum is rotating
forward (clockwise in the diagram), so the brake
band is pulled in the direction of rotation. This
tension is borne by end (10) installed by a pin to
lever (51, but actually, it is borne by point A at the
FI 1318023
mount of the lever and end.
Therefore, the brake band restricts the brake
drum with the fulcrum at point A, and pushes
out point B on the other side to the right.

2. Operation of brake when traveling in reverse


In the same ways as when traveling forward,
when the brake pedal is depressed, both ends of
the brake band are contracted to the inside.
When this happens, the outer drum is rotating in
reverse (counterclockwise in the diagram), so
the brake band is pulled in the direction of rota-
tion. This tension is borne by mount B of rod (6)
and the brake band.
Therefore, the brake band restricts the brake
drum with the fulcrum at point B, and pushes out
point A on the other side to the left.

FI 1318024

10-41
FINAL DRIVE

* The diagram shows the D31 E, S-20.

Il3Fl8020

1. Final dive flange OUTLINE


2. Cage
3. Pinion shaft (10 teeth) l The final drive is a spur gear, one stage reduction,
4. Gear (63 teeth) splash lubrication type.
5. Final drive case
6. Sprocket
7. Ring
8. Sprocket boss
9. Sprocket shaft
10. Cover
1 1. Floating seal

1O-42
TRACK FRAME
D31 E, P, PL, PLL-20
D31 S, Q-20
* The diagram shows the D31 E, S, Q-20.

7 6
114FO2031

1. Idler OUTLINE
2. idler cushion l The track frame supports the whole machine
3. Track weight, and moves the machine by driving
4. Carrier roller track (3) using the motive force of the power
5. Sprocket train transmitted from sprocket (5).
6. Track roller . Number of rollers
7. Track frame
Number of Number of
Model carrier roller track roller
(each side) (each side)

D31 E, S, Q-20 1 5
I I -
D31 P, PL-20 1 6
I I
D31 PLL-20
I 2 I *

1o-43
D31 P-20A
D37E-5
D37P-5A
* The diagram shows the D31 P-20A. D37P-5A.

%
6

113F18307

1. Idler OUTLINE
2. Idler cushion l The track frame supports the whole machine
3. Track weight, and moves the machine by driving
4. Carrier roller track (3) using the motive force of the power
5. Sprocket train transmitted from sprocket (5).
6. Track roller
7. Track frame l Number of rollers

1o-44
MAIN FRAME AND SUSPENSION

D31 E, S, Q-20

Il3Fl8022

I. Main frame
2. Cross-bar
3. Track frame
4. Bracket

OUTLINE
l The suspension consists of left and right brack-
ets (4) and cross bar (2) installed to the main
frame. It is a fixed type connecting the main
frame and track frame.

1o-45
D31 P-20A
D31 P, PL, PLL-20
D37P-5A
D37E-5

113F18308

1. Main frame
2. Cross-bar
3. Track frame
4. Bracket

OUTLINE
l The suspension consists of left and right brack-
ets (4) and crosS bar (2) installed to the main
frame. It is a fixed type connecting the main
frame and track frame.

1 O-46
STRUCTURE AND FUNCTION HYDRAULIC PIPING

HYDRAULIC PIPING
POWER ANGLE, POWER TILTDOZER

D31E-20 Serial No. 42001 - 42713


D31P-20A Serial No. 45001 - 47616
D37E-5 Serial No. 3001 - 3730
D37P-5A Serial No. 3001 - 3660

114FO2032

OUTLINE
1. Blade angle cylinder l The oil in hydraulic tank (8) is sucked up by hy-
2. Air bleeding valve draulic pump (3) installed to the engine, and is
3. Hydraulic pump sent to hydraulic control valve (6).
4. Blade lift cylinder The hydraulic control valve switches the flow of
5. Angle selector valve oil to lift cylinder (4), angle cylinder (I), or tilt
6. Hydraulic control valve cylinder (10) to operate the blade according to
7. Hydraulic filter the movement of the work equipment control
8. Hydraulic tank lever.
9. Suction safety valve If the hydraulic control valve is at the “HOLD”
10. Blade tilt cylinder position, the oil enters hydraulic filter (7) in-
stalled to the hydraulic tank and returns to the
hydraulic tank.

10-47
0
STRUCTURE AND FUNCTION HYDRAULIC PIPING

D31 E-20 Serial No. 42714 and up


D31P-20A Serial No. 47617 and up
D37E-5 Serial No. 3731 and up
D37P-5A Serial No. 3661 and up

Si3DO2145

1. R.H. blade angle cylinder OUTLINE


2. Air bleeding valve . The oil in hydraulic tank (7) is sucked up by hy-
3. Hydraulic pump draulic pump (3) installed to the engine, and is
4. R.H. blade lift cylinder sent to hydraulic control valve (5).
5. Hydraulic control valve The hydraulic control valve switches the flow of
6. Hydraulic filter oil to lift cylinders (4) and (8), angle cylinders (1)
7. Hydraulic tank and (9), or tilt cylinder (10) to operate the blade
8. L.H. blade lift cylinder according to the movement of the work equip-
9. L.H. blade angle cylinder ment control lever.
10. Blade tilt cylinder If the hydraulic control valve is at the “HOLD”
position, the oil enters hydraulic filter (6) installed
to the hydraulic tank and returns to the hydraulic
tank.

1028
STRUCTURE AND FUNCTION HYDRAULIC PIPING

STRAIGHT TILTDOZER

D31P, PL-20 Serial No. 45001 - 47616


D31PLL-20 Serial No. 45001 - 47653

Il3Fl8025

1. Hydraulic tank OUTLINE


2. Hydraulic pump l The oil in hydraulic tank (1) is sucked up by hy-
3. Hydraulic control valve draulic pump (2) installed to the engine, and is
4. Blade lift cylinder sent to hydraulic control valve (3).
5. Blade tilt cylinder The hydraulic control valve switches the flow of
6. Hydraulic filter oil to lift cylinder (4), or tilt cylinder (5) to oper-
ate the blade according to the movement of the
work equipment control lever.
If the hydraulic control valve is at the “HOLD”
position, the oil enters hydraulic filter (6) in-
stalled to the hydraulic tank and returns to the
hydraulic tank.
STRUCTURE AND FUNCTION HYDRAULIC PIPING

D31P, PL-20 Serial No. 47617 and up


D31PLL-20 Serial No. 47654 and up

SBD02146

1. R.H. blade lift cylinder OUTLINE


2. Hydraulic pump . The oil in hydraulic tank (5) is sucked up by hy-
3. Hydraulic control valve draulic pump (2) installed to the engine, and is
4. Hydraulic filter sent to hydraulic control valve (3).
5. Hydraulic tank The hydraulic control valve switches the flow of
6. L.H. blade lift cylinder oil to lift cylinders (1) and (61, tilt cylinder (7) to
7. Blade tilt cylinder operate the blade according to the movement of
the work equipment control lever.
If the hydraulic control valve is at the “HOLD”
position, the oil enters hydraulic filter (4) installed
to the hydraulic tank and returns to the hydraulic
tank.

’O-i9-’
STRUCTURE AND FUNCTION HYDRAULIC PIPING

DOZER SHOVEL
D31S. Q-20 Serial No. 41001 - 41183

1. Hydraulic tank OUTLINE


2. Hydraulic pump l The oil in hydraulic tank (1) is sucked up by hy-
3. Hydraulic control valve draulic pump (2) installed to the engine, and is
4. Bucket lift cylinder sent to hydraulic control valve (3).
5. Bucket dump cylinder The hydraulic control valve switches the flow of
6. Hydraulic oil filter oil to lift cylinder (4), or dump cylinder (5) to
operate the bucket according to the movement
of the work equipment control lever.
If the hydraulic control valve is at the “HOLD”
position, the oil enters hydraulic filter (6) in-
stalled to the hydraulic tank and returns to the
hydraulic tank.
The hydraulic filter is a cartridge type.

1O-49-2
HYDRAULIC PIPING
STRUCTURE AND FUNCTION

D31S, Q-20 Serial No. 41184 and up

SBOO2147

1. R.H. bucket lift cylinder OUTLINE


. The oil in hydraulic tank (6) is sucked up by hy-
2. Hydraulic pump
3. R.H. bucket dump cylinder draulic pump (2) installed to the engine, and is

4. Hydraulic control valve sent to hydraulic control valve (4).


5. Hydraulic oil filter The hydraulic control valve switches the flow of

6. Hydraulic tank oil to lift cylinders (1) and (8), or dump cylinders

7. L.H. bucket dump cylinder (3) and (7) to operate the bucket according to the

8. L.H. bucket lift cylinder movement of the work equipment control lever.
If the hydraulic control valve is at the “HOLD”
position, the oil enters hydraulic filter (5) installed
to the hydraulic tank and returns to the hydraulic
tank.
The hydraulic filter is a cartridge type.

1o-g-3
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM

HYDRAULIC CIRCUIT DIAGRAM


STRAIGHT TILTDOZER

D31P. PL, PLL-20

FLOAT LOWER RAISE


0

RIGHT TILT LEFT TILT

5 I I

II T

SAD02178

1. Hydraulic tank 5. Blade tilt valve spool


2. Hydraulic pump (SAL(2)-036) 6. Blade tilt cylinder
D31P. PL-20 Serial No.: 45001 - 47616 7. Check valve
D31PLL-20 Serial No.: 45001 - 47653 8. Blade lift valve spool
Hydraulic pump (SAR(2)-045) 9. Suction valve for blade lower
D31P, PL-20 Serial No.: 47617 and up 10. Blade lift cylinder
D31PLL-20 Serial No.: 47654 and up 11. Hydraulic filter
3. Main relief valve Cracking pressure: 0.1 MPa II.05 kg/cm*}
Set pressure: 12.7 MPa I175 kg/cm2} 12. Hydraulic tank breaker relief valve
4. Check valve Cracking pressure: 0.09 MPa IO.9 kg/cm21

1020
HYDRAULIC CIRCUIT SYSTEM
STRAIGHT TILTDOZER

D31 P, PL, PLL-20


+ Engine running, hydraulic control lever in “HOLD”.

114FO2034

10-51
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM

HYDRAULIC CIRCUIT DIAGRAM


POWER ANGLE, POWER TILTDOZER

D31E-20 Serial No.: 42001 - 42713


D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660

i 13

8 I

f4 I
9 1

I II IL--

-_ 4

-PcI
7
__!

SAD02179

1. Hydraulic tank 10. Blade angle cylinder


2. Hydraulic pump (SAL(2)-036) 11. Suction safety valve
3. Main relief valve 12. Check valve
4. Check valve 13. Blade lift valve
5. Blade tilt, angle valve 14. Blade lift cylinder
6. Left angle selector valve 15. Suction valve for blade LOWER
7. Right angle selector valve 16. Hydraulic filter
8. Air bleed valve 17. Hydraulic tank breaker relief valve
9. Blade tilt cylinder

1O&-.2
STRUCTURE AND FUNCTION HYDqAULlC CIRCUIT SYSTEM

HYDRAULIC CIRCUIT SYSTEM


POWER ANGLE, POWER TILTDOZER

D31E-20 Serial No.: 42001 - 42713


D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660
* Engine running, hydraulic control lever in “HOLD”.
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM

HYDRAULIC CIRCUIT DIAGRAM


POWER ANGLE, POWER TILTDOZER

D31E-20 Serial No.: 42714 and up


D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up

0 I? ~
14 f\ c\ h 15
w-f’ 0
FLOAT LOWER RAISE
13
14 i I- -L
I I I T TT T

7-a ’

:
7

LI
1C -
I I A
' ' SAD02180

1. Hydraulic tank 10. Blade tilt valve


2. Hydraulic pump (SAR(2)-045) 11. Blade tilt cylinder
3. Main relief valve 12. Check valve
Set pressure: 17.4 MPa I178 kg/cm*1 13. Blade lift valve
4. Check valve 14. Blade lift cylinder
5. Blade angle valve 15. Suction valve for blade LOWER
6. Blade angle cylinder 16. Hydraulic filter
7. Suction safety valve Cracking pressure: 0.1 MPa Il.05 kg/cm?
Cracking pressure: 24.5 MPa {250 kg/cm*} 17. Hydraulic tank breaker relief valve
8. Air bleed valve Cracking pressure: 0.09 MPa IO.9 kg/cm3
9. Check valve

’O-F’
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT SYSTEM

HYDRAULIC CIRCUIT SYSTEM


POWER ANGLE, POWER TILTDOZER

D31E-20 Serial No.: 42714 and up


D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up
+ Engine running, hydraulic control lever in “HOLD”.

SBD02151
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM

HYDRAULIC CIRCUIT DIAGRAM


DOZER SHOVEL

D31S, Q-20

SAD02181

1. Hydraulic tank 7. Safety valve for bucket tilt


2. Hydraulic pump (SAL(2)-036) Cracking pressure: 19.1 MPa {I95 kg/cm*}
D31S, Q-20 Serial No.: 41001 - 41183 8. Bucket dump cylinder
Hydraulic pump (SAR(2)-045) 9. Check valve
D31S, Q-20 Serial No.: 41184 and up 10. Bucket lift valve spool
3. Main relief valve 11. Suction valve for bucket lower
Set pressure: 17.2 MPa II75 kg/cm*} 12. Bucket lift cylinder
4. Check valve 13. Hydraulic filter
5. Bucket dump valve spool Cracking pressure: 0.1 MPa II.05 kg/cm*}
6. Safety valve for bucket dump 14. Hydraulic tank breaker relief valve
Cracking pressure: 9.8 MPa {IO0 kg/cm*) Cracking pressure: 0.09 MPa IO.9 kg/cm21

1o-&54
HYDRAULIC CIRCUIT SYSTEM
DOZER SHOVEL

D31 S, Q-20
* Engine running, hydraulic control lever in “HOLD”.

114FO2038
STRUCTURE AND FUNCTION HYDRAULIC CONTROL

HYDRAULIC CONTROL
D31E-20 Serial No.: 42001 - 42713 ($)- @ Q@
D3 1 P-20A Serial No.: 45001 - 47616
D31P. PL, PLL-20 Serial No.: 45001 and up
D31S, Q-20 Serial No.: 41001 and up
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660

0
2

I
D31E-20 Serial No. 42199 and up
D31P-20A Serial No. 45825 and Up
D37E-5 Serial No. 3235 and UP
D37P-5A Serial No. 3153 and up

SRDOI 189

Lever positions

Blade control lever


Selector button (tilt/angle)
(Power tilt, angledozer)
Lock lever
Main control valve
STRUCTURE AND FUNCTION HYDRAULIC CONTROL

D31E-20 Serial No.: 42714 and up


D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up

SBDO2152
Lever positions

Power angle,
power tiltdozer
1. Blade control lever
2. Lock lever
HOLD
3. Main control valve
Blade RAISE
Blade LOWER
Blade FLOAT
RIGHT TILT
LEFT TILT
R.H. angle

’o-26-1
STRUCTURE AND FUNCTION HYDRAULIC TANK AND FILTER

HYDRAULIC TANK AND FILTER


D31E-20 Serial No.: 42001 - 42713
D31 P-20A Serial No.: 45001 - 47616
D31P, PL, PLL-20 Serial No.: 45001 and up
D31S. Q-20 Serial No.: 41001 and up
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660

A-A

FI 1318037

1. Hydraulic control valve OUTLINE


2. Hydraulic filter l The hydraulic filter is a cartridge type.
3. Hydraulic tank
4. Filter head
5. Bypass valve

A. From control valve


B. To hydraulic tank

’o-F2
STRUCTURE AND FUNCTION HYDRAULIC CONTROL

D31E-20 Serial No.: 42714 and up


D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up

SAD02153

1. Hydraulic control valve OUTLINE


2. Hydraulic filter . The hydraulic filter is a cartridge type.
3. Hydraulic tank
4. Filter head
5. Bypass valve

A. From control valve


B. To hydraulic tank

1o-57
0
STRUCTURE AND FUNCTION HYDRAULIC CONTROL VALVE

HYDRAULIC CONTROL VALVE


D31E-20 Serial No.: 42001 - 42713
D31 P-20A Serial No.: 45001 - 47616
D31P. PL, PLL-20 Serial No.: 45001 and up
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660
k-C l--D

Il3FI8031

P. From hydraulic pump OUTLINE


AI. To tilt cylinder bottom (R.H. TILT) l The control valve is a 2-spool valve with spools
B1. To tilt cylinder head (L.H. TILT) for blade lift, and tilt/angle.
Aa. To lift cylinder bottom (LOWER) l Suction valve (22) acts to prevent negative
B2. To lift cylinder head (RAISE) pressure from being formed at the lift cylinder
T. To hydraulic tank bottom when the blade is lowered.
2 3 4

1 :\

114 lil 1'6 i7


B-B
18

20 21 22 23
13

12

A-A

D-D

Il3Fl8032

1. Valve body 9. Detent ball 17. Plun


2. Main relief valve 10. Detent ball 18. Plug
3. Blade tilt spool 11. Plug 19. Plug
4. Blade lift spool 12. Spring case 20. Plug
5. Detent and spring case 13. Return spring 21. Suction valve spring
6. Return spring 14. Plug 22. Suction valve
7. Detent plug 15. Checkvalve 23. Plug
8. Detent spring 16. Check valve spring

10-59
STRUCTURE AND FUNCTION HYDRAULIC CONTROL VALVE

D31E-20 Serial No.: 42714 and up


D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up

Al A2 A3

Bl 82 B3 #A

SAD02 I54

P. From hydraulic pump OUTLINE


Al. To R.H. angle cylinder bottom (L.H. ANGLE) . The control valve is a 3-spool valve with spools
Bl. To L.H. angle cylinder bottom (R.H. ANGLE) for blade lift, tilt, and angle.
A2. To tilt cylinder head (R.H. TILT) . Main relief valve (2) sets the pressure in the cir-
B2. To tilt cylinder bottom (L.H. TILT) cuit to 17.5 MPa 078 kg/cm*}.
A3. To lift cylinder bottom (LOWER) . The set pressure of the main relief valve can be
B3. To lift cylinder head (RAISE) adjusted by adjustment screw.
DA. Seal drain One turn of the adjustment screw adjusts the
T. To hydraulic tank pressure by 2.4 MPa t24.8 kg/cm*}.

’0-i9-’
STRUCTURE AND FUNCTION HYDRAULIC CONTROL VALVE

20 21 22 23

14 13 12 .I1 ‘”

A-A D-D

SAD02155

1. Valve body 9. Detent spring 17. Check valve spring


2. Main relief valve assembly 10. Detent ball 18. Plug
3. Angle valve spool 11. Detent ball 19. Suction safety valve
4. Tilt valve spool 12. Plug 20. Suction valve
5. Lift valve spool 13. Spring case (Lower side)
6. Detent case 14. Return spring 21. Suction valve spring
7. Spool return spring 15. Plug 22. Plug
8. Detent plug 16. Check valve 23. Plug

’O-i9-*
HYDRAULIC CONTROL VALVE

D31 S, Q-20

Il3Fl8033

P. From hydraulic pump AZ. TO lift cylinder head (LOWER)


AI. To dump cylinder head (TILT BACK) Bz. To lift cylinder bottom (RAISE)
B1. To dump cylinder bottom (DUMP) T. To hydraulic tank

OUTLINE
l The control valve is a 2-spool valve with spools l Safety valves (18) and (19) have a suction func-
for bucket lift, and dump. tion, and relieve the circuit when external shock
l Suction valve (22) acts to prevent negative pres- causes abnormally high pressure.
sure from being formed at the lift cylinder head
when the bucket is lowered.

1 O-60
B-B
18 19
\

20 21 22 23

'10
A-A
\
'11
Il3Fl8034

1. Valve body 9. Detent ball 17. Plug


2. Main relief valve 10. Detent ball 18. Bucket dump safety valve
3. Bucket dump spool 1 1. Plug 19. Bucket tilt safety valve
4. Bucket lift spool 12. Spring case 20. Plug
5. Detent and spring case 13. Return spring 21. Suction valve spring
6. Return spring 14. Plug 22. Suction valve
7. Detent plug 15. Check valve 23. Plug
8. Detent spring 16. Check valve spring

lo-61
STRUCTURE AND FUNCTION ANGLE SELECTOR VALVE

ANGLE SELECTOR VALVE


D31E-20 Serial No.: 42001 - 42713
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660

P2 Pl

I I4FO2040

1. Plug OUTLINE
2. Return spring l When the switch at the top of the work equip-
3. Valve body ment control lever knob is operated, the angle
4. Spool selector valve switches the flow of oil to the
5. Push pin angle cylinder.
6. Solenoid assembly l When the angle selector valve is switched OFF,
the flow of oil to the angle cylinder is cut, and
CI. To tilt cylinder bottom the oil flows only to the tilt cylinder to make it
(From tilt valve) possible to tilt the blade.
C2. From tilt valve
(To tilt cylinder head)
PI. Blind (to left angle cylinder bottom)
P2. To right angle cylinder bottom (blind)
( ): This shows the left angle selector valve.
OPERATION

pq Left tilt

114FO2041

1. When control lever is at right tilt and angle se- The oil entering port C2 then flows to port CI
lector switch is OFF and enters the head end of tilt cylinder (9).
When the angle selector switch is not being When this happens, the angle selector valve in
operated, solenoid (6) is deenergized, so the the circuit to angle cylinder (10) is closed, so
circuits between ports Pi and Cl and between the oil flows only to the tilt cylinder. When the
ports Pz and C2 are closed, and the circuit be- oil pressure in the circuit rises, the blade is
tween ports Cl and C2 is opened. In this con- tilted to the right.
dition, if the work equipment control lever is
moved to RIGHT TILT, tilt valve spool (7) moves
to the right and opens the circuit between ports
P and A and ports T and B.
When this happens, the oil from the pump
flows from port P, pushes check valve (8) open,
enters port A, and flows to port C2 of the left
angle selector valve.

1 O-63
,,, Right angle

Switch ON

<Cl

-C2

:
:r
A

.cz

114FO2042

2. When control lever is at right angle and angle The oil then enters the bottom end of left angle
selector switch is ON cylinder (10) and extends the left angle cylinder.
When the angle selector switch is operated, When the oil pressure in the circuit rises, the
solenoid (6) is actuated, so push pin (5) pushes left angle cylinder (10) extends, and the blade
down spool (4). When this happens, the circuits is angled to the right.
between port Pi and Cl and between port Pz
and C2 are opened.
In this condition, if the work equipment control
lever is moved to RIGHT ANGLE, the tilt valve
moves in the same way as in Item 1. The oil
from the pump flows from port C2 of the left
angle selector valve to port P2.

1O-64
STRUCTURE AND FUNCTION SUCTION SAFETY VALVE

SUCTION SAFETY VALVE


D31E-20 Serial No.: 42001 - 42713
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660

A
A-A

l- B

B-B
114FO2043

1. Valve body OUTLINE’


2. Left angle safety valve The circuit is normally closed, but if a pressure
3. Right angle safety valve above the set pressure is applied to the angle cy-
A. From left angle cylinder bottom linder, the oil at the bottom passes through the
B. From right angle cylinder bottom suction safety valve and is drained to the hydraulic
C. To hydraulic tank tank.
WORK EQUIPMENT

POWER ANGLE AND TILTDOZER


D31 E-20, D31 P-20A
D37E-5, D37P-5A

A-A B-B

L-

2
D-D

\ A \

E-E I F-F

H-H
G-G

1. Blade
2. Pithing rod
3. U-frame
4. Blade angle cylinder
5. Blade lift cylinder
6. Bracket
7. Blade tilt cylinder J-J
8. Cutting edge
9. End bit 114FO2044

1O-66
STRAIGHT TILTDOZER
D31 P, PL, PLL-20

A-A

E-E
F-F

G-G H-H

Il3FI8038

1. Blade
2. Blade tilt cylinder (Left frame side)
2. Brace (Right frame side)
3. Straight frame
4. Blade lift cylinder
5. Brace
6. Trunnion
7. Cutting edge
8. End bit

1 O-67
BUCKET AND LINK
D31 S, Q-20

A-A

B-B

c-c
D-D E-E
114FO2045

1. Bucket 6. Link
2. Rod 7. Loader frame
3. Lever 8. Bucket lift cylinder
4. Bucket dump cylinder 9. Bucket tooth
5. Lift arm

1O-68
STRUCTURE AND FUNCTION MONITOR SYSTEM

MONITOR SYSTEM
MONITOR PANEL

6 5 4 SBDOlSIS

1. Water temperature gauge 6. Starting switch


2. Fuel level gauge 7. Air cleaner clogging caution lamp
3. Service meter 8. Engine oil pressure caution lamp
4. Heater glow signal 9. Charge lamp
5. Lamp switch

MONITOR DISPLAY AND FUNCTION


” I I I

2 Category Symbol Display item Display range


I Display method
r
6 I I I I

04
SAD00520
Engine oil
pressure
Max. 49 kPa
IO.5 kg/cm? Display when starting switch is ON and
engine is running
. When normal: OFF
--* When there is (Engine oil pressure caution lamp and
Caution Charge
I improper charging charge lamp light up when starting
SAD00522

-:::
switch is turned ON, but go off after

i:: engine starts.)

I@ . _
7..
.. _ _

srooa997
Air cleaner
clogged
When air cleaner
is clogged
. When abnormal: ON

I I r

Display when starting switch is ON


Water
temperature
. Water temperature is displayed by
SAP00527
indicator

SAD00998
Gauges
I I I

Display when starting switch is ON


flil SAP00528
Fuel level . Level of remaining
indicator
fuel is displayed by

Display when starting switch is at HEAT


* Lights up during preheating (red hot
Pilot Preheating When preheating after 20 - 30 set)
. Goes out when starting switch is
returned from HEAT position
SAD00708

10-71
0
STRUCTURE AND FUNCTION SENSORS

SENSORS
. The signal from the sensor is input directly to the monitor panel.
The contact type sensors are always grounded at one end to the chassis.

Category Type of sensor Sensor method When normal When abnormal

Air cleaner clogging Contact OFF (open) ON (closed)


Caution
Engine oil pressure Contact OFF (open) ON (closed)

Engine water temperature Resistance


Gauge
Fuel level Resistance -

AIR CLEANER CLOGGING SENSOR

Structure of circuit

SBD02184

1. Hose 6. Spring Function


2. Connector 7. Terminal . The air cleaner clogging sensor is installed to the
3. Case 8. Filter outlet port of the air cleaner, and when the air
4. Diaphragm 9. Boss cleaner becomes clogged and the pressure (nega-
5. Guide tive pressure) reaches the specified pressure, the
switch is turned ON by the diaphragm, and the
lamp lights up to warn of the abnormality.

1O-.72
STRUCTURE AND FUNCTION SENSORS

ENGINE OIL PRESSURE SENSOR

Structure of circuit

58001537

1. Plug Function
2. Contact ring . The engine oil pressure sensor is installed to the
3. Contact engine cylinder block. The diaphragm detects the
4. Diaphragm oil pressure, and when it goes below the speci-
5. Spring fied pressure, the switch is turned ON, and the
6. Terminal lamp lights up to warn of the abnormality.

ENGINE WATER TEMPERATURE SENSOR

Structure of circuit
SAD02185

1. Terminal Function
2. Plug . The water temperature sensor is installed to the
3. Thermistor engine cylinder block. The change in the tem-
perature is detected as a change in the resistance
of the thermistor, and a signal is sent to the moni-
tor panel to display the temperature.

1o-73
0
STRUCTURE AND FUNCTION SENSORS

FUEL LEVEL SENSOR

1. Float Function
2. Variable resistor . The fuel level sensor is installed to the side face
3. Bracket of the fuel tank, and the float moves up and down
according to the fuel level. The movement of the
float is transmitted through the arm to actuate a
variable resistor and send a signal to the monitor
panel to indicate the remaining fuel level.

1O&74
20 TESTING AND ADJUSTING

Standard value table for engine ................................ .20-2 Bleeding air from steering circuit.. ........................... 20-23
Standard value table for chassis ............................... .20-4 Measuring and adjusting work equipment
Standard value table for electrical system.. .......... .20-9-4 main relief pressure.. ...................................... 20-23-I
Table of tools for testing, adjusting and Bleeding air from hydraulic cylinders.. ................... .20-24
troubleshooting .................................................. .20-10 Bleeding air from angle cylinder circuit .................. 20-25
Measuring engine speed .......................................... .20-12 Adjusting fuel control cable ..................................... .20-26
Measuring exhaust color ....................................... 20-12-2 Adjusting fuel control lever.. ..................................... 20-27
Adjusting valve clearance.. ....................................... .20-13 Procedure for adjusting engine stop
Measuring compression pressure ............................ 20-14 motor cable ......................................................... .20-28
Measuring blow-by pressure ................................ 20-15-I Adjusting engine stop solenoid linkage ............. ..20-29- 1
Testing and adjusting fuel injection timing ............ 20-16 Adjusting transmission control linkage ................... 20-30
Bleeding air from fuel circuit .................................... 20-18 Adjusting travel of inching pedal ............................. 20-32
Measuring engine oil pressure ................................ .20-19 Adjusting brake pedal, steering brake cylinder ..... .20-33
Testing and adjusting fan belt tension .................... 20-20 Adjusting brake lining clearance .............................. 20-34
Measuring power train oil pressure.. ....................... 20-21 TROUBLESHOOTING ................................................. .20-35
Adjusting PPC valve .................................................. .20-22

* The following precautions are necessary when using the STANDARD VALUE TABLE for testing and adjusting,
or for troubleshooting.
1. The values in the table are for new machines, and are obtained for reference to values for new machines and
the 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 values for judging failures are based on standards when shipping the machine from the factory, and on
the results of various tests. 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.

a When carrying out testing, adjusting or troubleshooting, stop the machine on level ground, install the safety
pins and block the tracks.

A When working in groups, use agreed signals and do not allow unauthorized persons near the machine.

A When checking the water level in the radiator, wait for the water to cool. Do not remove the radiator cap while
the water is hot. Boiling water may spurt out.

A Be careful not to get caught in rotating parts.


TESTlNG AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE

STANDARD VALUE TABLE FOR ENGINE


D31E. P, PL, PLL, S, Q-20
Applicable machine model
D31P-20A
D3lE-20 : 42001 - 42713 D31 E-20 : 42714 and UP
D31P. PL-20 : 45001 - 47616 D31P. PL-20 : 47617 and up
Machine serial No. D31P-20A : 45001 - 47616 D31P-20A : 47617 and up
D31PLL-20 : 45001 - 47652 D31PLL-20 : 47653 and up
D31S. Q-20 : 41001 - 41163 D31S. Q-20 : 41164 and up

Engine 6D95L-1 S4D102-1


-
Cat1 Standard Permissible Standard Permissible
Item Condition Unit
value value value value

High idling
,Z.500 - 2,635 2,500 - 2,635 2,355 - 2,485 2,355 - 2,485
1

Engine speed Low idling vm 700 - 750 700 - 750 750 - 850 750 - 850

Rated speed 2,350 2,350 2,350

Exhaust gas Whole speed range


temperature (Atmospheric temp.: 20°C)
“C Max. 600 700

At sudden acceleration
Exhaust gas Bosch
color scale
At high idling

Valve clearance Intake valve


(Normal tempera- mm
ture)
Exhaust valve

Compression Oil temperature: 40 - 60°C MPa


pressure (SAESO or (Engine speed:
{kg/cm*}
SAE15W-40 oil) 320-360 rpm)

Blow-by pressure (Water temp:


(SAESO or operating range) (mmPFl20)
SAE15W-40 oil) At rated output

(Water temp:
operating range) MPa 0.34 - 0.69 0.25 0.34 - 0.59 0.25
At high idling {kg/cm*} (3.5 - 7.0) 12.51 I3.5 - 6.0) I2.51
(SAE30 or SAE15W-40 oil)

At low idling MPa Min. 0.10 0.069 Min. 0.15 0.069


{kg/cm? Il.01 IO.71 11.51 IO.71
(SAESO or SAE15W-40 oil)
Oil pressure

At high idling MPa 0.29 - 0.64 0.21 0.29 - 0.59 0.21


{kg/cm*} {3.0 - 6.5) I2.11 13.0 - 6.0) t2.11
(SAEIOW oil)

At low idling MPa Min. 0.08 0.069 Min. 0.10 0.069


{kg/cm*} IO.81 10.71 U.01 IO.71
(SAElOW oil)

Whole speed range


Oil temperature "C go- 110 120 go- 110 120
(inside oil pan)

Fuel injection Compression Before


’ (degree) 16-c 1 16+ 1 16.5 + 1 16.5 + 1
timina Top Dead Center
Deflection when pushed
Fan belt tension with finger force of mm IO 8-12 -
approx. 59 N 16 kg} I

* ( ): Reference value

20-2
8
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE

D37E-5
Applicable machine model
D37P-5A
I
D37E-5 :3001 - 3730 D37E-5 : 3731 and up
Machine serial No.
D37P-5A : 3001 - 3660 D37P-5A : 3661 and up

Engine 6D95L-1 S4D102-1


I I
-
Cat Standard Permissible Standard Permissible
Item Condition Unit
gor value value value value

High idling 2,620 - 2,750 - 2,510 - 2,640 -

Engine speed Low idling rpm 700 - 750 - 750 - 850 -

Rated speed 2,500 - 2,500 -

Exhaust gas Whole speed range -


temperature Max. 600 700
(Atmospheric temp.: 20°C) “’ -

Exhaust gas
color

0.35 - 0.25 -
Valve clearance Intake valve
(Normal tempera- mm
ture) 0.50 - 0.51 -
Exhaust valve

Compression Oil temperature:


(Engine speed: 40 - 60°C MPa Min. 2.9 2.06 Min. 2.41 1.69
pressure (SAE30 or
SAEl5W-40 oil) 320 - 360 rpm) {kg/cm? I301 I211 (24.61 i17.21

Blow-by pressure (Water temp: Max. 490 980 Max. 490 980
(SAE30 or operating range) ~mJ&D~
SAE15W-40 oil) At rated output I501 {JO01 1501 UOOI

(Water temp:
operating range) MPa 0.34 - 0.69 0.25 0.34 - 0.59 0.25
At high idling {kg/cm21 {3.5 - 7.0} 12.51 (3.5 - 6.0) 12.51
(SAE30 or SAE15W-40 oil)

At low idling MPa Min. 0.10 0.069 Min. 0.15 0.069


(SAE30 or SAE15W-40 oil) ‘kg’cmzl {I .OI to.71 il.51 10.71
Oil pressure

At low idling

(SAElOW oil)

Whole speed range


Oil temperature “C go- 110 120 go- 110 120
(inside oil pan)

Fuel injection Compression Before


Top Dead Center o (degree) 165 1 16k 1 16.5 + 1 16.5 + 1
timing
Deflection when pushed
Fan belt tension with finger force of mm 10 8-12 - -
approx. 59 N 16 kg}
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

STANDARD VALUE TABLE FOR CHASSIS


D3 1 E-20 Serial No.: 42001 - 42713 D31P-20A Serial No.: 45001 - 47616
D31P, PL-20 Serial No.: 45001 - 47616 D37E-5 Serial No.: 3001 - 3730
D31PLL-20 Serial No.: 45001 - 47652 D37P-5A Serial No.: 3001 - 3660
D31S, Q-20 Serial No.: 41001 - 41183
-
Cat6

Unit Permissible value
Item Measurement conditions Standard value
gorY
-
- Centerof lever
Fuel control lever knob Slow + Full
- Engine stopped
- Center of lever N + Each
Gear shift lever knob speed range
* Engine stopped
- Center of lever N + Forward,
knob 35 - 45 35 - 45
Steering, directional reverse 1
lever
- Max. value to
end of stroke N --f Left,
* Engine stopped right turn 62 - 70 62 - 70
-
- Center of pedal Full stroke
Inching pedal 103 - 113 103 - 113
* Engine stopped I I
* Center of pedal To operating force
* Engine stopped of 147 N 115 kg)
Brake pedal (when clearance mm 103 - 113 162
between lining and
drum is 0.3 mm)

* Center of lever
knob
HOLD -_) RAISE 69 - 79 I -
69 79
- Engine stopped
HOLD + LOWER

LOWER --f FLOAT

Work equipment HOLD + Left tilt,


control lever
HOLD + Right tilt,

HOLD --f Left angle 64 - 74 I 64 - 74

HOLD + Right angle 64 - 74 I 64 - 74

f Center of lever Slow --f Full 67 - 83 {6.8 - 8.5) 1 67 - 83 t6.8 - 8.51


Fuel control lever knob
- Engine stopped Slow + stop 59 - 98 (6.0 - 10.01 1 59 - 98 16.0 - IO.01
- Center of lever
Between each
Gear shift lever knob 29 - 39 {3.0 - 4.0) 29 - 39 13.0 - 4.0)
speed range
- Engine stopped
* Center of lever
FttR
knob
- Engine stopped
Steering,
directional lever End of stroke
{

* Center of pedal
Inching pedal

Brake pedal

- Center of lever HOLD + RAISE,


20 - 29 (2.0 - 3.01 20 - 29 (2.0 - 3.0}
knob
* Engine stopped
29 - 59 13.0 - 6.0)
29 - 59 I3.0 - 6.0)

Work equipment
FLOAT + HOLD 15-44{1.5-4.5) 1 15-44(1.5-4.5)
control lever
29 - 49 13.0 - 5.01 29 - 49 13.0 - 5.01

25 - 39 12.5 - 4.0) 25 - 39 (2.5 - 4.0)


tilt

20-4
I
HOLD + Leh,
right angle
(when button
is ON)
25 - 39 {2.5 - 4.0) 25 - 39 {2.5 - 4.0)

@
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

?- Item Measurement conditions Unit Permissible value


Standard value
Y
- Oil temperature: Engine:
1.91 - 2.16 119.5 - 22) 1.91 - 2.16 119.5 - 22)
Transmission main 40 - 60°C Low idlinq
relief pressure . Gear shift lever Engine:
at neutral !.I1 - 2.40 121.5 - 24.5: 1.11 - 2.40 (21.5 - 24.5)
Full throttle
* f;lF6;p;rature: Engine:
0
Low idling 1.91 - 2.16 119.5 - 22) 1.91 - 2.16 (19.5 - 221
Steering main relief * Gear shift lever MPa
pressure at neutral kg/cm2)
- Steering lever or $i;he;bttle
!.I1 - 2.40 (21.5 - 24.5 !.I1 - 2.40 (21.5 - 24.5)
pedal operated
* Oil temperature: Engine:
Low idling Min. 15.2 {155} Min. 15.2 1155)
Work equipment main 40 - 60°C
relief pressure . Hydraulic cylinder Engine:
at end of stroke Full throttle 17.2 - 17.9 1175 - 183: 17.2 - 17.9 {175 - 183}

* On level ground
Forward 1st
- Engine at full
throttle
. Engine water Forward 2nd
temDeraure:
Witiin operating Forward 3rd
Travel speed range km/h
* Run-up distance: Reverse 1st
lo-30m
* Distance for
Reverse 2nd
measurement:
20 m
Reverse 3rd

Blade 100 100

* Raise blade from ground to 300 mm.


mm

hf (I I
BED00402

Put the corner of the blade on a


block, and operate the tilt to raise
Blade tilt the chassis fully.
(Downward movement
of chassis when blade From this position, measure 50 50
is tilted) hydraulic drift “h” of the blade.
Start to measure immediately
after setting in position.
Measure the amount of hydrau-
lic drift for the next 15 minutes.
Machine on level ground
Control lever in HOLD position
Engine stopped
Hydraulic oil temperature:
40 - 60°C
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

-
-r
Cat6
Item Measurement conditions Unit Standard value ‘ermissible value
gor
-

Bucket lift arm 100 100

BED00403
mm
t Top surface of lift arm, bottom of bucket
horizontal.
* From this position, measure hydraulic drift
“h” of the bucket hinge pin and extension
“e” of the dump cylinder.
Bucket 10 10
* Machine on level ground
* Control lever in HOLD position
. Engine stopped
* Hydraulic oil temperature: 40 - 60°C
* Measure the amount of hydraulic drift for
the next 15 minutes.

Blade Lift
* Ground
5
RAISE 2.1 2.1
Raise fully

* L.H. tilt fully


$
R.H. tilt fully
1
* L.H. angle fully
BED00404 LOWER 1.5
x 1.5
R.H. angle fully Tilt

L.H.
1.4 1.4
TILT

I sec.
BED00405

* Raise blade from ground to 300 mm


R.H.
1.6 1.6
TILT
Angle

L.H.
2.5 2.5
ANGLE

BED00406

t Raise blade from ground to 300 mm


R.H.
- Machine on level ground 2.6 2.6
. Engine: full throttle ANGLE
- Hydraulic oil temperature: 40 - 60°C

20-6
8
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

-
Catf
gor
Item
T Measurement conditions
TUnit Standard value ‘ermissible value

Blade Pitch
* Forward pitch
limit
FOR-
2 WARD 1.2 1.2
Rear pitch limit
PITCH

REAR
* Raise blade from ground to
PITCH 1.9 1.9
300 mm
* Engine: full throttle
* Hydraulic oil temperature: 40 - 60°C

Bucket Lift
* Ground
5
Raise fully
RAISE 5.9 5.9
* Dump fully
5
Tilt back fully
sec.

8ED00408
LOWER 3.0 3.0
Dump

DUMP 2.5 2.5

BED00409

t Top surface of lift arm horizontal. TILT


* Machine on level ground 2.1 2.1
BACK
* Engine: full throttle
b Hydraulic oil temperature: 40 - 60°C
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

D31E-20 Serial No.: 42714 and up D31P-20A Serial No.: 47617 and up
D31P, PL-20 Serial No.: 47617 and up D37E-5 Serial No.: 3731 and up
D31PLL-20 Serial No.: 47653 and up D37P-5A Serial No.: 3661 and up
D31S, Q-20 Serial No.: 41184 and up
-
Cats
Item Measurement conditions Unit Standard value Permissible value
wr I I
- Center of lever
Fuel control lever knob Slow + Full mm 110 - 145 110 - 145
* Engine stopped
- Center of lever N + Each
0
Gear shift lever knob 13 - 18 13 - 18
speed range (degree)
* Engine stopped
* Center of lever N + Forward,
Steering, directional knob reverse I 37 - 47 I 37 - 47
. Max. value to
lever
end of stroke
* Engine stopped

Inching pedal * Center of pedal Full stroke


. Engine stopped I
* Center of pedal To operating force
* Engine stopped of 147 N {15 kg1
Brake pedal (when clearance
between lining and
drum is 0.3 mm1

Work equipment
I 62 - 72 I 62 - 72

control lever LOWER + FLOAT


fD31P, PL, PLL, S, Q-20)
HOLD + Left tilt,
tilt back
HOLD + Right tilt,
dump
* Center of lever HOLD --f RAISE 59 - 72 59 - 72
knob
. Engine stopped
HOLD + LOWER 59 - 72 59 - 72

Work equipment
LOWER + FLOAT I 50 - 62 I 50 - 62

control lever
D31 E-20, D31 P-20A,
HOLD + Left tilt
I 55 - 68
I 55 - 68

I D37E-5, D37P-5A) 55 - 68 55 - 68

0 11 - 15 11 - 15

20-8
8
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Cate-
Item Measurement conditions Unit Standard value Permissible value
wry I I
1 25 - 64 {2.5--6.51 1 25 - 64 {2.5 - 6.5)

1 59 - 98 c6.0 - 10.0) 1 59 - 98 16.0 - 10.0)

16 - 24 Il.6 - 2.4) 16 - 24 U.6 - 2.4)

20 - 29 12.0 - 3.0) 20 - 29 {2.0 - 3.0)


Gear shift lever
1 16-2411.6-2.4) 1 16-24{1.6-2.4)
I I 1 20 - 29 12.0 - 3.0) I 20 - 29 f2.0 - 3.01
2nd + 1st I
3 - Center of lever F-R 17 - 56 11.7 - 5.7) 17 - 56 Il.7 - 5.7)
d Steering, directional knob
lever * Engine stopped Steering
: 25 - 39 {2.5 - 4.0) 25 - 39 I2.5 - 4.0)
End of stroke
z * Center of pedal
m Inching pedal End of stroke 1 74 - 103 {7.5 - 10.5) 1 74 - 103 17.5 - 10.5)
* Engine at low idling
E
s Brake pedal
* Center of pedal End of stroke 1 69-8817.0-9.0) 1 69-88{7.0-9.0)
1 * Engine at low idling
HOLD + Raise,
5L
20 - 29 12.0 - 3.0) 20 - 29 {2.0 - 3.0)
E
8 29 - 59 {3.0 - 6.0) 29 - 59 {3.0 - 6.0)
% Work equipment - Center of lever

8
b

P
.-
c
control
(D31P.
lever
PL, PLL, S, Q-20)

I
-
knob
Engine stopped
)
1 25 - 39 I2.5 - 4.0) 1 25 - 39 I2.5 - 4.0)
tilt
l”

G
0” HOLD + RAISE 1 27 - 47 12.8 - 4.8) 1 27 - 47 12.8 - 4.8)

HOLD + LOWER

LOWER + FLOAT
Work equipment - Center of lever
control lever knob 1 27 - 47 12.8 - 4.8) 1 27 - 47 {2.8 - 4.8)
HOLD + Left tilt
D31 E-20, D31 P-20A. * Engine stopped
D37E-5, D37P-5A 1 27 - 47 12.8 - 4.8) 1 27 - 47 12.8 - 4.8)
I HOLD + Right tilt

1 31 - 47 I3.2 - 4.8) 1 31 - 47 13.2 - 4.8)

31 - 47 13.2 - 4.8) 31 - 47 {3.2 - 4.8)


angle
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

-
Gate Measurement conditions Jnit Standard value Permissible value
Item
gorl I
* Oil temperature: Engine:
.91 - 2.16 U9.5 - 22) .91 - 2.16 119.5 - 221
rransmission main 40 - 60°C Low idling
elief pressure * Gear shift lever Enaine:
11 - 5.40 (21.5 - 24.5) .ll - 2.40 t21.5 - 24.51
at neutral &ii throttle
;lF6;pyture: Engine:
0 .91 - 2.16 119.5 - 221 .91 - 2.16 t19.5 - 22)
Low idling
Steering main relief Gear shift lever MPa
xessure It neutral .g/cm’!
11 - 2.40 (21.5 - 24.5) .I1 - 2.40 (21.5 - 24.5)

* Oil temperature: Engine:


Low idling Min. 15.2 I1551 Min. 15.2 1155)
Nork equipment main 40 - 60°C
,elief pressure * Hydrauliccylinder Engine:
at end of stroke 7.2 - 17.9 {175 - 1831 7.2 - 17.9 {I75 - 1831
Fui throttle
- On level ground
Forward 1st
- Engine at full
throttle
- Enqine water Forward 2nd
temperawe:
Within operating Forward 3rd
rravel speed range <m/h
. Run-up distance: Reverse 1st
lo-30m
* Distance for
Reverse 2nd
measurement:
20 m
Reverse 3rd

Blade 100 100

%,
t Raise blade from ground to 300 mm.
mm

BED00402

* Put the corner of the blade on a


block, and operate the tilt to raise
Blade tilt the chassis fully.
(Downward movement
From this position, measure 100
of chassis when blade
is tilted) hydraulic drift “h” of the blade.
Start to measure immediately
after setting in position.
Measure the amount of hydraw
lit drift for the next 15 minutes.
Machine on level ground
Control lever in HOLD position
Engine stopped
Hydraulic oil temperature:
40 - 60°C
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

-
Catf Unit Sl:andard value ‘ermissible value
Item Measurement conditions
w
-

Bucket lift arm 100 100

BED00403
mm
Lr Top surface of lift arm, bottom of bucket
horizontal.
f From this position, measure hydraulic drift
“h” of the bucket hinge pin and extension
“e” of the dump cylinder.
Bucket 10 10
p Machine on level ground
* Control lever in HOLD position
n Engine stopped
5 Hydraulic oil temperature: 40 - 60°C
* Measure the amount of hvdraulic drift for
the next 15 minutes.

Blade Lift
* Ground
$ RAISE 2.1 2.1
Raise fully

- L.H. tilt fully


2
R.H. tilt fully
L 2
* L.H. angle fully
BED00404 1.5 1.5
_OWER
z
R.H. angle fully Tilt

L.H.
1.6 1.6
TILT

BED00405 sec.

f Raise blade from ground to 300 mm


R.H.
1.6 1.6
TILT
Angle

L.H.
1.9 1.9
ANGLE

BED00406

f Raise blade from ground to 300 mm


R.H.
b Machine on level ground 1.9 1.9
b Engine: full throttle ANGLE
b Hydraulic oil temperature: 40 - 60°C
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

-
l-
Cat1

-go’
Item

Pitch
Measurement conditions
TUnit Standard value ‘ermissible value

Blade
* Forward pitch
limit FOR-
$ WARD 1.2 1.2
Rear pitch limit
PITCH

BED00407

REAR
* Raise blade from ground to
1.9 1.9
300 mm PITCH
t Engine: full throttle
* Hydraulic oil temperature: 40 - 60°C

Bucket Lift
’ Ground
$
Raise fully
RAISE 5.9 5.9
mDump fully
$
Tilt back fully
sec.

BED00408
.OWER 3.0 3.0 %
Dump 7
0

DUMP 2.5 2.5

BED00409

It Top surface of lift arm horizontal. TILT


Machine on level ground 2.1 2.1
BACK
Engine: full throttle
Hydraulic oil temperature: 40 - 60°C

20-9-3
8
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM

STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM


D31 E-20 Serial No.: 42001 and up D31P-20A Serial No.: 45001 and up
D31P, PL-20 Serial No.: 45001 and up D37E-5 Serial No.: 3001 and up
D31PLL-20 Serial No.: 45001 and up D37P-5A Serial No.: 3001 and up
D31S, Q-20 Serial No.: 41001 and up

lspec Measurement
Classifi tion Judgement table
onnector No. conditions
cations rethot

1) if the condition is as shown in the table below, 1) Start engine


the sensor is normal

Air cleaner clogging


sensor

f the condition is as shown in the table below, I) Turn starting


:he sensor is normal switch ON

Water temperature

Coolant temperature 50°C


sensor 60°C 56.3 f 5 R
8O’C 29.5 + 2.5 Q
100°C 16.5 + 0.9 R
106x 14.3 + 0.5 R

f the condition is as shown in the table below, I) Start engine


%
z
0 Engine oil pressure
:he sensor is normal

0.1 MPa or above


sensor EngineOil Pressure(t,c kgicn,~above) Min. 1 MR

Lessthan 0.1 MPa


Engineoil pressure Max. 1 R
(Lessthan 1.0 kg/cm3

f the condition is as shown in the table below, I) Turn starting


:he sensor is normal (Normal temperature: 25°C) switch ON

Full Approx. 10 R
Fuel level sensor
1 l/2 Approx. 32 R

Empty Approx. 80 R

202-4
TESTING AND ADJUSTING TABLE OF TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING

TABLE OF TOOLS FOR TESTING, ADJUSTING AND


TROUBLESHOOTING
D31E-20 Serial No.: 42001 - 42713 D31P-20A Serial No.: 45001 - 47616
D31P, PL-20 Serial No.: 45001 - 47616 D37E-5 Serial No.: 3001 - 3730
D31PLL-20 Serial No.: 45001 - 47652 D37P-5A Serial No.: 3001 - 3660
D31S. Q-20 Serial No.: 41001 - 41183

Test measurement
Gym bol Part No. Part Name Remarks
item I I

Engine speed Digital display L’. ” - 2’ooo rpm


H. 60- 19,999 rpm

Water temperature, _gg.g _ , 2ggC


Digital temperature
oil temperature, B 799-101-1500
exhaust temperature gauge
799-101-5001 Hydraulic tester Pressure 2.5, 5.9, 39.2, 58.8 MPa
gauge:
1 125, 60, 400, 600 kg/cm?
C 790-261-1201 69 MPa
Oil pressure Digital hydraulic tester Pressure gauge: I7oo kg/cm2I

1 MPa
2 799-401-2320 Hydraulic gauge
{IO kg/cm*}

Boost pressure D 799-401-2310 Pressure gauge 199.9 kPa {I,500 mmHg1

1 795-502-1590 Compression gauge 0 - 6.9 MPa 10 - 70 kg/cm21


assemblv Kit part No. 795-502-1205
Compression pressure E
2 795-502-1370 Adapter - %
z
F 799-201-1504 Blowby checker 0 - 4.9 kPa (0 - 500 mmHzO} 0
Blowby pressure

Intake valve: 0.35 mm


Valve clearance G 795-125-1370 Feeler gauge
exhaust valve: 0.5 mm
Discoloration: 0 - 70%
1 799-201-9000 Handy smoke checker (with standard color)
(Discoloration x & = Bosch index)
Exhaust color H
2 Commercially
Smoke meter
available

Operating force I Ei Push-pull scale 1

Stroke, hydraulic drift J


Commercially
available
Scale
I -
Commercially
Work equipment speed K Stop watch
available
Troubleshooting of For those owning 799-601-2500
L 799-601-7100 T-adapter kit
wiring harness, sensor 799-601-7000 is possible

Troubleshooting of Commercially -
M Tester
voltage, resistance value available

20-l 0
8
TESTING AND ADJUSTING TABLE OF TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING

D31E-20 Serial No.: 42714 and up D31P-20A Serial No.: 47617 and up
D31P, PL-20 Serial No.: 47617 and up D37E-5 Serial No.: 3731 and up
D31PLL-20 Serial No.: 47653 and up D37P-5A Serial No.: 3661 and up
D31S. Q-20 Serial No.: 41184 and up

Test measurement
;ymbol Part No. Part Name Remarks
item
1 799-203-8001 Multi-tachometer
A Digital display L: 60 - 2,000 rpm
Engine speed
2 795-790-2500 Adapter (drive) H:60 - 19,000 rpm
I
Water temperture, B 799-101-1502 Digital
gauge temperature -50 - 1,200”C
oil temperature -
799-101-5002 Hydraulic tester 2.5, 5.9, 39.2, 58.8 MPa
1 Pressure gauge’ 125, 60, 400, 600 kg/cm*)
790-261-1203 Digital hydraulic Pressure gauge: 68.6 MPa (700 kgmlcm’)
tester
2 799-401-2320 Hydraulic tester 1.0 MPa {IO kg/cm*}

l 799-101-5160 l Nipple PT1/8

Oil pressure C 3 799-101-5220 Nipple


10 x 1.25
07002-I 1023 O-ring
l 790-261-1311 Both male and female 14 x 1.5
(female PT1/8)
4 l 790-261-1321 l Adapter Both male and female 18 x 1.5
(female PT1/8)
l 790-261-1331 Both male and female 22 x 1.5
- (female PT1/8)
1 795-502-I 205 Compression gauge
Compression pressure E 0 - 6.9 MPa {O - 70 kg/cm*)
2 795-502-I 700 Adapter
-
1 799-201-1504 Blowby kit
Blowby pressure F 0 - 4.9 kPa {O - 500 mmHz01
2 795-790-I 950 Nozzle (tool)
- .
Valve clearance G Commercrally Feeler gauge
available
1 799-201-9000 Handy smoke checker Discoloration: 0 - 70%
Exhaust color H (with standard color)
2 Commercially Smoke meter
available (Discoloration x l/IO L Bosch index)

0 - 294 N {O - 30 kg}
Operating force I Ei Push-pull scale
0 - 490 N (0 - 50 kg}
I

Stroke, hydraulic drift J Commercially Scale -


available
Work equipment speed K Commercially Stop watch -
available
Troubleshooting of L 1 799-601-7100 1 T-adapter kit I -
sensor, wirinq harness
Measurement of voltaae. ”
M Commercially Tester -
resistance available
Measurement of P 791-502-1811 Wear gauge -
sorocket wear
Fuel injection timing 0 1 795-799-1130 1Gear

*O-A’
TESTING AND ADJUSTING MEASURING ENGINE SPEED

.MEASURlNG ENGINE SPEED


D31E-20 Serial No.: 42001 - 42713
D31P, PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660

A Be careful
ing or removing
not to touch any
the measurement
hot parts
equipment.
when install-

It Measure the engine speed under the following con-


ditions.
1) Coolant temperature: Within operating range
2) Power train oil temperature: 70 - 90°C
3) Hydraulic oil temperature: 45 - 55°C

1. Install the adapter of tachometer A to fuel injection


pipe (1).

2. Connect tachometer A and the adapter with a cable.

A Be careful not to touch


parts when measuring
any rotating
the engine speed.
parts or hot

3. Start the engine and measure the engine speed at


high idling and low idling.

65

20-l 2
8
TESTING AND ADJUSTING MEASURING ENGINE SPEED

D31E-20 Serial No. 42714 and up


D31P. PL-20 Serial No. 47617 and up
D31PLL-20 Serial No. 47653 and up
D31S, Q-20 Serial No. 41184 and up
D31P-20A Serial No. 47617 and up
D37E-5 Serial No. 3731 and up
D37P-5A Serial No. 3661 and up

g Be careful not to touch any hot parts when removing


or installing the measuring tools.
* Measure the engine speed under the following condi-
tions. / BED00367
. Cooling watertemperature: Within operating range
. Hydraulic oil temperature : 40 - 60°C

1. Remove engine side cover (left).

2. Remove cover (1).


* Use a filter wrench to remove and install the
cover.

3. Install adapter N2, then connect to multi-tachometer


Nl.

4. Start the engine, and measure the engine speed when


%
it is set to the conditions for measuring. I I NZ BED00366
z
0 . Measuring at low idling and high idling:
Measure the engine speed with the fuel control
lever set to low idling or high idling.

BED00369

*OiA*-’
TESTING AND ADJUSTING MEASURING EXHAUST COLOR

MEASURING EXHAUST COLOR


l When measuring in the field where there is no air
or electric power supply, use tool HI; when recor-
ding formal data, use tool H2.
* Raise the coolant temperature to the operating
range before measuring.

a Be careful not to touch any hot parts when remov-


ing or installing the measuring tools.

Measuring with Hl.


Install filter paper to tool HI.
Insert the exhaust gas suction port into the exhaust
pipe, accelerate the engine suddenly, and operate
the handle of tool HI at the same time to collect
the exhaust gas on the filter paper.
Remove the filter paper and compare it with the
scale supplied to judge the condition.

L
Measuring with H2.
1. Insert probe 0 into the outlet port of the exhaust
pipe (I), and tighten the clip to secure it to the ex-
haust pipe.
2. Connect the air hose and the socket of the probe
hose accelerator switch to tool H2.
* Keep the pressre of the air supply below 1.5 MPa
(15 kg/cm*}.
3. Connect the power cord to the AC1 OOV socket.
* When connecting the cord, check that the power
switch of tool H2 is OFF.
4. Loosen the cap nut of the suction pump, and fit the
114FO2067
filter paper.
* Fit the filter paper securely so that the exhaust
gas cannot leak.
5. Turn the power switch of tool H2 ON.
6. Accelerate the engine suddenly, and depress the ac-
celerator pedal of tool H2 at the same time to col-
lect the exhaust gas color on the filter.
7. Place the filter paper used to catch the exhaust gas
color on top of at least 10 sheets of unused filter
paper inside the filter paper holder, and read the
value shown.

20- 12-2
8
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE

ADJUSTING VALVE CLEARANCE


D31 E-20 Serial No.: 42001 - 42713
D31P, PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S. Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660

* Adjust the clearance between the valve and rocker


arm to the following values.

Unit: mm

1 Intake valve 1 Exhaust valve

Cold 0.35 0.5

1. Remove muffler (I), then remove the cylinder head


cover.

2. Rotate the crankshaft in the normal direction to


align pointer (3) with the 1.6 TOP mark on the
crankshaft pulley (2) when No. 1 cylinder is at com-
pression top dead center. When rotating, check the
movement of the valves.

\ / 114FO2069

3. When No. 1 cylinder is at compression top dead


Valve arrangement
center, adjust the valves marked 0.
When No. 6 cylinder is at compression top dead I I t I I I I I I

center, adjust the valves marked 0.


1 1 Cy;;derl 1 1 2 1 3 / 4 1 5 1 6 1

TDD00723

4. To adjust, insert tool G between rocker arm (4) and


valve stem (5) and turn adjustment screw (6) until
the clearance is a sliding fit. Then tighten locknut (7)
to hold the adjustment screw in position.
w Locknut: 44.1 t 4.9 Nm (4.5 z 0.5 kgm}

G 114FO2070

202 3
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE

5. Next, rotate the crankshaft one turn in the normal


direction and adjust the valve clearance of the remain-
ing valves marked 0.
Ir After adjusting No. 1 cylinder at compression top
dead center, it is also possible to turn the crank-
shaft 120” each time and adjust the valve clear-
ance of each cylinder according to the firing or-
der.
. Firing order: 1 - 5 - 3 - 6 - 2 - 4
* After tightening the locknut, check the clearance
again.

D31 E-20 Serial No.: 42714 and up


D31P, PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up

1. Remove engine side covers (left and right).

2. Remove engine hood assembly.

3. Remove air cleaner assembly.

4. Remove hydraulic pump assembly.


For details, see DISASSEMBLY AND ASSEMBLY, RE-
MOVAL OF HYDRAULIC PUMP ASSEMBLY.

5. Remove intake connector (1).

6. Remove bracket (2).

7. Remove oil supply hose (3).

8. Remove 4 cylinder head covers (4).

9. Remove plate (5) and cap (6).

10. Using tool 0, turn the crankshaft in the normal direc-


tion until timing pin (7) enters the hole in the gear to
set the No. 1 cylinder to the compression top dead
center position.
* Push the timing pin lightly while cranking.

11. In this position, adjust the clearance of the valves


marked l in the valve arrangement chart.
* After completion of adjustment, make counter
marks on the crankshaft pulley and gear case,
then remove the timing pin.

BED00375

20-13-l
8
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE

12. Rotate the crankshaft one turn in the normal direction


and align the counter marks made in Step 11.

13. In this position, adjust the clearance of the valves


marked o in the valve arrangement chart.
Cylinder NO. I 2 3 4

Exhaust valve 0 0 0 0

Intake valve l l

TKP00642

14. To adjust the valve clearance, loosen locknut (II),


and insert feeler gauge G between rocker lever (8)
and valve stem (9). and turn adjustment screw (IO)
until the clearance is a sliding fit. Then tighten locknut
(11) to hold the adjustment screw in position.
w Locknut: 24 Nm (2.45 kgm)
li After tightening the locknut, check the clearance
again.

* It is also possible to set the No. 1 cylinder to the


compression top dead center and adjust it, and then
%
to rotate the crankshaft 180” each time and adjust the
F
0 valve clearance of each cylinder according to the fir-
ing order.
. Firing order: 1 - 3 - 4 - 2

I I I I I BED003 77

2oii3-2
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE

MEASURING COMPRESSION PRESSURE


D31E-20 Serial No.: 42001 - 42713
D31P, PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660

A When measuring the compression pressure, be ex-


tremely careful not to touch the exhaust manifold or
other hot parts, or to get caught in the fan, fan belt,
or other rotating parts.

1. Adjust the valve clearance.


* For details, see ADJUSTING VALVE CLEARANCE.

2. Warm up the engine so that the oil temperature is


40 - 60°C.

3. Remove the nozzle holder assembly from the cylin-


der to be measured.

4. Install adapter E2 in the nozzle holder mount, and


connect compression gauge El.

5. Set tachometer drive A to the engine front cover.

6. Place the fuel control lever in the NO INJECTION


position. Crank the engine with the starting motor
and measure the compression pressure.

A If the fuel control lever is not placed at the NO IN-


JECTION position, fuel will spurt out.

* Measure the compression pressure at the point

Jr When measuring the compression


where the pressure gauge indicator remains steady.
pressure,
measure the engine speed to confirm that it is within

*
the specified range.
After measuring the compression pressure, install the
nozzle holder assembly.

20-14
8
TESTlNG AND ADJUSTING MEASURING COMPRESSION PRESSURE

D31 E-20 Serial No.: 42714 and up


D31P, PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up -Dl
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up

A When measuring the compression pressure, be care-


ful not to touch the exhaust manifold or muffler, or to
get your clothes caught in the fan, fan belt or other
rotating parts. BED00378

1. Adjust the valve clearance.


For details, see ADJUSTING VALVE CLEARANCE.

2. Warm up the engine to make the oil temperature 40 -


60°C.

3. Remove the nozzle holder assembly from the cylin-


der to be measured.
For details, see DISASSEMBLY AND ASSEMBLY, Re-
moval of nozzle holder assembly.

4. Install adapter D2 to the nozzle holder mount, then


%
connect compression gauge Dl.
z
0

5. Disconnect 2 engine stop solenoid wires (I).

6. Crank the engine with the starting motor and meas-


ure the compression pressure.
* Measure the compression pressure at the point
where the compression gauge indicator remains
steady.
t When measuring the compression pressure,
measure the engine speed to confirm that it is
within the specified range.

7. After measuring the compression pressure, install the


nozzle holder assembly.
& Thread: Seizure prevention compound
(Molycoat 1000 or equivalent)
m Nozzle holder assembly:
60 z 9 Nm (6.12 t 0.92 kgm}

20-g
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE

MEASURING BLOW-BY PRESSURE


D31E-20 Serial No.: 42001 - 42713
D31P, PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660

g When measuring the blow-by pressure, be extremely


careful not to touch the exhaust manifold or other hot
parts, or to get caught in the fan, fan belt, or other
rotating parts.

20-15-l
8
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE

D31E-20 Serial No.: 42714 and up


D31P, PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up

g Be careful not to touch any hot parts when removing


or installing the measuring tools.
Sr Measure the blow-by pressure under the following
conditions.
. Cooling water temperature: Within operating
range
. Hydraulic oil temperature : 40 - 60°C

1. Remove engine side cover (left).

2. Remove blow-by hose (1) from clamp, and install


nozzle Fl to hose.

3. Connect nozzle Fl and blow-by gauge F2 with hose.

4. Measure blow-by pressure with the engine at high


idling.
%
* Read the value when the gauge indicator becomes
: BED0038
0 steady.
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING

TESTING AND ADJUSTING


FUEL INJECTION TIMING
D31E-20 Serial No.: 42001 - 42713
D31P, PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660

There are two methods for checking and adjusting the


fuel injection timing of an injection pump.
l The “MATCH MARK ALIGNMENT” method, which is
used when the injection pump is installed to the
original engine and the pump is not being repaired.
l The “DELIVERY VALVE” method, which is used
when a repaired or replaced injection pump is in-
stalled to the engine.
or Before inspecting and adjusting the fuel injection
timing, bring the No. 1 cylinder piston to the top
dead center of the compression stroke. For details,
see ADJUSTING VALVE CLEARANCE.

TESTING AND ADJUSTING BY ALIGNING


MATCH MARKS
1. Set No. 1 cylinder at compression top dead center.
(See ADJUSTING VALVE CLEARANCE)
(View from flvwheel side1
Align pointer with 1.6T mark on crankshaft pulley,
then confirm that mark “C” on idler gear can be
seen.
If the mark “C” can not be seen, rotate the crankshaft
one more turn.

2. Remove cover (I).

3. Mount injection pump on engine, and insert pin (dia:


4 - 4.5 mm, length: 80 mm) in hole of drive gear
through hole “a”. l--
Then confirm that mounting holes of pump holder
and front gear cover are aligned.

114FO207E
4. Tighten mounting bolts, confirm that lines on injec- -
tion pump, pump holder, and front plate are
aligned.

5. If the position cannot be aligned, repeat Step 3.

6. After tightening all bolts, check that the lines on the


injection pump, injection pump holder, and front
plate are aligned.

20-l 6
@
TESTlNG AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING

TESTING AND ADJUSTING BY DELIVERY


VALVE METHOD

1. Align the 16” injection timing stamp line on crank-


shaft pulley (I) with pointer (2) by slowly rotating
the crankshaft in the normal direction.

2. Disconnect fuel injection pipe (3) for the No. 1 cylin-


der.

3. Remove delivery valve holder (4), remove spring (5)


and delivery valve (6) from delivery valve holder,
\ / 114F0206E
and reassemble delivery valve holder (4).

4. Place the fuel control lever in FULL position.

5. Loosen nuts (7) on injection pump mounting flange


slot, and loosen injection pump mounting bolts (8).

6. Turn injection pump outward, operating priming


pump, slowly turn injection pump to cylinder block
end, stop injection pump in the position where fuel
flow out from delivery valve holder stops.
* If fuel flow out does not stop when turning in-
jection pump either directions, rotate crankshaft
% one more turn.
z
0 * If turn injection pump outward, injection timing
is retard. If turn injection pump cylinder block
end, injection timing is advanced.

7. Tighten injection pump mounting bolts (8) and nuts


(7) on injection pump mounting flange slot in turn.

8. Remove delivery valve holder (4), assemble delivery


valve (6) and spring (5), install delivery valve holder
(4) again.
w Delivery valve holder:
41.65 t 2.45 Nm i4.25 t 0.25 kgm)

9. Connect fuel injection pipe (3).


I 423F302A
m Sleeve nut:
22.05 2 2.45 Nm 12.25 = 0.25 kgm1
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING

D31E-20 Serial No.: 42714 and up


D31P, PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up

Testing
Remove hydraulic pump assembly.
For details, see DISASSEMBLY AND ASSEMBLY, RE-
MOVAL OF HYDRAULIC PUMP ASSEMBLY.

Remove plate (I) and cap (2).

Using tool Q, turn the crankshaft in the normal direc-


tion until timing pin (3) enters the hole in the gear to
set the No. 1 cylinder to the compression top dead
center position.
Ir Push the timing pin lightly while cranking.
* Refer to the following and push timing pin (3)
securely into the gear.
. Dimension a when free: 24 mm
. Dimension b when there is gear contact:
20 mm
. Dimension c when pushed into gear hole: BED00370
16 mm

PI k----w,

BED00412

4. Remove cap (4).

5. Reverse pin (5) and push the notched portion in the


direction of timing pointer (6) of the fuel injection
pump.
* Set the notched groove perpendicular and push
in, then set horizontal and push in.
When setting it horizontal, if it is possible to push
in further than when it was perpendicular, the
fuel injection timing is correct.

4
BED00032 BED00031

20-17-l
8
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING

Adjusting
+ If the fuel injection timing is not correct, adjust as
follows.
1. Remove the fuel injection pump assembly.
t For details, see DISASSEMBLY AND ASSEMBLY,
REMOVAL OF FUEL INJECTION PUMP ASSEM-
BLY.

2. Rotate the shaft of the fuel injection pump, push tim-


ing pin (5) in to timing pointer (6) at the fuel injection
pump end, and align the injection timing on the fuel
injection pump itself.
* Keep the pin pushed in until the fuel injection
pump is installed.

3. Install the fuel injection pump assembly.


Sr For details, see DISASSEMBLY AND ASSEMBLY,
INSTALLATION OF FUEL INJECTION PUMP AS-
SEMBLY.
* After installing, remove the pin and set to the
original condition.

2oiA7-2
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT

BLEEDING AIR FROM FUEL


CIRCUIT
1. Automatic air bleeding
li It is possible to bleed the air more quickly if the
fuel tank is full.
I) Set the fuel control lever to the mid-range speed
position.
2) Set the starting switch to the START position,
D31E-20 Serial No.: 42001 - 42713
and hold it there for 20 seconds.
D31P. PL-20 Serial No.: 45001 - 47616
* When this is done, the starting motor will
D31PLL-20 Serial No.: 45001 - 47652
start after approx. 2 seconds and will then
D31S. Q-20 Serial No.: 41001 - 41183
stop. However, the electric pump for bleed-
D31P-20A Serial No.: 45001 - 47616
ing the air will continue to be actuated and
D37E-5 Serial No.: 3001 - 3730
will bleed the air.
D37P-5A Serial No.: 3001 - 3660
* Keep the switch at the START position for 20
seconds, regardless of whether the engine
starts or not.
3) Return the starting switch to the ON position and
wait for approx. 30 seconds.
4) Repeat Step 2).
Ir Keep the switch at the START position for 20
seconds, regardless of whether the engine
starts or not.
5) Return the starting switch to the ON position and
check that the engine continues to run.
* If the engine stops, repeat Step 4).

2. Manual air bleeding


D31E-20 Serial No.: 42714 and up
1) Loosen air bleed plug (I).
D31P. PL-20 Serial No.: 47617 and up
2) Loosen the feed pump knob, pump it up and
D31PLL-20 Serial No.: 47653 and up
down, and continue until no more bubbles come
D31S. Q-20 Serial No.: 41184 and up
out with the fuel from the air bleed plug.
D31P-20A Serial No.: 47617 and up
3) Tighten the air bleed plug.
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up
I

20-18
8
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE

MEASURING ENGINE OIL


PRESSURE
D31E-20 Serial No.: 42001 - 42713
D3lP, PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660

Precautions when measuring engine oil pressure

A Stop the machine on level ground, lower the


work equipment to the ground and apply the
parking brake.
Stop the engine before removing or installing
the plug and oil pressure gauge.
Measure with the oil -at the specified tempera-
ture.

1. Remove plug (1).

2. Install oil pressure gauge C2 (1.0 MPa ilO kg/cm%.

3. Start the engine and measure the oil pressure.

%
6
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE

D31E-20 Serial No.: 42714 and up


D31P, PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S. Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up

a Be careful not to touch any hot parts when removing


or installing the measuring tools.
* Raise the cooling water temperature to the operating
range before measuring.

1. Remove engine side cover (right).

2. Remove engine oil pressure pick-up plug (I) (PT1/8)


from engine oil filter bracket.
3. Install nipple C3, then connect oil pressure gauge C2
(1.0 MPa {IO kg/cm’}).

4. Start the engine, and measure the oil pressure with


the engine at low idling and high idling.

20-‘:-’
TESTING AND ADJUSTING TESTING AND ADJUSTING FAN BELT TENSION

TESTING AND ADJUSTING FAN BELT TENSION


(When standard alternator is installed)
Fan PU I I

D31E-20 Serial No.: 42001 - 42713


D31P, PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660

TESTING FAN BELT TENSION

1. Check the amount the fan belt deflects when pushed


with a force of 59 N (6 kg) at a point midway between
the fan pulley and the alternator pulley.

ADJUSTING FAN BELT TENSION

Loosen the mounting bolt of the alternator assembly


and belt tension adjustment bolt (1).

Using a bar, move the alternator to the outside, and


adjust the fan belt tension.

Tighten adjustment bolt (I), then tighten the alterna-


11 AFrVfk?
tor mounting bolt.

20-20
8
TESTING AND ADJUSTING MEASURING POWER TRAIN OIL PRESSURE

MEASURING POWER TRAIN OIL PRESSURE

A 1) Stop
work
the machine
equipment to
on
the
level
ground
ground,
and
lower
apply
the
the
parking brake.
2) Stop the engine before removing or installing
the plug and oil pressure gauge.
3) Measure with the oil at the specified tempera-
ture.

Measuring transmission modulating pressure


1. Remove plug (1) (PT l/8) from the transmission con-
trol valve, and install oil pressure gauge Cl (5.9 MPa
I60 kg/cm*)).

2. Start the engine and measure the oil pressure.

Measuring inching valve pressure


1. Remove plug (2) (PT l/8) from the transmission con-
trol valve, and install oil pressure gauge Cl (5.9 MPa
I60 kg/cm?).

2. Start the engine, set the gear shift lever to Fl, and
check that the oil pressure is approx. 0 when the
inching pedal is depressed fully.
j, There is a remaining pressure of 6.0 - 8.8 kPa
IO.7 - 0.9 cm?).

Measuring steering cylinder pressure


1. Remove plug (3) (PT l/8) from the transmission con-
trol valve, and install oil pressure gauge Cl (5.9 MPa
I60 kg/cm*)).

2. Start the engine, set the gear shift lever to N, and


measure the oil pressure when the steering lever is
operated.

11 PFO208C
TESTING AND ADJUSTING ADJUSTING PPC VALVE

Serial No.
ADJUSTING PPC VALVE D31E-20 : 42061 - 42713 D31P-20A : 45001 - 47616
D31P, PL-20 : 45001 - 47616 D37E-5 : 3001 - 3730
31PLL-20 : 45001 - 47652 D37P-5A : 3001 - 3660
If there is excessive play in the steering lever, adjust 31S, Q-20 : 41001 - 41183
as follows.
g Lower the work equipment to the ground and
stop the engine. Then loosen the oil filler cap
slowly to release the pressure inside the hydrau-
lic tank.

Remove the PPC valve.

Loosen locknut (I), and screw in disc (2) until it con-


tacts the head of 4 pistons (3).
* When adjusting, do not operate the pistons.

Hold disc (2) in position and tighten locknut (1) to the


specified tightening torque.

D31 E-20 Serial No.: 42001 - 42713


D31P, PL-20 Serial No.: 45001 - 47616
D31 PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31 P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660
w Locknut: 34.3 2 4.9 Nm {3.5 z 0.5 kgml

D3 1E-20 Serial No.: 42714 and up 209FO5367

D31P, PL-20 Serial No.: 47617 and up Serial No.


D31 PLL-20 Serial No.: 47653 and up D31E-20 42714 and up D3lP-20A: 47617 and up
D31S, Q-20 Serial No.: 41184 and up D31 P, PL-20 47617 and up D37E-5 : 3731 and up
D31PLL-20 47653 and up D37P-5A : 3661 and up
D3 1P-20A Serial No.: 47617 and up

a
D31.S. Q-20 41184 and UD
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up I
w Locknut: 112.7 + 14.7 Nm Ill.5 z 1.5 kgm1
2
With this adjustment, the clearance between disc (2)
and piston (3) is made 0 mm.
3
I 1

I 1

BED00400

20-22
0
TESTING AND ADJUSTING BLEEDING AIR FROM STEERING CIRCUIT

BLEEDING AIR FROM


STEERING CIRCUIT

Ir Bleed the air from the steering circuit as follows when


the PPC valve, brake cylinder, or piping have been
replaced or removed.
1. Start the engine, set the steering and directional lever
to the N position, and operate the lever at least 10
times to the left and right to bleed the air from the
steering circuit.

20-23
TESTING AND ADJUSTING MEASURING AND ADJUSTING WORK EQUIPMENT MAIN RELIEF PRESSURE

MEASURING AND ADJUSTING WORK EQUIPMENT MAIN


RELIEF PRESSURE
D31E-20 Serial No.: 42001 - 42713
D31P, PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660

Measuring and adjusting work equipment main relief pres-


sure

A Loosen the oil filler cap slowly to release the pres-


sure inside the hydraulic tank.

1. Remove plug (I) (PT l/8), and install oil pressure


gauge Cl (39.2 MPa 1400 kg/cm2}).

2. Start the engine, operate the hydraulic cylinder to the


end of its stroke to relieve the circuit, and measure
the oil pressure.

Adjusting work equipment main relief valve


1. Remove cap (3) of main relief valve (21, loosen locknut
(41, then turn adjustment screw (5) to adjust.
* Turn adjustment screw (5) as follows to adjust.
To INCREASE pressure, turn CLOCKWISE
To DECREASE pressure, turn COUNTERCLOCK-
WISE
* On turn of the screw adjusts the oil pressure by
approx. 2.43 MPa 124.8 kg/cm21).

114FO.2089

I 113F1.8101~

20-23-1
8
TESTING AND ADJUSTING MEASURING AND ADJUSTING WORK EQUIPMENT MAIN RELIEF PRESSURE

D3 1 E-20 Serial No.: 42714 and up


D31P, PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up

Measuring and adjusting work equipment main relief pres-


sure

\\- -J
A Loosen the oil filler cap slowly to release the pres- BED00392
sure inside the hydraulic tank.

1. Remove plug (1) (PT l/8), and install oil pressure


gauge Cl (39.2 MPa I400 kg/cm*}).

2. Start the engine, operate the hydraulic cylinder to the


end of its stroke to relieve the circuit, and measure
the oil pressure.

Adjusting work equipment main relief valve


1. Remove cap (3) of main relief valve (21, loosen locknut
(4), then turn adjustment screw (5) to adjust.
* Turn adjustment screw (5) as follows to adjust.
To INCREASE pressure, turn CLOCKWISE
To DECREASE pressure, turn COUNTERCLOCK-
WISE
* On turn of the screw adjusts the oil pressure by
approx. 2.43 MPa (24.8 kg/cm?).

I BED00395

2023-2
TESTING AND ADJUSTING BLEEDING AIR FROM HYDRAULIC CYLINDERS

BLEEDING AIR FROM HYDRAULIC CYLINDERS


* When operating the hydraulic cylinders for the first
time after replacing or reassembling the cylinders or
piping, always bleed the air from the hydraulic cylin-
ders as follows:
1) Start the engine and run at low idling for ap-
prox. 5 minutes.
2) Run the engine at low idling, and raise and
lower the cylinder 4 - 5 times.
* When operating the hydraulic cylinder, stop
the piston rod 100 mm from the end of its
stroke. Do not relieve the circuit under any
circumstances.
3) Run the engine at high idling and repeat step
2), then run the engine at low idling and operate
the piston rod to the end of its stroke to relieve
the circuit.
4) Carry out the procedure in Steps 2) and 3) for
the other cylinders also.

20-24
8
TESTING AND ADJUSTING BLEEDING AIR FROM ANGLE CYLINDER CIRCUIT

BLEEDING AIR FROM ANGLE CYLINDER CIRCUIT


(POWER ANGLE AND TILTDOZER)

A When loosening
under hydraulic
the
pressure.
plug, remember that it is still

A Operate the tilt slowly.


oil will spurt out.
If it is not operated slowly,

1. Loosen the hydraulic tank cap.


2. Raise the blade approx. 400 - 500 mm from the
ground.
* Raise the angle cylinder to horizontal or higher.
3. Run the engine at low idling.
4. Operate LEFT TILT and RIGHT TILT to the end of
the cylinder stroke IO times in turn to fill the tilt cy-
linder circuit with oil.
5. Angle the blade to the maximum left angle (retract
the left angle cylinder).
6. Loosen air bleed valve (1) two turns, and loosen air
bleed plug (2) of the left angle cylinder three turns.
7. Operate the RIGHT TILT (retract tilt cylinder) continu-
ously .and when no more bubbles come out with
the oil from plug (2), tighten plug (2).
8. Angle the blade to the maximum right angle (retract
the right angle cylinder).
9. Loosen air bleed valve (3) of the right angle cylinder
three turns.
10. Operate the RIGHT TILT (retract tilt cylinder) continu-
ously and when no more bubbles come out with
the oil from plug (3), tighten plug (3).
11. Tighten air bleed valve (1).

m Valve: 24.5 + 4.9 Nm 12.5 2 0.5 kgm}


12. After bleeding the air, check the hydraulic tank oil
level, then tighten the hydraulic tank cap.
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL CABLE

ADJUSTING FUEL CONTROL


CABLE

D31 E-20 Serial No.: 42714 and up


D31P, PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37P-5A Serial No.: 3661 and up

1. Fix the center of screws of fuel control cable (1) to


bracket (2).

2. Set the fuel control cable to the FULL position and


check that fuel injection pump lever (3) contacts FULL
stopper bolt (4). Measure dimension a of fuel control
cable (I) in this condition.
. Standard dimension a of fuel control cable:
244 mm

20-26
8
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL LEVER

ADJUSTING FUEL CONTROL LEVER


After setting control lever (1) in notched part, set
engine governor lever in idling position, then con-
nect cable (2).
* Judge the position of the notched part from the
clicking sound and difference in operating force.

Operate fuel control lever, set engine governor lever


in high idling position, then fit stopper bolt (3) and
fuel control lever (4), and tighten locknut (5).

Set engine governor lever in stop position, then fit


stopper bolt (6) and fuel control lever, and tighten
lock nut (5).
* Adjust governor lever to put governor lever and
stopper of fuel injection pump in contact at the
FULL and STOP position.

IO3FO620 I

20-27
8
TESTING AND ADJUSTING PROCEDURE FOR ADJUSTING ENGINE STOP MOTOR CABLE

PROCEDURE FOR ADJUSTING ENGINE STOP MOTOR CABLE


D3 1 E-20 Serial No.: 42001 - 42713
D31P, PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660

* This applies only to machines equipped with an engine stop mechanism operated by the starting switch
key.

114FO2091 114FO2092

1. Temporaily install ball joint (6) to the cable (3) of


engine stop motor (screw in fully, then turn back
approx. l/2 turns). Install ball joint (6) to stop lever
(2) of the injection pump also.

2. Pull the injection pump stop lever (2) by hand to


the ENGINE STOP position (NO INJECTION) position,
and temporarily assemble the cable to bracket (4).
When doing this, keep stop lever (2) in contact with
engine STOP stopper (I), and temporarily install the
cable to the bracket with locknut (5).
* The engine stop motor is delivered with the
cable pulled (engine stop).
* The stop lever of the fuel injection pump is at
the operating position when it is free (it is
pulled to the operating position by a spring).

20-28
8
TESTING AND ADJUSTING PROCEDURE FOR ADJUSTING ENGINE STOP MOTOR CABLE

3. Adjust so that clearance A between fuel injection


pump stop lever (2) and STOP stopper (1) is 1 - 2
mm when the engine stop motor is installed (when
the engine is stopped).
Adjustment can be carried out using nut (5) holding
the cable to the bracket or by carrying out fine ad-
justment of the amount that ball joint (6) is screwed
in.

4. Tighten all nuts and bolts.

5. Turn the engine starting switch ON/OFF several


114FO209:
times to check that the engine stop motor and cable
operate smoothly, then check the following points
again.
1) Check visually that there is slack in the engine
stop motor cable when the engine is running,
and that stop lever (2) of the fuel injection
pump has returned fully to the OPERATION side.
4 Check that the clearance A between stop lever
(2) and STOP stopper (1) is 1 - 2 mm when
the engine is stopped.
* Limit switches are built into the engine stop
motor at both ends of the cable stroke.
* Stroke of engine stop motor: 35 mm
% Stroke of fuel injection pump stop lever: 30 mm
6
TESTINGAND ADJUSTING ADJUSTING ENGINE STOP SOLENOID LINKAGE

ADJUSTING ENGINE STOP SOLENOID LINKAGE


D31E-20 Serial No.: 42714 and up
D31P, PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up

Assemble the solenoid and linkage.


. Installed length a of rod: 163 mm
-A-L
d

. Screwed-in depth b of solenoid: 6 mm


. Screwed-in depth c at center: 15 mm I BDW00533

. Screwed-in depth d of yoke: 12 mm


6 Coat the rod thread with thread tightener (LT-
2). However, there is danger that the joint
will stick, so do not coat the area within 5
mm from each tip.
w Locknut: 4.9 = 1 Nm {0.5 z 0.1 kgml

Install solenoid linkage assembly (1) to the engine


temporarily.
* Align with end e of the oblong hole (at the pump
end of the hole) in the mounting bracket.

BDW00534

3. Connect 2 solenoid wires (2).

4. Turn the starting switch ON.

Move solenoid linkage assembly (I) towards the fan


to adjust clearance f between fuel injection pump
stopper lever (3) and stopper (4) to the dimension
below.
. Clearance f: 1 - 2 mm

After tightening the mounting bolts fully, actuate the


solenoid several times to check that there are no
abnormalities.
Check particularly the points given below.
1) Check that no heat is generated when the sole-
noid is actuated. BDW00535

2) Check that the rubber boot and linkage do not


interfere with any other engine parts.

*O-*:-’
TESTING AND ADJUSTING ADJUSTING TRANSMISSION CONTROL LINKAGE

ADJUSTING TRANSMISSION CONTROL LINKAGE


D31E-20 Serial No.: 42001 - 42713
D31P, PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660

1. Insert a pin in pin hole portion d of lever (l), and


set so that points a, b, and c are in a straight line.
* The clearance A in this condition should be
0 mm.

2. In this condition, adjust rod (3) so that lever (2) is


perpendicular.
* Standard length B (distance between pins) of
rod (3): 65.7 mm

114FO2094

3. Set F-R spool (17) to the R, position, turn bolt (4),


and when it contacts the spool, turn it back half a
turn and lock it with locknut (5).

114FO209I

4. Set speed spool (18) to position 0, turn bolt (6),


and when it contacts the spool, turn it back half a
turn and lock it with locknut (7).
18 000 7 8
Next, set speed spool (18) to position 0, turn bolt
(8), and when it contacts the bracket, turn it back
half a turn and lock it with locknut (9).

114F0209E

20-30
@
TESTING AND ADJUSTING ADJUSTING TRANSMISSION CONTROL LINKAGE

5. Connect rods (IO) and (11) at the transmission end,


secure with locknuts (12) and (13), then connect to
the chassis end and secure with locknut (14).
* Standard length (distance between pins of rods
(10) and (11): 4
Dimension C: 486.2 mm
Dimension D: 332.2 mm
12
* Be careful not to twist the end of the rod when 5
tightening the locknut.
6
6. Set F-R spool (17) to the N position, and speed
__-__ 7
spool (18) to position 2, then connect rods (15) and
(16), and tighten the locknut. 9
* When connecting rod (15), check that lever (2) is
perpendicular. When connecting rod (16), check 6
that points a, b, and c in Step 1 are in a
straight line, and connect so that clearance A is 10
0 mm.
* Standard length (distance between pins of rods
(15) and (16)):
Dimension E: 444.9 mm
Dimension F: 511.7 mm

114FO2097

lU7 114FO2098

*Oi3’
TESTING AND ADJUSTING ADJUSTING TRANSMISSION CONTROL LINKAGE

D31 E-20 Serial No.: 42714 and up D31P-20A Serial No.: 47617 and up
D31P, PL-20 Serial No.: 47617 and up D37E-5 Serial No.: 3731 and up
D31PLL-20 Serial No.: 47653 and up D37P-5A Serial No.: 3661 and up
D31S, Q-20 Serial No.: 41184 and up

v ‘\J TDD00835

20-31-l
8
TESTING AND ADJUSTING ADJUSTING TRANSMISSION CONTROL LINKAGE

f-l ‘)
1

C
d

BDD00385

2021-2
TESTING AND ADJUSTING ADJUSTING TRANSMISSION CONTROL LINKAGE

* Tighten the locknuts of the rods and cables securely,


and bend the cotter pins securely.

1. To determine the neutral position for the directional


lever, set safety lock lever (I) to the LOCK position.

2. Connect directional control linkage rod (2) and speed


control linkage rod (3) to the dimensions below, then
tighten the locknuts.
* Distance a between pins of rod (2) (standard
length): 63 mm
Distance b between pins of rod (3) (standard
length): 93.3 mm

3. Connect directional control linkage rod (4) and speed


control linkage rod (5) to the dimensions below, then
tighten the locknuts.
* Distance c between pins of rod (4): 482.4 mm
Distance d between pins of rod (5): 489 mm

4. Connect directional control linkage rod (6) to the di-


mensions below, then tighten the locknut.
* Distance e between pins of rod (6): 487.2 mm

5. Connect speed control linkage rod (7) as follows.


1) Screw in rod end (8) at transmission control valve
end of rod (7) 12 mm, then secure to lever (9).

2) With lever (IO) pushed towards the transmission


control valve. align the position of the hole in
lever (IO) and the hole at rod end (9).
3) From this condition, rotate rod end (9) 2 turns.
4) Secure rod end (9) to lever (IO).
* Distance f between pins of rod (7) (reference
value): 332.2 mm

Push to transmission
control valve end

TDD00836

20-3 1-3
8
TESTING AND ADJUSTING ADJUSTING TRANSMISSION CONTROL LINKAGE

6. Adjust the stopper of the transmission control valve


as follows.
1) Set directional spool (11) to the R position, put
bolt (12) in contact with spool (II), then turn it
back l/2 turn and secure it with locknut (13).

BED00388

2) Set speed spool (14) to the 3rd or 1st position,


put bolt (15) in contact with spool (14) and bolt
(16) in contact with stopper (17), then turn them
18 15
back l/2 turn and secure them with locknuts (18)
and (19).

2021-4
TESTING AND ADJUSTING ADJUSTING TRAVEL OF INCHING PEDAL

ADJUSTING TRAVEL OF INCHING PEDAL


1. Adjust stopper bolt (2) so that distance of inching
pedal (I) from the surface of the floor plate is stan-
dard dimension A.
* Standard dimension A: 178 mm
2. Install rods (3), (4), (5), and (6) to the following stan-
dard dimensions.
* Standard length
Dimension B: 286.6 mm
Dimension C: 343.6 mm
Dimension D: 287.6 mm
Dimension E: 125.0 mm
3. Depress the inching pedal fully and check that the
stroke of the inching valve spool is standard dimen-
sion F.
* Standard dimension F: 23.5 mm
* The inching pedal is interconnected with the
brake, so after carrying out the adjustment in
Steps 1 - 3, carry out the following adjustment.
4. Adjust with rod (9) so that clearance a between
lever (7) and boss (8) is 0 mm.
* Before adjusting, adjust the brake lining clear-
ance.
For details, see TESTING AND ADJUSTING.
L 113F18104A

114FO209 114FO210(

20-32
8
TESTING AND ADJUSTING ADJUSTING BRAKE PEDAL, STEERING BRAKE CYLINDER

ADJUSTING BRAKE PEDAL, STEERING BRAKE CYLINDER


D3 1 E-20 Serial No.: 42001 - 42713
D31P, PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660

Sr Bend the cotter pin securely.

1. Connect brake cylinder (1) to lever (2).


* Connect so that clearance A between the oblong
hole in the yoke and the pin is 0 mm.
* Standard length B (distance between pins):
288.8 mm
2. Set brake lever (3) in a position where it does not
move to the rear, then connect yoke (4).
ir Standard length C (distance between pins): I 114F02101

124 mm

3. Adjust stopper bolt (6) so that distance of brake


pedal (5) from the surface of the floor plate is stan-
dard dimension D.
t Standard dimension D: 178 mm

% 4. Connect rod (7).


z * Standard length E (distance between pins):
286.6 mm
5. Connect rod (8).
t Standard length F (distance bwetwen pins):
846 mm
* Connect so that clearance b between the oblong-
hole in the yoke and the pin is 0 mm.
6. Adjust the brake lining clearance.
For details, see ADJUSTING BRAKE LINING CLEAR-
ANCE.
7. Check that the travel of brake pedal (5) is dimension
G.
* Standard dimensions
Dimension G: 110 - 126 mm
Dimension D: 178 mm

20-33
8
TESTING AND ADJUSTING ADJUSTING BRAKE PEDAL, STEERING BRAKE CYLINDER

D31E-20 Serial No.: 42714 and up D31P-20A Serial No.: 47617 and up
D31P, PL-20 Serial No.: 47617 and up D37E-5 Serial No.: 3731 and up
D31PLL-20 Serial No.: 47653 and up D37P-5A Serial No.: 3661 and up
D31S, Q-20 Serial No.: 41184 and up

BED00396

20-33-l
8
TESTING AND ADJUSTING ADJUSTING BRAKE PEDAL, STEERING BRAKE CYLINDER

Ir Tighten the locknuts of the rods and cables securely,


and bend the cotter pins securely.

1. Connect steering brake cylinder (1) to lever (2).


* Connect so that the clearance between the pin
and the oblong hole of the yoke is 0.
* Dimension a between pins of brake cylinder (1) :
280.8 mm

2. Set brake lever (3) to the 30” position (the position


where it does not move to the rear) and connect yoke
(4).
* Connect so that the clearance between the pin
and the oblong hole of the yoke is 0.
Sr Dimension b between pins of yoke (4): 124 mm

3. Connect stopper bolt (6) so that brake pedal (5) is


dimension c from the top surface of the floor plate.
Ir Dimension c: 178 mm

4. Connect rod (7).


* Dimension d between pins of rod (7) : 286.6 mm

5. Connect rod (8).


* Connect so that the clearance between the pin
and the oblong hole of the yoke is 0.
li Dimension e between pins of rod (8) : 846 mm

6. Connect yoke (9).


* Connect so that the clearance between the pin
and the oblong hole of the yoke is 0.

7. Connect rod (IO).


* Dimension f (reference value) between pins of
rod (IO): 281.8 mm

8. Operate steering and check that clearances between


knob (11) and guide (12) are dimensions g and h.
Ir Clearance dimension g when operating R.H. steer-
ing: 21.7 mm BDD00397
* Clearance dimension h when operating L.H. steer-
ing: 40.7 mm

9. Adjust clearance of brake lining.


For details, see ADJUSTING CLEARANCE OF BRAKE
LINING.

10. Check that the travel of brake pedal (5) is dimension j


when the clearance of the brake lining is 0.3 mm
(standard).
* Dimension j: 107.7 mm

BED00398

2023-2
TESTING AND ADJUSTING ADJUSTING BRAKE LINING CLEARANCE

ADJUSTING BRAKE LINING CLEARANCE


If the travel of the brake pedal has become ex-
cessive, or the steering clutch or brake have been
disassembled, adjust the lining clearance as follows.
Remove cover (1).

Tighten adjustment nut (2) to 39.2 Nm (4 kgm} to


bring lining (4) into tight contact with brake drum (3).

Turn adjustment nut (2) back 2.5 turns to adjust


standard clearance A to 0.3 mm.

114FO2103

114FO2104

20-34
@
TROUBLESHOOTING

Points to remember when troubleshooting _.......__............................................................................... 20-36


Sequence of events in troubleshooting ..__............_............................................................................... 20-37
Precautions when carrying out maintenance .. . . . . . . .. . .. . . . . .. . . . . . . . .. .. . . .. . .. . . . . . .. . . . . . .. . . . . . .. .. . . .. . .. . . . . .. . . . . . .. . . . . .. . 20-38
Handling connectors . . . . . . . .. . . . . . . . .. . . . . . . . . . . . . .. . . . . . . .. . .. . . . . . . .. . . . . . . . . .. . . . . . .. . . .. . .. . . .. . . . . .. . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. .......... 20-45
Checks before troubleshooting . .. . . . . . . . . .. .. . . . . . . . . .. . . . . . . .. . . .. . . . . . .. . . . . . .. . .. . . . . . .. . . . . . .. . . . . .. . . . . . .. . .. . . .. .. . . . . .. . . . . . .. . . . . . . . 20-46
Troubleshooting of engine system (S mode) . . . . . . . .. . .. . . .. .. .. . . . . . .. . . . . .. . . .. . .. . .. . . . . . .. . . . . . .. . . . . .. . .. . . .. . .. . . . .. . . . . . .. . 20-47
Method of using troubleshooting charts .. . . . . . . .. . .. . . . . . . .. . . . . . .. .. . . .. . . .. . . . . .. . . .. . .. . . . . . . . .. . . . . . .. . . . . . . .. . . . . .. . . . .. . . 20-48

Serial No.
D31 E-20 : 42001 - 42713 . . .. . . . .. . . . . . .. . .. . . . . . . .. . .. . . . . . . .. . . . . . . .. . .. . . . . .. . . . . . .. . . . . . . . . .. . . . . . . .. . . . . . .. . . . . . .. .. . . .. . .. . . . . .. 20-54
D31P, PL-20 : 45001 - 47616
D31 PLL-20 : 45001 - 47652
D31S, Q-20 : 41001 - 41183
D31 P-20A : 45001 - 47616
D37E-5 : 3001 - 3730
D37 P-5A : 3001 - 3660

Serial No.
D31 E-20 : 42714 and up . . . . . . .. . . .. . . . . . . .. . . .. . . .. . . .. . . . . . .. . . .. . . . . . .. . . . . .. . . . . . .. . .. . . .. . .. . . . . . . .. . . . . . .. .. . . .. . .. . . . . . .. . . . . .. 20-72
D31P, PL-20 : 47617 and up
D31 PLL-20 : 47653 and up
D31S, Q-20 : 41184 and up
031 P-20A : 47617 and up
D37E-5 : 3731 and up
D37P-5A : 3661 and up

Troubleshooting of hydraulic and mechanical system (H mode) .. . . . . . .. . .. . . . . .. . . . . . . .. . . . . .. . . .. . . .. . .. . . . . . .. . . . . 20-73

20-35
@
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING

g Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.

a When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.

a If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.

A Be extremely careful not to touch any hot parts or to get caught in any rotating parts.

A When disconnecting wiring, always disconnect the negative (-) terminal of the battery first.

A When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.

The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.

1. When carrying out troubleshooting, do not hurry 4) Check the stroke of the control valve spool.
to disassemble the components. 5) Other maintenance items can be checked ex-
If components are disassembled immediately any ternally, so check any item that is considered
failure occurs: to be necessary.
. Parts that have no connection with the fail- 4. Confirming failure
. %
ure or other unnecessary parts will be disas- Confirm the extent of the failure yourself,
:
sembled. and judge whether to handle it as a real fail- 0
. It will become impossible to find the cause ure or as a problem with the method of op-
of the failure. eration, etc.
It will also cause a waste of manhours, parts, or * When operating the machine to reenact
oil or grease, and at the same time, will also lose the troubleshooting symptoms, do not
the confidence of the user or operator. carry out any investigation or measure-
For this reason, when carrying out troubleshoot- ment that may make the problem worse.
ing, it is necessary to carry out thorough prior 5. Troubleshooting
investigation and to carry out troubleshooting in . Use the results of the investigation and in-
accordance with the fixed procedure. spection in Items 2 - 4 to narrow down the
2. Points to ask user or operator causes of failure, then use the troubleshoot-
1) Have any other problems occurred apart from ing flowchart to locate the position of the
the problem that has been reported? failure exactly.
2) Was there anything strange about the ma- * The basic procedure for troubleshooting
chine before the failure occurred? is as follows.
3) Did the failure occur suddenly, or were there 1) Start from the simple points.
problems with the machine condition before 2) Start from the most likely points.
this? 3) Investigate other related parts or in-
4) Under what conditions did the failure occur? formation.
5) Had any repairs been carried out before the 6. Measures to remove root cause of failure
failure? . Even if the failure is repaired, if the root cause
When were these repairs carried out? of the failure is not repaired, the same failure
6) Has the same kind of failure occurred be- will occur again.
fore? To prevent this, always investigate why the
3. Check before troubleshooting problem occurred. Then, remove the root
1) Check the oil level cause.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.

20-36
8
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING

SEQUENCE OF EVENTS IN TROUBLESHOOTING

Office, shop
TEW00180 a TEW00181 Jobsite

,tep 1
[Examination, confirmation of symptoms 1
When a request for repairs is received, first II
-------
ask the following points.
-------
Ring 1 Ring I
. Name of customer
. Type, serial number of machine
. Details of jobsite, etc.
Ask questions to gain an outline of the prob-
lem.
. Condition of failure
. Work being carried out at the time of the TEW00182
failure
. Operating environment
. Past history, details of maintenance, etc.

tep 2
Determining probable location of cause

1) Look at the troubleshooting section of the


shop manual to find locations of ’possible
causes.

TEW00184

tep 3
IPreparation of troubleshooting toolsl

1) Look at the table of troubleshooting


the shop manual and prepare
tools in
the necessary
U -II-
I- TEW00185

essay L
tools. Pinpoint locations of failure (carry out
. T-adapter troubleshooting)
* Hydraulic pressure gauge kit, etc. - Decide action to take
2) Look in the parts book and prepare the net- -
replacement parts. 1) Before starting troubleshooting, locate and
__~..^...^^

manual, select a troubleshooting flowchart


that matches the symptoms, and carry out

Step 6
LRe-enacting failure]

. Drive and operate the machine to confirm


the condition and judge if there is really a
failure.
TEW00188

tep 4 _ 9 , lly?P5
-1 Ask operator questions to confirm details of
failure.

. Was there anything strange about the ma-


chine before the failure occurred?
. Did the failure occur suddenly?
. Had any repairs been carried out before the
- __
TEW00189 failure?

IIC TEWOOlSO

20-37
@
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a long period, and to prevent failures or other
troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and re-
pairs must be carried out. This section deals particularly with correct repair procedures for mechatronics
and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling
electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil).

1. POINTS TO REMEMBER WHEN HANDLING


ELECTRIC EQUIPMENT

I) Handling wiring harnesses and connectors


Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are more
likely to be affected by the direct effects of rain,
water, heat, or vibration. Furthermore, during
inspection and repair operations, they are fre-
quently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely care-
ful when handling wiring harnesses.
TEW00191

Main failures occurring in wiring harness


Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to
Improper insertion
occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces.

I TEW00192

Defective crimping or soldering of connec-


tors
The pins of the male and female connectors
are in contact at the crimped terminal or
soldered portion, but if there is excessive
force brought to bear on the wiring, the plat-
ing at the joint will peel and cause improper
connection or breakage.

TEW00193

20-38
@
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

@ Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the solder-
ing may be damaged, or the wiring may be
broken.

@ High-pressure water entering connector


The connector is designed to make it diffi-
cult for water to enter (drip-proof structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the con-
nector, depending on the direction of the
water jet.
As already said, the connector is designed
to prevent water from entering, but at the
same time, if water does enter, it is difficult &
.
for it to be drained. Therefore, if water should
get into the connector, the pins will be short-
TEW00195
circuited by the water, so if any water gets
in, immediately dry the connector or take
other appropriate action before passing elec-
tricity through it.

@ Oil or dirt stuck to connector


If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins, the
oil will not let the electricity pass, so there
will be defective contact.
If there is oil or grease stuck to the connec-
tor, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a con- TEW00196
tact restorer.
* When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
* If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before clean-
ing with compressed air.

20-39
@
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

2) Removing, installing, and drying connectors and


wiring harnesses

0 Disconnecting connectors
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. I TEW00197

* Never pull with one hand.

When removing from clips


When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
* If the connector is twisted up and down 0
or to the left or right, the housing may
break.

TBW00485

0 Action to take after removing connectors r

After removing any connector, cover it with


a vinyl bag to prevent any dust, dirt, oil, or
water from getting in the connector portion.
* If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always cover
the connector.

TEW00198

20-40
0
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

0 Connecting connectors
0 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- Clicks into position
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.
* If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth.
TWmllQcl
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.
* If there is any damage or breakage, re-
place the connector.

0 Fix the connector securely.


Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in
the connector until the stopper clicks into
position.
%
z
0 0 Correct any protrusion of the boot and any
misalignment of the wiring harness
For connectors fitted with boots, correct any
protrusion of the boot. In addition, if the
wiring harness is misaligned, or the clamp
is out of position, adjust it to its correct po-
sition.
* If the connector cannot be corrected eas-
ily, remove the clamp and adjust the
position.

0 If the connector clamp has been removed,


be sure to return it to its original position.
Check also that there are no loose clamps.

20-41
@
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

l Drying wiring harness


If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must be
washed in water, do not use high-pressure wa-
ter or steam directly on the wiring harness.

If water gets directly on the connector, do as


follows.
@ Disconnect the connector and wipe off the
water with a dry cloth.
Ir If the connector is blown dry with com-
TEW00196
pressed air, there is the risk that oil in
the air may cause defective contact, so
remove all oil and water from the com-
pressed air before blowing with air.

@ Dry the inside of the connector with a dryer.


If water gets inside the connector, use a dryer
to dry the connector.
* 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.

TEWOOZOZ

@ Carry out a continuity test on the connector.


After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
* After completely drying the connector,
blow it with contact restorer and reas-
semble. T-adapter

TEW00203

20-42
@
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3) Handling control box


0 The control box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
0 Do not open the cover of the control box
unless necessary.

0 Do not place objects on top of the control


box.
0 Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with your
hand.
0 During rainy weather, do not leave the con-
trol box in a place where it is exposed to
rain.

TEW00205

Do not place the control box on oil, water,


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

II TEWOO206

2. Points to remember when troubleshooting electric circuits


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

20-43
@
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3. POINTS TO REMEMBER WHEN HANDLING


HYDRAULIC EQUIPMENT

With the increase in pressure and precision of hy-


draulic equipment, the most common cause of fail-
ure is dirt (foreign material) in the hydraulic circuit.
When adding hydraulic oil, or when disassembling
or assembling hydraulic equipment, it is necessary
to be particularly careful.

11 Be careful of the operating environment.


Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.

2) Disassembly and maintenance work in the field


If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to confirm the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and main-tenance of hydraulic equip-
ment should be carried out in a specially pre-
pared dustproof workshop, and the performance
should be confirmed with special test equipment.

3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from en-
tering. If the opening is left open or is blocked
with a rag, there is danger of dirt entering or of
the surrounding area being made dirty by leak-
ing oil so never do this.
Do not simply drain oil out on to the ground,
collect it and ask the customer to dispose of it,
or take it back with you for disposal.

TEW00208

4) Do not let any dirt or dust get in during refilling


operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.

20-44
@
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

5) Change hydraulic oil when the temperature is


high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be drained
out easily from the circuit together with the oil,
so it is best to change the oil when it is still
warm. When changing the oil, as much as pos-
sible of the old hydraulic oil must be drained
out. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain
plug in the circuit.) If any old oil is left, the
contaminants and sludge in it will mix with the
new oil and will shorten the life of the hydraulic
oil.

6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.

%
7
0

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 3~) particles that the filter
built into the hydraulic equipment cannot re-
move, so it is an extremely effective device.

I TEwoo211 I

20-45
@
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING

CHECKS BEFORE TROUBLESHOOTING

Item Judgement Action


value

1. Check fuel level, type of fuel - Add fuel

2. Check for impurities in fuel - Clean, drain

3. Check hydraulic oil level - Add oil

4. Check hydraulic strainer - Clean, drain

5. Check swing machinery oil level - Add oil

6. Check engine oil level (oil pan oil level), type of oil - Add oil

7. Check coolant level - Add water

8. Check dust indicator for clogging - Clean or replace

9. Check hydraulic filter - Replace

1. Check for looseness, corrosion of battery terminal, wiring - Tighten or replace

2. Check for looseness, corrosion of alternator terminal, wiring - Tighten or replace

3. Check for looseness, corrosion of starting motor terminal, wiring - Tighten or replace

1. Check for abnormal noise, smell - Repair

2. Check for oil leakage - Repair

3. Carry out air bleeding - Bleed air

1. Check battery voltage (engine stopped) 20 - 3ov Replace %


.?-
2. Check battery electrolyte level - Add or replace z

3. Check for discolored, burnt, exposed wiring - Replace

4. Check for missing wiring clamps, hanging wiring - Repair

5. Check for water leaking on wiring (be particularly careful attention - Disconnect

to water leaking on connectors or terminals) connector and dry

6. Check for blown, corroded fuses - Replace

7. Check alternator voltage (engine running at l/2 throttle or above) After runninc I Replace
for several
minutes:
27.5 - 29.5 V

8. Check operating sound of battery relay (when switch is turned ON/OFF) - Replace

20-46
8
TROUBLESHOOTING OF ENGINE
(S MODE)

Method of using troubleshooting charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-48

D3 1 E-20 Serial No.: 42001 - 42713 D31P-20A Serial No.: 45001 - 47616
D31P, PL-20 Serial No.: 45001 - 47616 D37E-5 Serial No.: 3001 - 3730
D31PLL-20 Serial No.: 45001 - 47652 D37P-5A Serial No.: 3001 - 3660
D31S, Q-20 Serial No.: 41001 - 41183
s- 1 Starting performance is poor (starting always takes time) ........................................................................ 20-54
s- 2 Engine does not start ...................................................................................................................................... 20-55
s- 3 Engine does not pick up smoothly (Follow-up is poor). ............................................................................. 20-58
s- 4 Engine stops during operations.. ................................................................................................................... 20-59
s- 5 Engine does not rotate smoothly .................................................................................................................. 20-60
S- 6 Engine lacks output (no power) ..................................................................................................................... 20-61
s- 7 Exhaust gas is black (incomplete combustion) ............................................................................................ 20-62
S- 8 Oil consumption is excessive (or exhaust gas is blue). .............................................................................. 20-63
s- 9 Oil becomes contaminated quickly.. .............................................................................................................. 20-64
S-IO Fuel consumption is excessive ...................................................................................................................... 20-65
S-II Oil is in cooling water, or water spurts back, or water level goes down.. ............................................... 20-66
s-12 Oil pressure lamp lights up (drop in oil pressure) ...................................................................................... 20-67
s-13 Oil level rises ................................................................................................................................................... 20-68
s-14 Water temperature becomes too high (overheating) .................................................................................. 20-69

% s-15 Abnormal noise is made.. ............................................................................................................................... 20-70


z S-16 Vibration is excessive.. .................................................................................................................................... 20-71
0

D31 E-20 Serial No.: 42714 and up D31P-20A Serial No.: 47617 and up
D31P, PL-20 Serial No.: 47617 and up D37E-5 Serial No.: 3731 and up
D31PLL-20 Serial No.: 47653 and up D37P-5A Serial No.: 3661 and up
D31S, Q-20 Serial No.: 41184 and up
s- 1 Starting performance is poor (starting always takes time) ........................................................................ 20-72
s- 2 Engine does not start ................................................................................................................................ ...20-72-1
(1) Engine does not turn ......................................................................................................................... ...20-72-1
(2) Engine turns but no exhaust smoke comes out (fuel is not being injected) ................................ .20-72-2
(3) Exhaust smoke comes out, but engine does not start (fuel is being injected). ............................ .20-72-3
s- 3 Engine does not pick up smoothly (follow-up is poor). .......................................................................... .20-72-4
s- 4 Engine stops during operations .................................................................................................................. 20-72-5
s- 5 Engine does not rotate smoothly (hunting) ............................................................................................. .20-72-6
S- 6 Engine lacks output (no power) ................................................................................................................. .20-72-7
s- 7 Exhaust smoke is black (incomplete combustion). .................................................................................. .20-72-8
S- 8 Oil consumption is excessive (or exhaust gas is blue). .......................................................................... .20-72-g
s- 9 Oil becomes contaminated quickly.. ......................................................................................................... 20-72-10
S-IO Fuel consumption is excessive ................................................................................................................ .20-72-l 1
S-l 1 Oil is in cooling water, or water spurts back, or water level goes down ............................................ 20-72-12
s-12 Oil pressure caution lamp lights up (drop in oil pressure) .................................................................. .20-72-13
s-13 Oil level rises (water, fuel in oil) ............................................................................................................... 20-72-14
s-14 Water temperature becomes too high (overheating) ............................................................................ .20-72-15
s-15 Abnormal noise is made.. .......................................................................................................................... 20-72-16
S-16 Vibration is excessive ................................................................................................................................. 20-72-17

20-47
8
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING CHARTS

METHOD OF USING TROUBLESHOOTING CHARTS

This troubleshooting chart is divided into three


sections: questions, check items, and troubleshoot-
ing. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspeciton with-
out using troubleshooting tools.
Next, troubleshooting tools or direct inspection
are used to check the high probability causes to
make final confirmation.

[Questions]
Sections @ + @ in the chart on the right corre-
sponds to the items where answers can be ob-
tained from the user. The items in @ are items
that can be obtained from the user, depending
on the user’s level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under 0 in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information @ that he has obtained from the
user and the results of @ that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].

20-48
@
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING CHARTS

The basic method of using the troubleshooting chart


is as follows.
Items listed for [Questions] and [Check items1 that
have a relationship with the Cause items are marked
with 0, and of these, causes that have a high prob-
ability are marked with Q.
Check each of the [Questions] and [Check items] in
turn, and marked the 0 or 8 in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is
the most probable cause, so start troubleshooting
for that item to make final confirmation of the cause.
’ %I. For [Confirm recent repair history] in the
[Questions] Section, ask the user, and mark
the Cause column with n to use as reference
+ for locating the cause of the failure. How-
ever, do not use this when making calcula-
tions to narrow down the causes.
,X2. Use the A in the Cause column as reference
for [Degree of use (Operated for long pe-
riod)] in the [Questions] section as reference.
As a rule, do not use it when calculating the
points for locating the cause, but it can be
included if necessary to determine the order
for troubleshooting.
%
z
0

20-49
63
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING CHARTS

. Example of troubleshooting when exhaust gas is black


Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three
symptoms have causal relationship with this problem: [Exhaust gas slowly became black], [Power
slowly became weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with
five causes. Let us explain here the method of using this causal relationship to pinpoint the most
probable cause.

s-7 Exhaust gas is black (incomplete combustion)


General causes why exhaust gas is black
. Insufficient intake of air
. Improper condition of fuel injection
. Excessive injection of fuel

Degree of use 1 Operated for long period

Y I Engine pickup IS poor and combustion IE irregular IC

t Clanging sound IE heard from around cylinder head I


Exhaust noise is abnormal IC

1 When turbocharger is rotafed by hand, ,t is found fo be heavy Ia

Speed of some cylinders does not change when operating


reduced cvlinders

When valve clearance is checked direnly it IS found to be


outside standard val”e

20-50
8
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING CHARTS

rrl,,
Five causes

Step 1

Clarify the relationship between the three


symptoms in the [Questions] and [Check items1
section and the five Cause items in the vertical
column.
J

eF
Three symptoms

Add up the total of Oand 0 marks where the


horizontal lines for the three symptoms and the
vertical columns for the causes intersect.
(I) Clogged air cleaner element: 000
(2) Air leakage between turbocharger
and head: 00
(3) Clogged, seized injection nozzle: 0
(4) Defective contact of valve, valve seat: 0
(5) Worn piston ring, cylinder: 0

Step 3

The calculation 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 0. The Remedy is
given as [Clean], so carry out cleaning, and the
exhaust gas color should return to normal.

20-51
8
D31 E-20 Serial No.: 42001 - 42713 D31P-20A Serial No.: 45001 - 47616
D31P, PL-20 Serial No.: 45001 - 47616 D37E-5 Serial No.: 3001 - 3730
D31PLL-20 Serial No.: 45001 - 47652 D37P-5A Serial No.: 3001 - 3660
D31S. Q-20 Serial No.: 41001 - 41183

S-l Starting performance is poor (Starting always takes time)


General causes why starting performance is poor
. Defective electrical system
. Insufficient supply of fuel
- Insufficient intake of air
* Improper selection of fuel
(At ambient temperature of -10°C or below, use
ASTM D975 No. 1, and -10°C or above, use ASTM
D975 No. 2 diesel fuel.)
* Charging rate of battery.

the above table.


. Incold weather the specific gravity must be for the charging rate of at
least 75% in the above table.

20-54
@
S-2 Engine does not start
0 Engine does not turn

General causes why engine does not turn


. Internal parts of engine seized
l If internal parts of the engine are seized, carry
out troubleshootin’g for “Engine stops during
operations”.
- Failure in power train
* Defective electrical system

When starting switch is

turned to START, pinion ain 0

I I movesout,but Makes rattlina noise and


0 0 0
does not turn
/ When starting switch is turned to START, pinion does not move out 0 0 0
5
C
When starting switch is turned to ON, there is no clicking sound 0 8
P Battery terminal is loose Q
r
When starting switch is turned to ON, linkage does not move

When battery is checked, battery electrolyte is found to be low

Specific gravity of electrolyte, voltage of battery is low

For the following conditions 1) - 5). turn the starting switch OFF,

connect the cord, and carry out troubleshooting at ON

1) When terminal B and terminal C of starting switch are connected,

engine starts

2) When ternimal B and terminal C of starting motor are connected,

engine starts

3) When terminal B and terminal C of safety relay are connected,

enaine starts

4) When terminal of safety switch and terminal B of starting motor

are connected. enaine starts

5) There is no 24V voltage between terminal b and terminal E of

batterv relav

When ring gear is inspected directly, tooth surface is found to be


I
chipped

Does not move even when fuel cut solenoid linkage is disconnected

Does not move even when engine stop motor linkage is disconnected

I
0 Engine turns but no exhaust gas comes out
(Fuel is not being injected)

General causes why engine turns but no exhaust gas


comes out
. Supply of fuel impossible
* Supply of fuel is extremely small
. Improper selection of fuel (particularly in
winter)

Standards for use of fuel

Degree of use Operated for long period A a a

Exhaust gas suddenly (when starting again) stops coming out 8 8 0

Replacement of filters has not been carried out according to operation


: 0 8
.g manual

2 Fuel tank is found to be empty 0


u
There is leakage from fuel piping 0

Mud is stuck to fuel tank cap 0

When starring switch is turned ON, linkage does not move Q Q

When fuel filter is drained, fuel does not come out I IO


When engine is cranked with starting motor,
i 0
‘D 1) injection pump coupling does not rotate
; 2) NO fuel comes out even when fuel filter air bleed plug is loosened 0 0 0 0
_? 3) No fuel spurts Outeven when injection pipe sleeve nut is loosened Q 0 0

Rust and water are found when fuel is drained 0 0
0 Exhaust gas comes out but engine does not
start
(Fuel is being injected)

General causes why exhaust gas comes out but


engine does not start
* Lack of rotating force due to defective electri-
cal system
* Insufficient supply of fuel
. Insufficient intake of air
. Improper selection of fuel

Suddenly failed to start Q 0


I
fienqine is cranked, abnormal noise is heard from around head 101 I I I I I I I I I I I I I
Engine oil must be added more frequently 0
z
.g
c.9 Non-specified fuel has been used 1 101 / 1 / I I I ) / I 01 /
z Replacement of filters has not been carried out according to operation
zi 0 Q 0
manual

Rust is found when fuel is drained

Dust indicator is red

I Indicator lamp does not light up

Starting motor cranks engine slowly 0

Mud is stuck to fuel tank cap 0

When fuel lever is placed at FULL position, it does not contact stopper 0

When engine is cranked with starting motor,

1) Little fuel comes out even when injection pump sleeve nut is 0

loosened

.Z 2) Little fuel comes out even when fuel filter air bleed plug is
Q 0 0
z loosened
z
” There is leakage from fuel piping 0

, When exhaust manifold is touched immediately after starting engine, , , , , , , , , , , , / 6%I I I


temperature of some cylinder is low

When fuel filter is drained, no fuel comes out Co

1 Remove head cover and check directly I.1 I I I I I I I I I I I I


When control rack is pushed, it is found to be heavy or does not return / 1.1 1 1 I I I I I / I / 1
When comoression oressure is measured, it is found to be low I I.1 I I I I I I I I I I
When fuel filter, strainer are inspected directly, they are found to be

clogged
S-3 Engine does not pick up smoothly (Follow-up is poor)
General causes why engine does not pick up
smoothly
- Insufficient intake of air
. Insufficient supply of fuel
1 Improper condition of fuel injection
. Use of improper fuel

er no load is normal, but speed suddenly drops

2028
S-4 Engine stops during operations
General causes why engine stops during
operations
. Seized parts inside engine
. Insufficient supply of fuel
* Overheating
* If there is overheating and insufficient
output, carry out troubleshooting for over-
heating.
- Failure in power train
* If the engine stops because of a failure in
the power train, carry out troubleshooting
for the chassis.

Confirm recent repair history

Degree of use Operated for long period a a

Abnormal noise was heard


QQQOQQ 0 0 0
and engine stops suddenly

Condition when engine Engine overheated and stopped Q 0 0


I

stopped Engine stopped slowly 000

1 There was hunting andengine


&J ” ” 0
stopped

Fuel gauge lamp lights up I I I I I IQI I


Fuel tank is found to be empty

Replacement of filters has not been carried out according to

operation manual

Non-specified fuel has been used

When feed pump is operated, there is no response or it is heavy 1 10101 lo1 I I I


Mud is stuck to fuel tank cam III1 I I I I I I I
Engine turns, but stops when transmission control lever is

oDerated I I I I I I I

Try to turn by hand using bar

ring tool

20-$9
S-5 Engine does not rotate smoothly
General causes why engine does not rotate
smoothly (hunting)
. Air in fuel system
* Defective governor mechanism
. Defective electrically controlled throttle
mechanism
(electrically controlled throttle type)
* If there is no hunting when the electrically
controlled throttle rod is disconnected, carry
out troubleshooting for the electrical sys-
tem.

Condition of hunting

Fuel tank is

Replaceme,,L yI

operation manual

Rust is found when fuel is drained

c
Leakage from fuel piping

When feed pump is operated,

1) No response, light, return is quick

2) No resoonse. lioht. return is normal


Ennin.3 ,,,ed
L,,J,,,_ Ena sometimes rises too high Q Q
$ . Q
Sometimes is difficult to stop engine 0

Seal on injection pump has come off 0 8

When governor lever is moved it is found to be stiff

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


S-6 Engine lacks output (no power)
General causes why engine lacks output
- Insufficient intake of air
. Insufficient supply of fuel
. improper condition of fuel injection
. Use of improper fuel
(if non-specified fuel is used, output drops)
. Lack of output due to overheating
* If there is overheating and insufficient
output, carry out troubleshooting for over-
heating.

When exhaust manifold is touched immediately after starting engine,

When air element is inspected directly, it is found to be clogged 1.1 1 1 1 I I 1 I I 1 1


When trubocharoer is rotated bv hand. it is found to be heavv I /.I I I I I I I I I I

When fuel cap is inspected directly, it is found to be clogged .


S-7 Exhaust gas is black (incomplete combustion)
General causes why exhaust gas is black
. insufficient intake of air
. Improper condition of fuel injection
. Excessive injection of fuel

Confirm recent recxaw historv

1 Degree of use I Operated for hong period I IA IA IA I I I I I IA I I

Color of exhaust gas


:
n

z Engine oil must be added more freque ntlv


2l Suddenly 0 0 0 0
Power was lost
Gradually 0 0 0 0

Non-specified fuel has been used 0 0

/ Noise of interference is heard from around turbocharqer Q

Muffler is crushed IQ 1
Leakage of air between trubocharger and head, loose clamp 0
I

standard value

20-$2
S-8 Oil consumption is excessive (or exhaust gas is blue)
* Do not run the engine at idling for more than
20 minutes continuously. (Both low and high
idling)
General causes why oil consumption is excessive
- Abnormal combustion of oil
* External leakage of oil
- Wear of lubrication system

1 When compression pressure is measured, it is found to be low 1.101 I I I I I I I I I I I


When breather element is inspected, it is found to be clogged with
0
dirty oil

There is external leakage of oil from engine 0 l 0 l


Pressure-tiahtness test of oil cooler shows there is leakaae l
Excessive play of turbocharger shaft 1 ~0~0~ 1 1
Check rear seal directlv I I I I I I I I I I I.1 I
When intake manifold is removed, dust is found inside
I I I I I I I I I I I I.1
1 When intake manifold is removed, inside is found to be dirty with oil
S-9 Oil becomes contaminated quickly
General causes why oil becomes contaminated
quickly
. Intake of exhaust gas due to internal wear
. Clogging of lubrication passage
* Improper combustion
. Use of improper oil
. Operation under excessive load

2024
S-l 0 Fuel consumption is excessive
General causes why fuel consumption is exces-
sive
. Leakage of fuel
. Improper condition of fuel injection
* Excessive injection of fuel

More than for other machines

Condition of fuel consumption

Exhaust gas color


S-l 1 Oil is in cooling water, or water spurts back, or water level goes down
Generl causes why oil is in cooling water
* Internal leakage in lubrication system
* Internal leakage in cooling system
S-12 Oil pressure lamp lights up (drop in oil pressure)
General causes why oil pressure lamp lights up
* Leakage, clogging, wear of lubricating system
* Defective oil pressure control
* Use of improper oil (improper viscosity)
* Deterioration of oil due to overheating
* Standards for engine oil selection

Selection of oil SAE number


Type of oil according to ambient temperature
-20 -10 0 10 20 30 40 50°C

Engine oil

Condition when oil pressure

When oil filter is inspected directly, it is found to be clogged 0 l P


‘Z
Remove oil pan and check directly 0 l l 8
F f %
.Z Oil pump rotation is heavy, there is play 0 2m
0 cl.r
2 2:

I
There is catching of relief valve, regulator valve, spring,
t 0 a 2:
valve guide is broken
2 I5: I
When oil level sensor is replaced, oil pressure sensor lamp goes out
S-13 Oil level rises
* If there is oil in the cooling water, carry out
troubleshooting for “Oil is in cooling water”.
. Water in oil (cloudy white)
* Fuel in oil (diluted, and smells of diesel fuel)
* Entry of oil from other component

_c I

: When pump auxiliary equipment is removed, seal is found to be broken l


x
Remove head cover and check directly 0
a
C Remove injection pump and check directly l
There is improper contact of thermostat seat valve 0

20$8
S-14 Water temperature becomes too high (overheating)
General causes why water temperature becomes
too high
- Lack of cooling water (deformation, damage of
fan)
. Drop in heat dissipation efficiency
* Defective in cooling circulation system
* Rise in oil temperature of power train
* Carry out troubleshooting for chassis.

Water temperature gauge

Radiator water level sensor lights up

Fan belt whines under sudden load

1 Power train oil level enters red range before engine watertemperature 1 1 1 1 1 I 1 1 1 I 1 I0

Temperature difference between top and bottom radiatwtanks is


l
excessive
.L”
Temperature difference between top and bottom radiator tanks

sliaht

(51 When water filler port is inspected, the core is found to be clogged 0
.g
When a function test is carried out on the thermostat, it does not open
8 0
5 even at the cracking temperature

When water temperature is measured, it is found to be normal l


e When oil cooler is inspected directly, it is found to be clogged 0 6
I- b
When measurement is made with radiator cap tester, set pressure is
0 %
found to be low >
$
When compression pressure is measured, it is found to be low 0 c
Remove oil pan and check directly l

2069
S-l 5 Abnormal noise is made
* Judge if the noise is an internal noise or an
external noise.
General causes why abnormal noise is made
. Abnormality due to defective parts
* Abnormal combustion noise
. Air sucked in from intake system

Color or exhaust gas


S-l 6 Vibration is excessive
t If there is abnormal noise together with the
vibration, carry out troubleshooting for “Abnor-
mal noise is made”.
General causes why vibration is excessive
- Defective parts (abnormal wear, breakage)
- Improper alignment
- Abnormal combustion

Seal on injection pump has come off I I I I I I I I


TESTING AND ADJUSTING S-l

D31E-20 Serial No.: 42714 and up D31P-20A Serial No.: 47617 and up
D31P, PL-20 Serial No.: 47617 and up D37E-5 Serial No.: 3731 and up
D31PLL-20 Serial No.: 47653 and up D37P-5A Serial No.: 3661 and up
D31S, Q-20 Serial No.: 41184 and up

S-l Starting performance is poor (starting always takes time)


General causes why exhaust smoke comes out but
engine takes time to start
. Defective electrical system
. Insufficient supply of fuel
. Insufficient intake of air
. Improper selection of fuel
(At ambient temperature of IO’C or below, use
ASTM D975 No. 1)
* Battery charging rate
y
Amb,sntrm- ,o&ya- go/o 80% 75% 70%
aratwe

20°C 1.28 1.26 1.24 1.23 1.22


0°C 1.29 1.27 1.25 1.24 1.23
-10°C 1.30 1.28 1.26 1.25 1.24
l The specific gravity should exceed the value
for the charging rate of 70% in the above table.
. In cold areas the specific gravity must ex-
ceed the value for the charging rate of 75%
in the above table.

Legend
0 : Possible causes (judging from Questions and check items)
0 : Most orobable causes (iudaina from Questions and Check items)
a : Possible causes due to l&gih of use (used for a long period)
: Items to confirm the cause

20-72
@
TESTING AND ADJUSTING s-2

S-2 Engine does not start


(I) Engine does not turn / Causes I

General causes why engine does not turn


. Internal parts of engine seized
* If internal parts of the engine are seized,
carry out troubleshooting for “Engine
stops during operations”.
. Defective electrical system

Legend
0 : Possible causes (judging from Questions and check items)
0 : Most probable causes (judgingfrom Questions and Check items)
A: Possible causes due to length of use (used for a long period)
l : items to confirm the cause.
1 1 Confirm recent repair history I I I I I I I I I

When starting switch is

turned to START, pinion

moves out, but

When starting switch is turned to START, pinion does not move out 0
C
:: When starting switch is turned to ON, there is no clicking sound 0 0
m
6 Battery terminal is loose 0

When battery is checked, battery electrolyte is found to be low 0

Specific gravity of electrolyte, voltage of battery is low 1.1 1


For the following conditions 1) - 5). turn the starting switch

OFF, connect the cord, and carry out troubleshooting at ON

1) When terminal B and terminal C of starting switch are

2) When terminal B and terminal C of starting motor are


:::I::::::

3) When terminal B and terminal C of safety relay are

connected, engine starts I I I


4) Engine starts when safety switch terminal and starting

motor B terminal is connected I I I /@I I I I


5) There is no 24V between battery relay terminal M and

a
terminal E I I I I IaI I I
When ring gear is inspected directly, tooth surface is

20-72- 1
@
TESTING AND ADJUSTING s-2

(21 Engine turns but no exhaust smoke comes


out (fuel is not being injected)

* Check that the monitor panel does not dis-


play any abnormality in the governor control
system.
General causes why engine turns but no ex-
haust smoke comes out
. Supply of fuel impossible
l Supply of fuel is extremely small
. Improper selection of fuel (particularly in win-
Causes
ter)

* Standards for use of fuel

Ambient temprature
Type of fuel

Diesel fuel

LWJ~“”

0 : Possible causes (judging from Questions and check items)


0 : Most probable causes (judging from Questions and Check items)
n : Possible causes due to length of use (used for a long period)
: Items to confirm the cause.

When engine is cranked with starting motor,


E 0
(u 1) Injection pump coupling does not turn
.=
%
al 2) No fuel comes out even when fuel filter air bleed plug is loosened 0 00 0
6 3) No fuel spurts out even when injection pipe sleeve nut is loosened 0 0 0

Rust and water are found when fuel tank is drained 00

20-72-2
@
TESTING AND ADJUSTING s-2

(3) Exhaust smoke comes out but engine does


not start
(Fuel is being injected)

* General causes why exhaust smoke comes


out but engine does not start
Causes
. Lack of rotating force due to defective elec-
trical system
. Insufficient supply of fuel
. Insufficient intake of air
. Improper selection of fuel and oil

Legend
0 : Possible causes (judging from Questions and check items)
0 : Most probable causes (judging from Questions and Check items)
A : Possible causes due to length of use (used for a long period)

Replacement of filters has not been carried out according

When feed pump is operated, operation is too light or too heavy 0


I 1 When iniectionnozzleis testedasindividualpart,sprat conditionis foundto be moor 1 1 1 0
When fuel cap is inspected directly, it is found to be clogged 1 1 1 0

20-72-3
@
TESTING AND ADJUSTING s-3

S-3 Engine does not pick up smoothly (follow-up is poor)


Causes

General causes why engine does not pick up smoothly


. Insufficient intake of air
. Insufficient supply of fuel
. Improper condition of fuel injection
. Improper fuel used

Legend
0: Possible causes (judging from Questions and check items)
0 : Most probable causes (judgingfrom Questionsand Check items)
1: Possible causes due to length of use (used for a long period)

High idling speed

When exhaust manifold is touched immediately after

starting engine, temperature of some cylinders is low

20. Blow-by gas is excessive

20-72-4
@
TESTING AND ADJUSTING s-4

S-4 Engine stops during operations


General causes why engine stops during opera-
tions
. Seized parts inside engie
. Insufficient supply of fuel
. overheating
* If there is overheating and the engine stops,
carry out troubleshooting for overheating.
. Failure in power train
* If the engine stops because of a failure in the
power train, carry out troubleshooting for the
hydraulic system (H MODE).
Legend
0 : Possible causes (judging from Questions and check items)
0 : Most probable causes (judging from Questions and Check items)
a: Possible causes due to length of use (used for a long period)
l : Items to confirm the cause.
-
Confirm recent repair history

Degree of use of machine Operated for long period nn


Abnormal noise was heard
and engine stopped suddenly 000000 0 0 Q
Condition when
engine stopped
2
2
z
2
u

Replacementof filters has not been carried out accordingto OperationManual

Non-specified fuel is being used

When feed pump is operated, operation is too light or too heavy 1 1 1 I I I I lolol IQI I I
Mud is stuck to fuel tank cap
/ Engine rotates, but stops when power train is operated

Try to turn by
hand using
barring tool

Rust and water are found when fuel tank is drained

Metal particles are found when oil is drained


-
When oil pan is removed and inspection is made directly,
it is found to be abnormal

I When head cover is removed and inspection is made


directly, it is found to be abnormal
F
When gear train is inspected, it does not turn

Rotates when pump auxiliary equipment is removed

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

I I nsoect feed oumo directlv

1 Wh en control rack is oushed. it it found to be heavv. or does not return

20-72-5
@
TESTING AND ADJUSTING s-5

S-5 Engine does not rotate smoothly (hunting)


General causes why engine does not rotate
smoothly
. Air in fuel system
. Defective governor mechanism
. Defective electric governor mechanism
* If hunting does not occur when the rod be-
tween the governor motor and the injection
pump is disconnected, troubleshoot by us-
ing the electrical system troubleshooting (E
mode).

Legend
0: Possible causes (judging from Questions and check items)
0 : Most probable causes (judgingfrom Questionsand Check items)
A: Possible causes due to length of use (used for a long period)

I Condition of hunting
2
7J
%
CI

Replacement of filters has not been carried out according

to Operation Manual I I I

-
When governor lever is moved it is found to be stiff 0
-
When injection pump is tested, governor is found to be

improperly adjusted
0
-
F
._ When control rack is pushed, it is found to be heavy, or
5
2 does not return
-
4 When fuel cap is inspected directly, it is found to be clogged
9
e 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 I -

2
5
Q
-

20-72-6
@
TESTING AND ADJUSTING S-6

S-6 Engine lacks output (no power)


General causes why engine lacks output
. Insufficient intake of air
. Insufficient supply of fuel
. Improper condition of fuel injection
. Improper fuel used Causes
(if non-specified fuel is used, output drops)
. Lack of output due to overheating
* If there is overheating and insufficient output,
carry out troubleshooting for overheating.

Legend
0 : Possible causes (judging from Questions and check items)
0 : Most probable causes (judging from Questions
and Check items)
A : Possible causes due to length of use (used for a long period)

1 Confirm recent reoair historv

Replacement of filters has not been carried out according

Non-specified fuel is beinq used


Dust indicator is red
Black
Color of exhaust gas
Blue under light load
Noise of interference is heard from around turbocharger
Blow-by gas is excessive
Engine pickup is poor and combustion is irregular
High idling speed under no load is normal, but speed
E
2 suddenly drops when load is applied
Y
When exhaust manifold is touched immediately after
:
5 starting engine, temperature of some cylinders is low
There is hunting from engine (rotation is irregular)
Clanging sound is heard from around cylinder head
Hiah idlina speed of ermine is low
1 Lnakaoe from fuel ninino

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


When turbocharger is rotated by hand, it is found to be heavy
When compression pressure is measured, it is found to be low
P
._ When fuel filter, strainer are inspected directly, they are found to be clogged
s
When feed pump strainer is inspected directly, it is found to be clogged
_?
I Speed does not change when operation of certain cylinders is stopped
X When control rack is pushed, it is found to be heavy, or does not return
2
Whenvalve clearanceis checkeddirectly, it is found to be outside standard value
c
When lever is placed at FULL position, it does not contact stopper
When feed pump is operated, operation is too light or too heavy
When fuel cap is inspected directly, it is found to be clogged

Remedy

20-72-7
@
TESTING AND ADJUSTING s-7

S-7 Exhaust smoke is black


(incomplete combustion)
Causes

General causes why exhaust smoke is black


. Insufficient intake of air
. Improper condition of fuel injection
. Excessive injection of fuel

Legend
0: Possible causes (judging from Questions and check items)
0 : Most probable causes (judging from Questions and Check items)
A: Possible causes due to length of use (used for a long period)
l : Items to confirm the cause.

Confirm recent repair history

Color of exhaust gas

Power was lost

Leakage of air between turbocharger and head, loose clamp

When control rack is pushed, it is found to be heavy, or does not return 1 10


I I I I I I I I I I I I

20-72-8
@
TESTING AND ADJUSTING S-8

S-8 Oil consumption is excessive (or exhaust smoke is blue)


* Do not run the engine at idling for more than
20 minutes continuously. (Both low and high
idling)
General causes why oil consumption is exces-
sive
. Abnormal combustion of oil
. External leakage of oil
l Wear of lubrication system
Causes

Legend
0 : Possible causes (judging from Questions and check items)
0 : Most probable causes (judging from Questions and Check items)
A: Possible causes due to length of use (used for a long period)
l : Items to confirm the cause.
/ / -I
Confirm recent repair history I I I I I I I I I I I I I I

20-72-9
TESTING AND ADJUSTING s-9

S-9 Oil becomes contaminated quickly


General causes why oil becomes contaminated
quickly
. Intake of exhaust gas due to internal wear
. Clogging of lubrication passage
. Improper fuel
. Improper oil used
. Operation under excessive load

Legend
0 : Possible causes (judging from Questions and check items)
0 : Most probable causes (judgingfrom Queaions and Check items)
n : Possible causes due to length of use (used for a long period)
l : Items to confirm the cause.
Confirm recent repair history

20-72- 10
@
TESTING AND ADJUSTING S-IO

S-IO Fuel consumption is excessive


General causes why fuel consumption is exces-
sive
. Leakage of fuel
. Improper condition of fuel injection
. Excessive injection of fuel

Legend
() : Possible causes (judging from Questions and check items)
0 : Most probable causes (judging from Questions and Check items)
/‘J : Possible causes due to length of use (used for a long period)

Confirm recent repair history I I I I I I I I I

Condition of fuel
I lolol I I I I I

When exhaust manifold is touched immediately after


I L=lr?l I I I I
starting engine, temperature of some cylinders is low

Match mark on injection pump is misaligned 0


There is external leakage of fuel from engine 0

Engine oil level rises and smells of diesel fuel 0 00


Enaine low idlina speed is hiah 0 0

20-72-l 1
@
TESTING AND ADJUSTING S-l 1

S-II Oil is in cooling water, or water spurts back, or water level goes down
General causes why oil is in cooling water
. Internal leakage in lubrication system
. Internal leakage in cooling system

ing from Questions and check items)


judging from Questionsand Check items)
o length of use (used for a long period)

P
‘S
Pressure-tightness test of oil cooler shows there is leakage l
8 Pressure-tightness test of cylinder head shows there is leakage 0
5
L2 Remove cylinder head and inspect directly a
z
$ Remove oil pan and inspect directly 00
I

20-72- 12
C3
TESTING AND ADJUSTING s-12

S-12 Oil pressure caution lamp lights up (drop in oil pressure)


General causes why oil pressure lamp lights up
. Leakage, clogging, wear of lubricating system
. Defective oil pressure control
. Improper oil used (improper viscosity)
. Deterioration of oil due to overheating

* Standards for engine oil selection

Ambient temperature

1
Type of oil -
-22
-30

Causes

Engine oil

Legend
0 : Possible causes (judging from Questions and check items)
@ : Most probable causes (judgingfrom Queaions and Check items)
n : Possible causes due to length of use (used for a long period)
l : Items to confirm the cause.

Condition when oil

pressure lamp lights up

U Engine oil is insufficient


6
Metal particles are found when oil is drained 0

Metal particles are stuck to oil filter element 0 0


Oil is cloudy white or smells of diesel oil 0
L
.i
I filter is inspected directly, it is found to t

Remove oil pan and inspect directly


F
._
ij Oil pump rotation is heavy, there is play /
,”
1 There is catching of relief valve or regulator valve, spring or
I I IaM ldl
valve guide is broken

When oil pressure is measured, it is

standard value

20-72- 13
@
TESTING AND ADJUSTING s-13

S-13 Oil level rises (water, fuel in oil)


j, If there is oil in the cooling water, carry out
troubleshooting for “Oil is in cooling water”.
General causes why oil level rises
l Water in oil
. Fuel in oil (diluted, and smells of diesel fuel)
Causes
. Entry of oil from other component

Legend
0: Possible causes (judging from Questions and check items)
0 : Most probable causes (judgingfrom Questionsand Check items)
A: Possible causes due to length of use (used for a long period)
l : Items to confirm the cause.

20-72-14
@
TESTING AND ADJUSTING s-15

S-15 Abnormal noise is made Causes


* Judge if the noise is an internal noise or an I / I / l/i I, II
external noise.
General causes why abnormal noise is made
. Abnormality due to defective parts
. Abnormal combustion
. Air sucked in from intake system

Legend
0 : Possible causes (judging from Questions and check items)
0 : Most probable causes (judging from Questions and Check items)
A: Possible causes due to length of use (used for a long period)
l : Items to confirm the cause.
Confirm recent repair history III I II I I I I II

II Blow-by gas is excessive

Noise of interference is heard from around turbocharger


(
I 101 I I I I I I I I I

20-72- 16
@
TESTING AND ADJUSTING S-16

S-16 Vibration is excessive


* If there is abnormal noise together with the
vibration, carry out troubleshooting for “Ab-
normal noise is made”.
General causes why vibration is excessive
. Defective parts (abnormal wear, breakage)
. Improper alignment
. Abnormal combustion
I Causes I

Legend
0: Possible causes (judging from Questions and check items)
0 : Most probable causes (judgingfrom Questions and Check items)
,&,: Possible causes due to length of use (used for a long period)
0: Items to confirm the cause.

Remove oil pan and inspect directly I.1 I I I I I I

20-72- 17
@
METHOD OF USING TROUBLESHOOTING CHART

Explanation of symbols used in chart


In the Cause column, the action to take to remove the cause is marked with the following symbols.
x: Replace a: Repair A: Adjust C: Clean

Method of using chart


The OS marked in the chart indicate only the causes
that can be judged from troubleshooting; the causes
that cannot be judged are left blank.
In the chart on the right, if troubleshooting item 1 is
abnormal, a - d are probable causes, but no decision
can be made regarding e. For this reason, the follow-
ing troubleshooting item must also be carried out.
(There is danger that there may be more than one
problem.)
If the problem in troubleshooting item 1 does not
apply, the cause is not a - d, but before judging that
the cause is e, carry out troubleshooting items 2 to 5.
If the results of troubleshooting item 1 show an ab-
normality, but troubleshooting item 2 shows no ab-
normality, the cause is not c or e, so the cause must
be one of a, b, or d. If troubleshooting item 3 is car-
ried out and an abnormality is found, the cause must
be either b or d. Carry out troubleshooting item 4 to
investigate if the cause is b or d.
%
If the results of the troubleshooting show that there
z
0
is an abnormality, fill in the OS in black, and if the
results are normal, cross out the OS and go on to the
next troubleshooting item to narrow down the cause.
Example 1
Troubleshooting 1 + Abnormal The chart for Troubleshooting
unnecessary
Troubleshooting 2 + Normal example 1
Troubleshooting 3 + Abnormal shows that the
Troubleshooting 4 + Normal cause is b.

Example 2
Troubleshooting 1 -+ Normal The chart for
Troubleshooting 2 -+ Abnormal example 2
shows that the
cause is e.

+ In this case, it can be judged that the cause is


e without carrying out troubleshooting item
2, but carry out troubleshooting item 2 for
confirmation.
Troubleshooting _
unnecessary

2oYi74
Example 3
Troubleshooting 1 + Abnormal The chart for
Troubleshooting 2 + Abnormal example 3
Troubleshooting 3 + Normal shows that the L!

cause is a, c,
or e.
X
III
A X

Continue to the next troubleshooting item.

Troubleshooting 4 + Normal The chart for


Troubleshooting 5 + Normal example 3-l
shows that
the cause is c.

Example 4
Troubleshooting 1 + Abnormal The chart for
Troubleshooting 2 + Normal example 4
shows that
the cause is
a, b, or d.

Continue to the next troubleshooting item.

Troubleshooting 3 + Abnormal The chart for


Troubleshooting 4 + Abnormal example 4-l
%
Troubleshooting 5 + Normal shows that the
z
0 cause is a or d.

As the above examples show, it is not always neces-


sary to carry out all the troubleshooting checks.

Even if one of the causes has several OS, if it has only


one 0, that cause can be removed from the list of
possibilities.
H-l. Machine does not start
Causes
Ask the operator the following questions. I ’ I i
. Did the problem start suddenly?
Yes = Internal parts seized, broken
. Was any abnormal sound heard when this hap-
pened?
Yes = Part broken

Checks before troubleshooting


. Is the level of oil in the transmission or bevel
gear case correct?
. Is the stroke of the valve spool correct?
. Is the universal joint broken?
. Is the steering brake locked?

a a n
No. C X X c a x x a
Problems X X X
1 Trsncmiccinn nt tmn J’..-.
. l..llll.ll--l”ll r”,‘.r nonarstwa ahnnrmal .._._”
...__II..I...._. nnice when
....-..
oil temperature is low 0

2 Machine does not start in any gear speed 0 0 0 0 0 0 0

3 Machine starts normally in some gear speed 000

When gear shift lever is shifted into position, universal


4 joint does not rotate also engine does not stall 0

z
When gear shift lever is shifted into position,
5 0 0
engine stalls
Machine does not start when oil temperature is
6 higher

0 0 0

3
7

9 0

IO
:
+ If none of the above problems appear, the steering clutch is slipping.
Ir If the transmission modulating pressure is low but none of the items in the table is the cause, there may be
cracks or other damage in a valve or the tramsmission.

I
Hydraulic tester X: Replace n: Repair
Troubleshooting
tools A: Adjust C: Clean
Thermistor temperature gauge I
H-2. Drawbar pull is weak, travel speed is slow

Ask the operator the following questions.


. How long has the operator been operating the
machine?
. Why does he feel that the performance has
dropped?
= Probability of defect
. Performance is lower than other machines (in
particular, large machines)
= Probability that machine is normal

Checks before troubleshooting


. Is the level of oil in the transmission or bevel
gear case correct?
. Is oil leaking from piping or valve joint?
. Is steering brake locked?
. Is track shoe tension correct?

Checks for abnormalities


. Use the STANDARD VALUE TABLE to check that
the drawbar pull and travel speed are actually
poor.

Remedy
c X
X

I
Transmission pump generates abnormal noise when oil temperature
1 is ._..
._ Inw 0
2 Drawbar pull, travel speed are normal in some speed ranges

3 Transmission modulating pressure is low in any gear speed range 0 0

4 Transmission modulating pressure is normal in some speed ranges

When transmission modulating pressure is measured, oil pressure


5 gauge indicator is unstable and fluctuates violently 0

6 Engine speed is slow

Ir If the result is g. Devective engine, go to troubleshooting for the engine.


Sr If none of the above problems appear, there is probably a defect in the brake or steering system.

Thermistor temperature gauge Hydraulic tester


Troubleshooting
tools
Tachometer
H-3. Excessive time lag when starting or shifting gear checks before troubleshooting

Checks before troubleshooting


. Is the level of oil in the tansmission case correct?
. Is oil leaking from piping or valve joint?

Checks for abnormalities


. Use the STANDARD VALUE TABLE to check that
the time lag is actually excessive.

Ir If none of the above problems appear, the steering clutch is slipping.

Troubleshooting
Hydraulic tester X: Replace o: Repair
tools A: Adjust C: Clean
Thermistor temperature gauge
H-4. Steering does not work properly

Checks before troubleshooting


. Before carrying out the troubleshooting, check I Causes I
the following points.

Carry out trouble-


Ye% shooting according
to troubleshooting
‘es Is travel of brake chart
- pedal normal ? -
Yes ~
- Haswarming up ~
Adjust band
- Isdrawbar pull, - operation being -
No clearance
travel speed carried out ?
normal ? Carry out warming
- Is time lag No up operation
when starting
or accelerating
;;;ry&No. 2
normal ?
-No
troubleshooting

Remedy A
No. C X xx
Problems X
1 Time lag is excessive when steering to both left and right 0

2 Time lag is excessive when steering in one direction (left or right) 0 0 0

3 Steering lever is heavy 0

4 When steering lever is returned to neutral, machine does not


travel in a straight line 0

5 Machine turns gradually, but does not turn on the spot 0 0

6 Machine cannot even turn gradually 0 0

I
Hydraulic tester
Troubleshooting
tools

2029
H-5. Machine moves when engine is started

Problem Cause
1. Engine starts when gear shift lever is placed in any speed range + Defective neutral safety switch

2. When gear shift lever is at neutral and engine is started, -+ Seized tansmission clutch
machine moves

3. As above, but condition returns to normal after warming-up + Dragging caused by high viscosity
operation is carried out for 10 - 15 min of oil (is suitable oil being used?)

H-6. Excessive shock when starting or shifting gear

Checks for abnormalities


. There is a certain amount of shock, but it is difficult to measure if it is excessive or not, so use the
following guidelines to judge if it is excessive.
. The shock has clearly become much greater suddenly.
. The shock is excessive when compared with similar models.

Causes Remedy
. Defective operation, modulating valve throttle clogged + c*a*x
. Defective operation, quick return valve throttle clogged + c-a-x

H-7. Level of oil in transmission case or bevel gear case changes

%
1. If the level of the oil in the transmission case goes down and the level of the oil in bevel gear case goes
z
up: + Defective O-ring or oil seal at transmission output shaft + x 0

X: Replace n: Repair
A: Adjust C: Clean
H-8. Lack of blade lifting force, speed

Checks before troubleshooting


. Is oil level in hydraulic tank correct?
. Is stroke of work equipment lever and control
valve spool correct?

Checks for abnormalities


Yes Normal
Yes Is relief pressure abcdefgh
normal at low -
When engine is idling ? Carry out troubleshooting
run at high idling - according to troubleshooting
and blade is No chart
raised to
maximum height, Yes $r~ is a in toubleshooting
is relief pressure
normal ? Is relief pressure
~ - normalat low -
No idling ? Carry out troubleshooting
according to troubleshooting
No chart

Remedy A A A A C
_ ”
/\
C X
Problems X x x ;; x
When engine is run at high idling and blade is tilted to maximum,
1 0 0 0 0
relief pressure is too low
When engine is run at high idling and blade is tilted to maximum,
2 0
relief pressure is normal

3 Hydraulic pump generates abnormal noise 0

4 Excessive hydraulic drift 0

5 Discharge amount of hydraulic pump is too low 0 0

3 When control lever is operated, blade lifting speed is slow,


0
but circuit pressure is too high

Hydraulic tester 0: Repair


Troubleshooting
tools C: Clean
Flowmeter kit

20-81
H-9. Impossible to raise blade or push up chassis

Ask the operator the following questions.


. Did the problem start suddenly?
Yes = Parts seized, broken
. Was any abnormal sound heard when this hap-
pened? Where did the sound come from?
Yes = Parts seized, broken
. Had there been any symptoms before (drop in
speed, etc.)?
Yes = Parts worn, spring deteriorated

Checks before troubleshooting


. Is oil level in hydraulic tank correct?
. Is stroke of work equipment lever and control
valve spool correct?

When plug is removed from pressure pickup port and engine is


1 0
cranked, no oil comes out
When engine is run at high idlin there is almost no rise in hydraulic
’ pressure m the blade RAISE (L 8 WER) circuit 0 0 0

When engine is run at high idling and blade is tilted to maximum,


3 0 0
there is almost no rise in relief pressure
4 When engine is run at high idling and blade is tilted to maximum,
relief pressure 1s normal 0

6 When piping at,bottom endcf liftcylinder is removed, and control lever is operatedto
RAISEwith engrneat low rdlrng,011comes out from bottom end but cylrnderdoes not move

6 When there is load, discharge amount of hydraulic pump is almost zero 0 0

Hydraulic tester
Troubleshooting
toois
Flowmeter kit I
H-10. Excessive hydraulic drift of blade
I Causes I

Ask the operator the following questions. I Control valve


. Did the problem start suddenly?
Yes = Dirt caught in valve, parts broken
. Did this problem gradually become worse?
Yes = Parts worn

Checks before troubleshooting


. When rod of work equipment control lever is
disconnected at control valve end, does hydrau-
lic drift come within standard value?
Yes = Rod bent, twisted, or other defect

Checks for abnormalities


. Use the STANDARD VALUE TABLE to check that
the hydraulic drift of the blade is actually exces-
sive.

Remedy A C A
No. X
Problems x x x

1 Hydraulic drift is excessive even when piping at lift cylinder head end is blocked 0

2 Condition returns to normal when top and bottom suction valves are interchanged 0

3 When blade is raised to maximum height, piping at cylinder bottom end is removed, and control lever
0
IS moved to RAISE posrtron with engine at low idling, oil comes out from cylinder bottom end

4 1As in Item 3, but no oil comes out lol 101 1

H-l 1. Blade moves up and down during leveling operations (control lever at HOLD)

. Measure hydraulic drift of blade.


If it exceeds standard value + Go to 10. Excessive hydraulic drift of blade.
If it is within standard value + There is a vacuum inside the cylinder + Use the blade lift cylinder
to raise the chassis, then lower the chassis slowly to remove the problem.

* If this problem occurs frequently it Defective suction valve

H-12. Blade goes down

1) Blade goes down when work equipment control lever is operated from HOLD to RAISE.
2) Blade goes down gradually when engine is stopped and work equipment control lever is at RAISE.

Remedy
Cause: Defective oil-tightness of check valve for lift control valve + C x l

20-83
H-13. Blade tilt lacks power, speed, impossible to push up chassis with tilt

Checks before troubleshooting


. Is oil level in hydraulic tank correct?
. Is stroke of work equipment lever and control
valve spool correct?
I Causes I

Checks for abnormalities

Yes Cause is a in toubleshooting


li%?‘re
11FH chart
No idling ? Carry out troubleshooting
according to troubleshooting
No chart

No. Remedyj c
Problems 1x1 lXlXlXl
When engine is run ai t high idling and blade is lifted to maximum height,
1 0 0 0
relief pressure is too IIDW 101 I
3 When engine is run at high idling and blade is lifted to maximum height,
0
relief pressure is normal
When engine is run at high idling and blade is lifted,
3 0
movement is not regular
When blade is moved to maximum left tilt, piping at head end of cylinder is removed,
4 and control lever is operated to left tilt with engine at low idling, oil comes out 0
from head end of cylinder (applicable to power angle, power tilt dozer)
When blade is moved to maximum right tilt, piping at bottom end of cylinder
5 is removed, and control lever is operated to right tilt with engine at low idling, 0
oil comes out from head end of cylinder (applicable to straight tiltdozer)

6 Discharge amount of hydraulic pump is too low 0 0

, When control lever is operated, speed is slow, but circuit pressure


0
is too high

Hydraulic tester
Troubleshooting
tools
Flowmeter kit
H-14. Blade cannot be tilted

Ask the operator the following


.
questions.
Did the problem start suddenly?
I Causes I

Pump Control valve linder S”‘enoid E’ectrica’


Yes = Parts seized, broken
. Was any abnormal sound heard when this hap- ///
pened? Where did the sound come from?
Yes = Parts broken
. Had there been any symptoms before (drop in
speed, etc.)?
Yes = Parts worn, spring deteriorated

Checks before troubleshooting


. Is oil level in hydraulic tank correct?
. Is stroke of. work equipment lever and control
valve spool correct?

No.

When piping is removed from side of tilt cylinder to which tilting is


impossible, and control lever is operated to side to which tilting is
impossible with engine at low idling, oil comes out from side to which
tilting is impossible but cylinder does not move
When there is load, discharge amount of hydraulic pump is
0 0
almost zero

Tilt and angle do not work, but lift is normal 0

Tilt does not work, but angle is normal 0 0 0

Hydraulic tester X: Replace n: Repair


Troubleshooting
tools A: Adjust C: Clean
Flowmeter kit
H-15. Excessive hydraulic drift of blade tilt

Ask the operator the following


. Did the problem
questions.
star-t suddenly?
I Causes I
,ontrol
linder
Yes = Parts broken valve
pi
. Did this problem gradually become worse?
Yes = Parts worn

Checks before troubleshooting


. When rod of work equipment control lever is
disconnected at control valve end, does hydrau-
lic drift come within standard value?
Yes = Rod bent, twisted, or other defect

Checks for abnormalities


. Use the STANDARD VALUE TABLE to check that
the hydraulic drift when the blade is tilted is actu-
ally excessive.

I I I
Remedy a A
No. X
Problems \_x x

When blade is moved to maximum left tilt, piping at head end of cylinder is removed,
1 and control lever is operated to left tilt with engine at low idling, oil comes out from head end 0
of cylinder (applicable to power angle, power tilt dozer) I I I

When blade is moved to maximum right tilt, piping at bottom end of cylinder is removed,
2 and control lever is operated to right tilt with engine at low idling, oil comes out from head 0
end of cylinder (applicable to straight tiltdozer) ’ I I
-
3 Same as in items 1 and 2, but no oil comes out lolol
-

X: Replace A: Repair
A: Adjust C: Clean
H-16. Blade angle lacks power, speed (applicable to power angle, power tilt dozer)

Checks before troubleshooting


. Is oil level in hydraulic tank correct?
. Is stroke of work equipment lever and control
valve spool correct?

Checks for abnormalities


Causes
YES
Normal

Carry qut troubleshooting,


;;cc&rdmg to troubleshootmg

;;w~ is a in toubleshooting
normal I I I Is relief oressurel I
H
?

Carry gut troubleshooting,


.a;atirdlng to troubleshootmg

* This troubleshooting chart shows lack of power


for angling to the right; in the case of lack of
power for angling to the left, read “left” for
“right”, and “right” for “left”.

Hydraulic tester
Troubleshooting
tools
Flowmeter kit
H-17. Blade cannot be angled
(applicable to power angle tiltdozer)

Ask the operator the following questions.


. Did the problem start suddenly?
Yes = Parts seized, broken
. Was any abnormal sound heard when this hap-
pened? Where did the sound come from?
Yes = Parts broken
. Had there been any symptoms before (drop in
speed, etc.)?
Yes = Parts worn, spring deteriorated

Checks before troubleshooting


. Is oil level in hydraulic tank correct?
. Is stroke of work equipment lever and control
valve spool correct?

engine is cranked, no oil comes out


When engine is run at high idling, there is almost no
rise in the blade anale circuit
3 WhFn engine is run at high idling and blade is raised to
maximum height, there is almost no rise in relief pressure 0 0

4 When engine is run at high idling and blade is raised to


maximum height, relief pressure is normal
When piping at bottom end of right angle cylinder is removed,
5
and control lever is operated to right angle with engine at low
idling, oil comes out from bottom end of right angle cylinder
but cylinder does not move

When piping at bottom end of left angle cylinder is removed,


II
4-L
and control lever is operated to left angle with engine at low
6 idling, oil comes out from bottom end of left angle cylinder
but cylinder does not move
When there is load, discharge amount of hydraulic
7 0
DumD is almost zero

8 1Tiltandan g Ie d o not work, but angle is normal I I I


9 Angle does not work, but tilt is normal

Hydraulic tester
Troubleshooting
toois
Flowmeter kit
H-18. When blade is angled, blade returns to straight position or shakes during operations
(control lever at HOLD)

Checks before troubleshooting


. Is oil level in hydraulic tank correct?
. Is stroke of work equipment lever and control
valve WOOI correct?

Remedy
No.
Problems

When blade is set to maximum right angle,.piping at bottom end of right angle cylinder is
removed, and control lever is operated to right angle with engine at low idling,
oil comes out from bottom end of right angle cylinder
When blade is set to maximum left angle, and piping at bottom end of left angle cylinder is

m
2 removed, and control lever is operated to left angle with engine at low idling,
oil comes out from bottom end of left angle cylinder

3 Oil comes out for both Items 1 and 2 0 0

4 Oil does not come out for either Item 1 or 2 0


H-19. Lift arm lacks lifting power, speed

Checks before troubleshooting


. Is oil level in hydraulic tank correct?
. Is stroke of work equipment lever and control
valve spool correct?

Checks for abnormalities


Normal

Carry qut troubleshooting,


;g;;drdlng to troubleshootmg

Cause is a in toubleshooting
chart

Carry out troubleshooting


IL according to troubleshooting
No chart

Hydraulic tester X: Replace A: Repair


Troubleshooting
tools A: Adjust C: Clean
Flowmeter kit

20690
H-20. Impossible to raise lift arm, impossible to raise chassis

Ask the operator the following questions.


. Did the problem start suddenly?
I Causes I

Yes = Parts seized, broken


. Was any abnormal sound heard when this hap-
pened? Where did the sound come from?
Yes = Parts broken
. Had there been any symptoms before (drop in
speed, etc.)?
Yes = Parts worn, spring deteriorated

Checks before troubleshooting


. Is oil level in hydraulic tank correct?
. Is stroke of work equipment lever and control
valve spool correct?

Checks for abnormalities


. Relief pressure

Troubleshooting
Hydraulic tester X: Replace n: Repair
tools A: Adjust C: Clean
Flowmeter kit

20-9 1
H-21. Excessive hydraulic drift of lift arm

Ask the operator the following questions.


. Did the problem start suddenly?
Yes = Dirt caught in valve, parts broken
. Did this problem gradually become worse?
Yes = parts worn

Checks before troubleshooting


. When rod of work equipment control lever is dis-
connected at control valve end, does hydraulic
drift come within standard value?
Yes = Rod bent, twisted, or other defect

Checks for abnormalities


. Use the STANDARD VALUE TABLE to check that
the hydraulic drift of the lift arm is actually ex-
cessive.

No.
Problems

1 When lift arm is raised to maximum height, piping at head end of cylinder is removed, and control lever is
operated to RAISE with engine at low idling, oil comes out from head end of cylinder 0

2 As in Item 1, but no oil comes out 0

3 Condition returns to normal when top and bottom suction valves are interchargeed 0

X: Replace 0: Repair
A: Adjust C: Clean

20-&92
H-22. Bucket tilt back lacks power, speed

Checks before troubleshooting


. Is oil level in hydraulic tank correct?
. Is stroke of work equipment lever and control
valve spool correct?
I Causes I
Checks for abnormalities

I ,ye: Normal

Bfly$ g$?“‘“/-o Ca;: out troubleshooting


according to troubleshooting

No 1 idling ? 11 Carry out troubleshooting


according to troubleshooting
No chart

Remedy a fI c
No. C x E X
Problems X x x x
When engine is run at high idling and lift arm is raised to maximum height,
1 0 0 0
relief pressure is too low
3 When engine is run at high idling and lift arm is raised to maximum height,
relief pressure is normal 0 0

3 Hydraulic pump generates abnormal noise 0

When bucket is tilted back to maximum, piping at bottom end of


4 dump cylinder is removed, and control lever is operated to tilt back with 0
engine at low idling, oil comes out from bottom end of cylinder

5 Discharge amount of hydraulic pump is too low 0 0

6 Lift arm speed is normal 0

When control lever is operated, bucket tilt back speed is slow,


7 0
but circuit pressure is too high

Hydraulic tester

ITroubleshooting
tools
Flowmeter kit

20-93
H-23. Impossible to tilt back bucket

Ask the operator the following questions.


. Did the problem start suddenly? I Causes I

Yes = Parts seized, broken


. Was any abnormal sound heard when this hap-
pened? Where did the sound come from?
Yes = Parts broken
. Had there been any symptoms before (drop in
speed, etc.)?
Yes = Parts worn, spring deteriorated

Checks before troubleshooting


. Is oil level in hydraulic tank correct?
. Is stroke of work equipment lever and control valve
spool correct?

1 Remedy
No.
Problems -
When plug is removed from pressure pickup port and engine is cranked,
1 0
no oil comes out

2 When engine is run at high idling, there is almost no rise in the bucket tilt back circuit 0 0 0 0

1When engine is run at high idling and lift arm is raised to maximum height,
0 0
re is almost no rise in relief pressure
en engine is run at high idling and lift arm is raised to maximum height,
sf pressure is normal 0 0

en piping at bottom end of dump cylinder is removed, and control lever is operated to tilt
5 0
back with engine at low idling, oil comes out from bottom end but cylinder does not move

6 When there is load, discharge amount of hydraulic pump is almost zero 0

Hydraulic tester
Troubleshooting
tools
Flowmeter kit
H-24. Impossible to dump bucket, impossible to raise chassis with dump cylinder

Checks before troubleshooting


. Is oil level in hydraulic tank correct?
. Is stroke of work equipment lever and control
valve spool correct?

Go to H-22. Bucket
tilt back lacks power,

Hydraulic tester
Troubleshooting X: Replace n: Repair
tools
Flowmeter kit A: Adjust C: Clean
H-25. Bucket dump speed is slow

Checks before troubleshooting


. Is oil level in hydraulic tank correct?
. Is stroke of work equipment lever and control
valve spool correct?
I Causes I

Checks for abnormalities Tank - Pump Control valve

abcdefg

m[[v[ ,iIut troubleshooting


according to troubleshooting

Yes Et;? is a in toubleshooting

figi$q[ Carry out troubleshooting


according to troubleshooting
No chart

-I
No. ’ c x c X
Problems X x x x
. When enaine is run at hiat 1 idling and lift arm is raised to maximum height,
0 0 0
’ relief pressure is too low-
When engine is run at high idling and lift arm is raised to maximum height,
2 0 0
relief pressure is normal

3 Hydraulic pump generates abnormal noise 0

When bucket is dumped to maximum, piping at head end of dump cylinder


4 is removed, and control lever is operated to dump with engine at low idling, 0
oil comes out from head end of cvlinder

5 1 Discharge amount of hydraulic pump is too low IololIIIl


6 1 Lift arm speed is normal I I I Id I
I
71 When control lever is operated, bucket dump speed is slow,

but clrcult oressure is too hiah I I lol I I I

Hydraulic tester X: Replace n: Repair


Troubleshooting
toois A: Adjust C: Clean
Flowmeter kit
H-26. Excessive hydraulic drift of bucket dump circuit

Ask the operator the following questions.


. Did the problem start suddenly? I Causes I
Yes = Dirt caught in valve, parts broken
. Did this problem gradually become worse?
Yes = Parts worn

Checks before troubleshooting


. When rod of work equipment control lever is
disconnected at control valve end, does hydrau-
lic drift come within standard value?
Yes = Rod bent, twisted, or other defect

Checks for abno,rmalities


. Use the STANDARD VALUE TABLE to check that
the hydraulic drift of the bucket is actually exces-
sive.

Remedy a C x
No.
Problems x x
When bucket is tilted back to maximum, piping at bottom end of dump cylinder is removed, and control
1 lever is operated to tilt back with engine at low idling, oil comes out from bottom end of dump cylinder
0

2 As in Item 1, but no oil comes out

3 Condition returns to normal when top and bottom suction valves are interchanged 0

20-97
H-27. Bucket moves up and down along ground surface during leveling operations, but lift arm
moves irregularly (control lever at HOLD)

Troubleshooting and causes


. Measure hydraulic drift of lift arm.
If it exceeds standard value
+ Go to H-21. Excessive hydraulic drift of lift arm.
If it is within standard value
+ There is a vacuum inside the cylinder
+ Use the lift arm (lift cylinder) to raise the chassis, then lower the chassis slowly to remove the
problem.
* If this problem occurs frequently
+ Defective suction valve

H-28. Lift arm goes down

1) Lift arm goes down for a moment when work equipment control lever is operated from HOLD to RAISE.
2) Lift arm goes down gradually when engine is stopped and work equipment control lever is at RAISE.
Cause: Defective sealing of check valve for bucket lift control valve + Remedy: C -x

H-29. Bucket moves irregularly during leveling operations (control lever at HOLD)

Troubleshooting and causes


. Measure hydraulic drift of bucket dump.
If it exceeds standard value
+ Go to H-26. Excessive hydraulic drift or bucket dump. %
:
If it is within standard value 0

+ There is a vacuum inside the cylinder


+ Use the bucket (dump cylinder) to raise the chassis, then lower the chassis slowly to remove
the problem.
* If this problem occurs frequently
+ Defective suction valve in dump circuit

H-30. Bucket dumps

1) Bucket dumps for a moment when work equipment control lever is operated from HOLD to TILT BACK.
2) Bucket goes down gradually when engine is stopped and work equipment control lever is at TILT BACK.
Cause: Defective sealing of check valve for bucket dump control valve + Remedy: C - x

H-31. When bucket is dumped to maximum, it is impossible to raise lift arm

Cause: Defective opening valve of safety valve in dump circuit -+ Remedy: C l x

X: Replace & Repair


A: Adjust C: Clean
H-32. Work equipment control levers are heavy

Checks for abnormalities


. Use the STANDARD VALUE TABLE to check that
the operating force for levers is actually too great.

Remedy A A A
No. X x x
Problems X x x

1 Levers are heavy when oil pressure is high 0

2 Levers are heavy when oil temperature is high 0

Levers are sometimes heavy when operated, regardless of oil pressure or 0


3
temperature
Levers are always heavy when operated, regardless of oil pressure or 0
4
temperature
30 DISASSEMBLY AND ASSEMBLY

METHOD OF USING MANUAL . . . . . . . . .. .. . . . . . . .. . 30-3 MODULATING VALVE


PRECAUTIONS WHEN CARRYING OUT Disassembly .......................................... .30-54
OPERATION . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . . .. . .. . . .. . .. . . . 30-4 Assembly ................................................ 30-55
SPECIAL TOOL LIST .._............................... 30-5-I SELECTOR AND INCHING VALVE
STARTING MOTOR Removal and Installation .................... 30-56
Removal and Installation . . .. .. . . . . . .. . . . .. . .. . 30-6 Disassembly ........................................... 30-57
ALTERNATOR Assembly ................................................ 30-58
Removal and Installation . . .. . .. . . . . . .. . . .. . 30-7-I MAIN RELIEF VALVE
ENGINE OIL COOLER CORE Removal and Installation .................... 30-59
Removal and Installation . .. . .. . . . . . .. . . . .. . 30-7-3 STEERING PPC VALVE
FUEL INJECTION PUMP Removal and Installation .................... 30-60
Removal and Installation . .. . .. . . . . . .. . . . .. . .. . 30-8 Disassembly and Assembly.. ............... .30-61
WATER PUMP STEERING CLUTCH
%
Removal and Installation . ..._............... 30-10 Removal .................................................. 30-62
:
0 THERMOSTAT Installation .............................................. 30-64
Removal and Installation . .._............. 30-10-2 Disassembly ........................................... 30-65
NOZZLE HOLDER Assembly ................................................ 30-67
Removal and Installation . .. . . . . . .. . .. . . . . . .. 30-12 BEVEL GEAR SHAFT AND BEVEL GEAR
TURBOCHARGER Removal .................................................. 30-70
Removal and Installation . . .. .. . . . . . . .. . . . 30-13-2 Installation .............................................. 30-73
CYLINDER HEAD FINAL DRIVE FIRST PINION
Removal and Installation . .. . . .. . . . . . .. . . .. . . 30-14 Removal and Installation .................... 30-77
RADIATOR GUARD FINAL DRIVE
Removal . . . . . .. .. . . . . . .. . .. . . . . . .. . . .. . . . . . . .. . . . . . . .. . .. . 30-I 6 Disassembly ........................................... 30-79
Installation . .. . . . . . .. . . . . . . . .. . . . . . . . .. . .. . . . . . .. . . .. . . . . 30-17 Assembly ................................................ 30-82
RADIATOR TRACK FRAME
Removal .. . . . . . .._........................................ 30-18 Removal and Installation ..................... .30-87
Installation . .. . . . . . .. .. .. . . . . .. . . . . .. . . . . .. . . . . . . .. .. . . . . 30-19 RECOIL SPRING
RADIATOR RADIATOR GUARD
l Removal and Installation ..................... .30-89
Removal . .. . . . . . .. . . .. . . . . . .. . . . . . . . . .. . . . . . .. . . . . . . .. . 30-19-I Disassembly ........................................... 30-91
Installation . .. . .._.................................... 30-19-4 Assembly ................................................ 30-92
ENGINE IDLER
Removal and Installation . . . . . . .. . . . . . .. . .. . . 30-20 Removal and Installation ..................... .30-93
DAMPER Disassembly ........................................... 30-94
Removal and installation . . . . . . .. . . . . . . .. . .. . . . 30-22 Assembly ................................................ 30-96
HYDROSHIFT TRANSMISSION CARRIER ROLLER
Removal . .. . .. . . .. . . .. . . . . . .. . . . . . . . . . .. . . . . .. . . .. . . .. . .. . 30-24 Removal and Installation ..................... .30-98
Installation . .. . . . . . . . . . .. . . . . . . .. . . .. . . . . .. . . . . . .. . .. . . . . 30-26 Disassembly ........................................... 30-99
Disassembly .. . . . . . .. . . .. . . . . . . .. . . . . . . . . .. . . . . . . .. . .. . 30-27 Assembly .............................................. 30-100
Assembly .. . . . . . . . . . . .. . . . . . .. . .. . . .. .. . . . . . .. .. . . . . . . . . . 30-39 TRACK ROLLER
MODULATING VALVE AND PUMP Removal and Installation ................... .30-101
Removal and Installation . . .. . .. . . . . . . .. . .. . . 30-53 Disassembly ........................................ .30-102
Assembly .............................................. 30-103

30-l
0
TRACK SHOE BUCKET DUMP CYLINDER
Removal and Installation . . .. . .. . . . . . . .. . .. . . 30-105 (D31S, Q-20) . . . . . . .. . . . . . . .. . .. . . . . . .. .. .. . . . . . . .. . . . 30-122
HYDRAULIC PUMP HYDRAULIC CYLINDER
Removal and Installation . . . . . . . . .. .. . . . . . .. . 30-I 06 Disassembly . .. . . . . . . . . .. . . . .. . . .. . .. . . . . . .. . . . . . . .. . 30-I 23
HYDRAULIC CONTROL VALVE Assembly .. . . . . . . .. .. . . . . . . . .. . . . . .. . .. . . . . . . . . .. . .. . . . 30-124
Removal and Installation . . .. . .. . . . . . . .. . .. . . 30-107 WORK EQUIPMENT
Disassembly and assembly . .. . .. . . . . . .. . . . 30-108 Removal and Installation
BLADE LIFT CYLINDER (D31 E, P-20, D31 P-20A,
Removal and Installation D37E-5, D37P-5A) . . . . . .. . . . . . . . .. . .. . . . . . . . 30-I 26
(D31 E, P-20, D31 P-20A, (D31 PL, PLL-20) . . .. .. . . . . . . . . .. .. . . . . . . .. .. . 30-127
D37E-5, D37P-5A) . . .. . .. . . . . . .. . . . . . . . . . ...30-116 BLADE
(D31PL, PLL-20) . .. . .. . . . . . .. . . . . . . . .. .. . . . . . 30-117 Removal and Installation
BLADE TILT CYLINDER (D31E, P-20, D31P-20A,
Removal and Installation D37E-5, D37P-5A) . . .. . .. . . . . . .. . . .. . . . . . .. . 30-128
(D31 E, P-20, D31 P-20A, (D31 PL, PLL-20) . . .. .. . . .. . . .. . . . . . .. . .. . . . . . 30-129
D37E-5, D37P-5A) . . . . . . . . .. .. . . . . . . . .. . ....30-118 WORK EQUIPMENT
(D31 PL, PLL-20) . . . . . . .. . . .. . . . . . .. .. . . . . . ...30-119 Removal and Installation
BLADE ANGLE CYLINDER (D31 S, Q-20) . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . .. 30-130
Removal and Installation BUCKET
(D31 E, P-20, D31 P-20A, Removal and Installation
D37E-5, D37P-5A) . .. . . . . . . . .. . . . . . . .. . . . . . . 30-120 (D31S, Q-20) . . . . . . . . .. .. . . . . . . .. . . . . . . .. .. .. . 30-131
BUCKET LIFT CYLINDER OPERATOR’S SEAT FRAME
Removal and Installation Removal . . . . . . . .. . . .. . . . . . .. . . . . . . .. . .. . . . . . .. . . . .. . .. . . 30-132
(D31 S, Q-20) . .. . .. . . . . . . . .. . . . . . .. . . .. . . . . . .. 30-121 Installation . .. . . . . . .. . .. . . . . .. . . . . . . . .. . .. . . . . . . .. . . .. . 30-133

%
z
0

30-2
a
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL

METHOD OF USING MANUAL

1. When removing or installing unit assemblies


@ When removing or installing a unit assembly, the order of work and techniques used are given
for the removal operation; the order of work for the installation operation is not given.
@ Any special techniques applying only to the installation procedure are marked m, and the
same mark is placed after the relevant step in the removal procedure to indicate which step in
the installation procedure it applies to.

(Example)
REMOVAL OF 0 0 0 0 ASSEMBLY . . . . . . . .. . .. Title of operation
g . . .. .. . . . . . . . .. . . . . . .. . .. . . . . . . .. . . . . . . . . . .. . . . . . . .. .. . . . . . . .. . . . . . . .. Precautions related to safety when carrying out
the operation
1. XXXX(1) . . . . . .. . . . . . . .. . .. . . . . . . . .. . . . . .. . .. . . . . . . .. . . . . . . . . . Stepinoperation
* . .. . . . .._.......................................................... Technique or important point to remember
when removing XXXX (I).
2. n a n n (2): .. . . . . . . . . . .. . . . . . . .. . . .. . . . . . . .. . .. . .. . .. . . . . . m Indicates that a technique is listed for use
during installation
3. 0 0 0 0 assembly (3)

.................................. .................. ........ Quantity of oil or water drained

INSTALLATION OF 0 0 0 0 ASSEMBLY . . ..Title of operation


l Carry out installation in the reverse order to removal.
a . .. . .. . . . . . . .. . . . . . . .. .. . . . . . .. . . . . . . . .. .. . . . . . . . .. . .. . . . . . . .. Technique used during installation
* . . . . . . .. . . . . . . .. . .. . . . . . . .. . . . . . .. .. . . . . . . . .. . . . . . . . . . .. . . . . . . .. . .. Technique or important point to remember when
installing n n a a (2).
. Adding water, oil . . .. . . .. . . . . . . .. . .. . . . . . .. . . . . . . . Step in operation
* .. . . . . . . . . .. . . . . . . . . .. . .. . . . . . . .. . . . . . .. . . .. . . . . . . .. . . . . . . .. Point to remember when adding water or oil

%2...................... .............................. ..... Quantity when filling with oil and water

2. General precautions when carrying out installation or removal (disassembly or assembly) of units
are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow
these precautions when carrying out the operation.

3. Listing of special tools


@ For details of the description, part number, and quantity of any tools (Al, etc.) that appear in
the operation procedure, see the SPECIAL TOOLS LIST given in this manual.

30-3
a
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION

PRECAUTIONS WHEN CARRYING OUT OPERATION


[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the
general precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
. If the coolant contains antifreeze, dispose of it correctly.
. After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from
entering.
. When draining oil, prepare a container of adequate size to catch the oil.
. Confirm the match marks showing the installation position, and make match marks in the neces-
sary places before removal to prevent any mistake when assembling.
. To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors. Do not pull the wires.
. Fit wires and hoses with tags to show their installation position to prevent any mistake when
installing.
. Check the number and thickness of the shims, and keep in a safe place.
. When raising components, be sure to use lifting equipment of ample strength.
. When using forcing screws to remove any components, tighten the forcing screws uniformly in
turn.
. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt
from entering after removal.
* Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Hoses and tubes using sleeve nuts

Nominal
number I
Plug (nut end)
I Sleeve nut (elbow end) Use the two items below as a set

02
03 07376-50210
07376-50315 07221-20210
07221-20315 (Nut),
(Nut), 07222-00210
07222-00312 (Plug)
(Plug) %
04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug) z
0
05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)
06 0737650628 07221-20628 (Nut), 07222-00616 (Plug)
IO 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)

2) Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-l 0400 0737 I-30400
05 07379-00500 07378-10500 0737 I-30500

3) If the part is not under hydraulic pressure, the following corks can be used.

n
a

43 I-
Taper l/8

L
-I
m
a

30-4
0
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION

2. Precautions when carrying out installation work


. Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
. Install the hoses without twisting or interference.
. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
. Bend the cotter pins and lock plates securely.
. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded
portion with 2 - 3 drops of adhesive.
. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there
is no dirt or damage, then coat uniformly with gasket sealant.
. Clean all parts, and correct any damage, dents, burrs, or rust.
. Coat rotating parts and sliding parts with engine oil.
. When press fitting parts, coat the surface with anti-friction compound (LM-P).
. After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then
connect securely.
. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and
align the direction of the hook.
. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one
side.

* When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and
other hydraulic equipment removed for repair, always bleed the air as follows:
Start the engine and run at low idling.
Operate the work equipment control lever to operate the hydraulic cylinder 4 - 5 times,
stopping the cylinder 100 mm from the end of its stroke.
%
Next, operate the hydraulic cylinder 3 - 4 times to the end of its stroke.
z
0 After doing this, run the engine at normal speed.
When using the machine for the first time after repair or long storage, follow the same
procedure.

3. Precautions when completing the operation


. If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run
the engine to circulate the water through the system. Then check the water level again.
. If the hydraulic equipment has been removed and installed again, add engine oil to the specified
level. Run the engine to circulate the oil through the system. Then check the oil level again.
. If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
* For details, see TESTING AND ADJUSTING, Bleeding air.
. Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.

30-5
a
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST

SPECIAL TOOL LIST

* Tools with part number790T-000OOOOcannot be supplied (they are items to be locally manufac-
tured).
* Necessity: n : Cannot be substituted, should always be installed (used)
Ir 0: Extremely useful if available, can be substituted with commercially available part
sr New/remodel:N: Tools with new part numbers, newly developed for this model.
* R: Tools with upgraded part numbers, remodeled from items already available for
other models.
* Blank: Tools already available for other models, used without any modification.
* Tools marked 0 in the Sketch column are tools introduced in special sketches (See SKETCHES OF
SPECIAL TOOLS).

Component Symbol Nature of work,


Part No. Part Name rz$,,l Sketch
remarks
Removal of cylinder
head assembly (%) Al 795-799-l 130 Gear n 1 Barring
Installation of cylinder Tightening of cylinder
head assembly CX) A4 790-31 l-l 1 IO Wrench n 1
head bolt
I
Al 795-799-l 130 Gear n 1 Barring
Installation of fuel
injection pump
assembly (%+I

Removal of nozzle 1 . 1 , 1 1 E,“llfrnyal of nozzler


holder assembly (x+) J 1 795-799-1170 1 Puller

Disassembly and
Operational check of
assembly of Oil leak tester ’ ’ %
A 790-301-1600 A HYDROSHIFT trans-
HYDROSHIFT trans-
mission assembly n 1 mission clutch piston Z
0

791-431-5000 Compressor n 1

Disassembly and 790-101-1102 Pump n 1


Compression of clutch
assembly of steering A
Puller (294 kN . 1 spring
clutch assembly 790-101-2102 {30 ton))

I 790-201-2750 I Spacer 1~111 I I


Removal of steering
A 791-422-6000 Remover & n 1
mstaller clutch flange nut
Removal of steering
B 791-422-2001 Remover B n 1
clutch flange

Removal of bevel C 791-423-1501 Remover n 1 Removal of bevel gear


gear shaft and bevel shaft and taper bearing
gear assembly Cl 790-101-3201 Bearing puller n 1 inner race

Preload check of bevel gear


D 791-422-1300 Wrench n 1 shaft and taper bearing
$thering of bevel gear
E 791-423-1800 Centering tool n 1

6%): D31 E-20 Serial No. 42714 and up


D31P, PL-20 Serial No. 47617 and up
D31PLL-20 Serial No. 47653 and up
D31P-20A Serial No. 47617 and up
D31S, Q-20 Serial No. 41184 and up

30-5-l
a
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST

Component Symbo I Part No. Part Name rer$$el Sketch Nattrrm;;kyrk,

A 791-422-6000 Remover a w 1 Installation of steering


Installer clutch flange nut
B 791-440-4000 1 Installer B ImIll I I
Press-fitting of steering
Bl 790-101-I 102 Pump n 1 clutch flange
Installation of bevel
gear shaft and bevel Puller (294 kN , 1
B2 790-101-4200 {3o ton])
gear assembly
Insertion of bevel gear
C 791-422-1600 Seal guide H 1 shaft and oil seal gauge
I I
1 Adjustment of preload of bevel
D 791-422-1300 Wrench n 1

E 791-423-1800 Centering tool n 1

Removal of final drive A 791-422-6000 pemover


Installer & W 1
1st pinion assembly
B 791-422-2001 Remover B n 1

A 791-422-6000 Remover 8~
Installer n 1

Installation of final B 791-440-4000 Installer n 1


drive 1st pinion
assembly Bl 791-101-1102 1 Pump ImIll I ~Press-fitting of flange

790-101-4200 Puller
(30 (294 kN
ton)) . 1
B2
Removal of sprocket
A 791-522-7110 Socket H 1 end nut

Disassembly of final B 791-521-1002 Remover A n 1


drive assembly
Bl 790-101-1102 1 Pump 1w1/ I Removal of sprocket
Cylinder (686 n 1
82 790-101-1600 kN {70 ton))
I
Installation of sprocket
A 791-522-7110 Socket w 1 end nut
C 791-521-2001 Installer A n 1

IbIll -1
Assembly of final
drive assembly Cl 790-101-1102 1 Pump Press-fitting of sprocket
Cylinder (686 . 1
c2 790-101-1600 kN {70 tonj)

D Installation of floating
seal

Disassembly, assem-
bly of recoil spring A
790-101-1102 ( Pump IbIll 7 I

assembly Cylinder (686 H 1


790-101-1600 kN 170 tonj~

Assembly of track Oil leak check and


roller assembly B refilling oil
Disassembly of A 790-502-I 003 (&lcdder repair . 1
hydraulic cylinder l

assembly B 790-330-I 100 Wrench w 1

30-5-2
0
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST

Assembly of hydraulic
cylinder assembly

30-5-3
a
DISASSEMBLY AND ASSEMBLY STARTING MOTOR

REMOVAL OF STARTING
MOTOR ASSEMBLY

D31E-20 Serial No.: 42001 - 42713


D31P, PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660

ADisconnect the cable from the negative (-) terminal


of the battery. -4 /
Il4FO2105

1. Remove cover of engine left side.

2. Disconnect fuel control cable (1). m

3. Disconnect engine stop motor cable (2) together


with bracket (3). a

4. Disconnect starting motor wiring (4) and (5).

5. Remove starting motor assembly (6).

INSTALLATION OF STARTING
MOTOR ASSEMBLY
D3 1 E-20 Serial No.: 42001 - 42713
D3lP, PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D3lS, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660

l Carrv out installation in the reverse order to removal.

p?iJ
* Adjust the control cable. For details, see TEST-
ING AND ADJUSTING, ADJUSTING FUEL CON-
TROL LEVER.

m
* Adjust the cable. For details, see TESTING AND
ADJUSTING, ADJUSTING ENGINE STOP MOTOR
CABLE.

30-6
a
DISASSEMBLY AND ASSEMBLY STARTING MOTOR

REMOVAL OF STARTING
MOTOR ASSEMBLY

D31E-20 Serial No.: 42714 and up


D31P, PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up

A Disconnect the cable from the negative (-) ter-


minal of the battery.

1. Remove right engine side cover.

2. Remove adiabatic plate (I).

3. Disconnect terminal B (STB) (2) and terminal C


(l-pin connector) (3). 0

4. Remove starting motor assembly (4). m

$
rr
5 INSTALLATION OF STARTING
0
MOTOR ASSEMBLY
D31E-20 Serial No.: 42714 and up
D31P, PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up

. Carry out installation in the reverse order to


removal.
CLPO2024

w Terminal B mounting nut:


17.64 2 1.96 Nm Il.8 + 0.2 kgmj

w Starting motor assembly mounting bolt:


42.95 t 5.98 Nm {4.38 f 0.61 kgm)

* Coat the whole circumference with 1.0 mm


of gasket sealant (LG-4) at a point 4 mm
from the inside of the starting motor gasket.

30-7
a
DISASSEMBLY AND ASSEMBLY ALTERNATOR

REMOVAL OF ALTERNATOR
ASSEMBLY

D31 E-20 Serial No.: 42001 - 42713


D31P. PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660

ADisconnect the cable from the negative (-) terminal of


the battery.

Remove cover of engine right side.

Disconnect wiring (1) from alternator.

Remove mounting bolt (2) of adjustment plate, then


loosen mounting bolt (3) and nut, and remove fan belt
(4). j

Remove mounting bolt and nut, then remove alterna-


tor assembly (5).

%
6

INSTALLATION OF
ALTERNATOR ASSEMBLY

D31E-20 Serial No.: 42001 - 42713


D31P, PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660

l Carry out installation in the reverse order to removal.

* Adjust the fan belt tension. For details, see


STANDARD VALUE TABLE FOR ENGINE RE-
LATED PARTS.

30-7-l
0
DISASSEMBLY AND ASSEMBLY ALTERNATOR

REMOVAL OF ALTERNATOR
ASSEMBLY
~2
D31 E-20 Serial No.: 42714 and up
D31P, PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up I’

a Disconnect the cable from the negative (-) ter-


minal of the battery.

1. Remove right engine side cover.


2. Loosen locknut (I) and remove bolt (2). (Revers-
ible fan specification) m

3. Using ratchet handle @(insertion angle: 9.5 mm),


raise tensioner (3) and remove fan belt (4).
g Be extremely careful not to get your fingers
caught between the tensioner and pulley
when removing the fan belt.

4. Remove terminal R (AIR) (5) and terminal B (ALB)


(6).
%
* The wiring at the R terminal is yellow. I
z ' CEO02251
0

5. Remove alternator assembly (7). a


* There are spacers installed to the mounting
bolts, so be careful not to lose them.

INSTALLATION OF
ALTERNATOR ASSEMBLY
D31E-20 Serial No.: 42714 and up
D31P. PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up --u-Ji - J / CEtl02252
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up

. Carry out installation in the reverse order to


removal.

Put the fan belt under tension from tensioner


(31, adjust bolt (2) so that clearance a between
bolt (2) and tensioner (3) is 0, then secure with
locknut (I).
m
w Alternator assembly mounting bolt:
42.95 + 5.98 Nm I4.38 + 0.61 kgm}
* Use a straight edge and check that the end
face of the alternator pulley is level with the
end face of the other pulleys.
30-7-2
a
DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER CORE

REMOVAL OF ENGINE OIL


COOLER CORE ASSEMBLY

D31E-20 Serial No.: 42714 and up


D31P, PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up

1. Remove alternator assembly.


For details, see REMOVAL OF ALTERNATOR AS-
SEMBLY.

2. Disconnect turbocharger lubrication hose (I).


Ir Disconnect at the engine oil cooler end.

3. Remove oil filter (2). a

4. Remove cooler cover assembly (3). a

5. Remove cooler core (4) from oil cooler cover


assembly.

INSTALLATION OF ENGINE OIL


COOLER CORE ASSEMBLY
D31E-20 Serial No.: 42714 and up
D31P, PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up

l Carry out installation in the reverse order to


removal.

w Oil filter:
13.04 z 1.96 Nm {I.33 2 0.2 kgm}

w Oil cooler assembly mounting bolt:


24.03 f 4.02 Nm (2.45 = 0.41 kgm}

30-7-3
a
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP

REMOVAL OF FUEL INJECTION


PUMP ASSEMBLY

D31E-20 Serial No.: 42001 - 42713


D31P, PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660

1. Remove cover of engine left side.

2. Disconnect fuel control cable (1) and engine stop


motor cable (2). m

3. Disconnect fuel supply hose (3) and fuel hoses (4).


* Fit a blind plug in supply hose (3) to prevent
fuel from leaking out.

4. Remove lubrication tube (5).

5. Disconnect 6 fuel injection pipes (6). m

6. Remove bracket (7), then remove fuel injection


pump assembly (8). m

I Il4FO2108

30-8
0
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP

INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY

D31 E-20 Serial No.: 42001 - 42713


D31 P, PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S. Q-20 Serial No.: 41001 - 41183
D31 P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660

. Carry out installation in the reverse order to removal.

m
* Adjust the cables. For details, see TESTING AND
ADJUSTING, ADJUSTING FUEL CONTROL LEVER
and ADJUSTING ENGINE STOP MOTOR CABLE.

m Sleeve nut:
22.06 z 2.45 Nm (2.25 = 0.25 kgm)

m
. Install the fuel injection pump as follows.
1) Set No. 1 cylinder at compression top dead center.
+ Rotate the crankshaft in the normal direction
and align the pointer with the 1.6 TOP line 014OF107
on the crankshaft pulley. If the match mark
on the idler gear cannot be seen, rotate the
crankshaft one more turn.
2) Replace with bolt @ and fix drive gear (11) in
position.
3) Injection pump assembly
+ Insert pin @ (0 4.0 - 4.5 mm, length = approx.
100 mm) through cover mounting bolt hole
a, and check that the pin enters the casting
hole in the drive gear smoothly.
4) Remove bolt 0, and replace it with a standard
bolt.
. Adjust the fuel injection timing and bleed the air from
the fuel system. I I4FO2 109
For details, see TESTING AND ADJUSTING.

il4FO21 IO
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP

REMOVAL OF FUEL INJECTION


PUMP ASSEMBLY

D3 1 E-20 Serial No.: 42714 and up


D31P, PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up

1. Drain fuel from fuel tank.

2. Remove engine left cover.

3. Remove hydraulic pump assembly.


For details, see REMOVAL OF HYDRAULIC PUMP
ASSEMBLY.

4. Disconnect rod (1) of engine stop solenoid.


* Disconnect at the fuel injection pump end.

5. Disconnect 2 wires (2) and remove engine stop


solenoid (3). a
* Be careful not to drop the spacer.

6. Remove delivery tubes (4).

7. Disconnect fuel tubes (5), (61, and (7), fuel hose


(8), and lubrication tube (9). a

30-9- 1
0
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP

8. Remove cap (IO). a


* Use a filter wrench to remove.

9. Remove nut (11) and washer (12). m


* Be careful not to drop the nut or washer
inside the case.

CED02259

10. Using tool AZ, disconnect shaft and drive gear


of fuel injection pump.

CED02260

11. Remove sound absorbing material (13).

12. Remove fuel injection pump mount bracket (14).


m

13. Remove 4 nuts (151, then remove fuel injection


pump assembly (16). m

CED02262

30-9-2
a
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP

INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY

D31E-20 Serial No.: 42714 and up


D31P, PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up

l Carry out installation in the reverse order to


removal.

* Adjust the engine stop solenoid.


For details, see TESTING AND ADJUSTING,
Adjusting engine stop solenoid linkage.

Delivery tube sleeve nut:


24 + 4 Nm 12.45 + 0.41 kgm}

Fuel tube l-joint:


24 f 4 Nm 12.45 + 0.41 kgm}
Lubrication tube l-joint:
12 + 2 Nm Il.2 + 0.2 kgm}

Ir Turn the cap 180” to tighten it.

Ifmm
. Install the fuel injection pump assembly as
follows.
1) Loosen bolt, move plate (22) to the side,
then remove cap (23).

2) Using tool Al, crank the engine slowly in


the normal direction, and push No. 1 cylin-
der compression top dead center position-
ing pin (17) into the gear.

30-9-3
a
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP

* Refer to the following and push posi-


tioning pin (17) securely into the gear.
. Dimension a when free: 24 mm
. Dimension b when there is gear con-
tact: 20 mm
. Dimension c when pushed into gear
hole:16 mm
* When the positioning pin is pushed in,
stop barring the engine immediately (oth-
erwise, the positioning pin will break).
ET-l CED02263

3) Remove plug (19), then remove timing pin


(20).

4) Reverse the position of timing pin (19) 180”,


align the timing pin groove with pointer (21)
inside the pump, then temporarily tighten
plug (19).
* If the tooth of pointer (21) cannot be
aligned with the timing pin hole, rotate
the shaft of the fuel injection pump to
align the pointer tooth.

ii
CEP05301 CEP05302

5) Align fuel injection pump shaft with drive


gear and install fuel injection pump assem-
bly (16).

6) Tighten nut (15).


m Nut: 43 c 6 Nm (4.38 + 0.61 kgm}
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP

7) Install washer (121, and tighten nut (II).


-k Be extremely careful not to drop the nut
or washer inside the case when install-
ing.
w Nut: 12.5 t 2.5 Nm Il.27 + 0.25 kgm}
* This is not the final torque value.
* To prevent damage to the No. 1 cylinder
compression top dead center position-
ing pin, be careful not to tighten the nut
to more than the above tightening
torque.
CED02259
8) Remove meshing of No. 1 cylinder compres-
sion top dead center positioning pin (17).

CLPO2075

9) Remove plug (191, reverse mounting posi-


tion of timing pin (20), then assemble and
install plug to fuel injection pump.
m Plug: 14.7 Nm (1.5 kgm}

IO) Tighten drive gear mounting nut (I I) of fuel


injection pump fully.
w Nut: 95 + 10 Nm (9.7 + 1.02 kgm}

11) Carry out the rest of the installation in the


reverse order to removal.
CEP0530
* Adjust fuel injection timing.
For details, see TESTING AND ADJUSTING,
Adjusting fuel injection timing.

. Bleeding air
Sr Bleed the air from the fuel line.
For details, see TESTING AND ADJUSTING,
Bleeding air from fuel circuit.

30-9-5
a
DISASSEMBLY AND ASSEMBLY WATER PUMP

REMOVAL OF WATER PUMP


ASSEMBLY
D31 E-20 Serial No.: 42001 - 42713
D31P, PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660
1. Loosen radiator drain valve and drain cooling water.
2. Remove exhaust pipe (1) and left and right engine
side covers (2), disconnect reserve tank hose, then
remove engine hood (3).

& kg Engine hood assembly: 40 kg

3. Remove fan guard (4) and shroud (5).


4. Disconnect radiator hoses (6), (7) and wire (8) of
water temperature gauge sensor.
5. Loosen mounting bolt of adjustment plate, then
mounting bolt and nut, and remove fan belt (9) and
fan (IO).
6. Remove fan pulley (11). @J
7. Remove water pump assembly (12).

INSTALLATION OF WATER
PUMP ASSEMBLY
D31 E-20 Serial No.: 42001 - 42713 %
D31P, PL-20 Serial No.: 45001 - 47616 6
D31PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660
l Carry out installation in the reverse order to removal.
m
* Adjust the fan belt tension. For details, see
STANDARD VALUE TABLE FOR ENGINE RELA-
TED PARTS.
l Refilling with water
* Add water to the specified level from filler port,
and run the engine to circulate the water
through the system. Then check the water level
again.

30-10
0
DISASSEMBLY AND ASSEMBLY WATER PUMP

REMOVAL OF WATER PUMP


ASSEMBLY
D3 1 E-20 Serial No.: 42714 and up
D31P. PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S. Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up

1. Drain coolant.

2. Remove alternator assembly.


For details, see REMOVAL OF ALTERNATOR AS-
SEMBLY.

3. Remove water pump assembly (I). m

INSTALLATION OF WATER
PUMP ASSEMBLY
D31E-20 Serial No.: 42714 and up
D31P, PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up

. Carry out installation in the reverse order to


removal.

w Water pump assembly mounting bolt:


24.03 + 4.02 Nm 12.45 2 0.41 kgm}

. Refilling with water


Add water through the water filler to the speci-
fied level.
Run the engine to circulate the water through
the system. Then check the water level again.

30-l o-1
a
DISASSEMBLY AND ASSEMBLY THERMOSTAT

REMOVAL OF THERMOSTAT
D31 E-20 Serial No.: 42001 - 42713
D31P, PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660

1. Loosen radiatqr drain valve and drain cooling water.

2. Remove cover of engine right side.

3. Disconnect hose (I), and remove connector (2).

4. Remove thermostat (3).

INSTALLATION OF
THERMOSTAT
D31E-20 Serial No.: 42001 - 42713
D31P. PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660

l Carry out installation in the reverse order to removal.

l Refilling with water


* Add water to the specified level from filler port,
and run the engine to circulate the water
through the system. Then check the water level
again.

30- 1o-2
a
DISASSEMBLY AND ASSEMBLY THERMOSTAT

REMOVAL OF THERMOSTAT
ASSEMBLY
D3 1 E-20 Serial No.: 42714 and up
D31 P, PL-20 Serial No.: 47617 and up
D31 PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31 P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up

1. Drain coolant.

2. Remove alternator assembly.


For details, see REMOVAL OF ALTERNATOR
ASSEMBLY.

Disconnect hose (I I.

Disconnect radiator inlet port hose (2).

Remove alternator bracket (3).

Remove thermostat housing (4).

7. Remove thermostat (5).


%
z
0

INSTALLATION OF
THERMOSTAT ASSEMBLY
D3 1 E-20 Serial No.: 42714 and up
D31P, PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S. Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up

l Carry out installation in the reverse order to CEDO2280

removal.

m Alternator bracket mounting bolt:


24.03 2 4.02 Nm I2.45 + 0.41 kgm}

w Thermostat housing mounting bolt:


24.03 f 4.02 Nm I2.45 = 0.41 kgm}

. Refilling with water


* Add water through the water filler to the
specified level.
Run the engine to circulate the water through
the system. Then check the water level again.

30-l 1
a
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER

REMOVAL OF NOZZLE
HOLDER ASSEMBLY

D31 E-20 Serial No.: 42001 - 42713


D31P, PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660

1. Remove clamp (l), then disconnet fuel injection pipe


(2). m

2. Disconnect spill hose (3).

3. Remove the bolt, then remove nozzle holder assem-


bly (4). 133f
* When removing the nozzle holder assembly,
clean around the nozzle holder assembly and fit
a blind plug to prevent dust or dirt from enter-
ing.

F07 I27
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY

D31 E-20 Serial No.: 42001 - 42713


D31P, PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660

. Carry out installation in the reverse order to removal.

/I
w Sleeve nut:
22.06 t 2.45 Nm i2.25 + 0.25 kgml

/izJ
* When installing the nozzle holder assembly, check
the nozzle holder mount, and clean before install-
ing.

w Nozzle holder mounting bolt:


44.13 + 4.90 Nm (4.5 + 0.5 kgm}

30-12
0
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER

REMOVAL OF NOZZLE
HOLDER ASSEMBLY
D31 E-20 Serial No.: 42714 and up
D31P. PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up

1. Remove left engine side cover.

- CED02270
2. Remove air cleaner mounting bolts (2) and (3).
* Support the air cleaner with block 0.

3. Disconnect wiring (AS1 and AS2) (4).

4. Loosen 2 clamps (5), remove air duct (6) at air


cleaner end, then remove air cleaner assembly.

5. Remove air supply connector (8).


+ When removing the No. 3 nozzle holder as-
sem bly

6. Remove muffler bracket (9).


* When removing the No. 4 nozzle holder as-
sem bly

7. Remove 4 delivery tubes (IO). m

8. Remove spill tube (II). m


DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER

9. Loosen nut (12) and remove nozzle holder as-


sembly (13). m
* If it is difficult to remove the nozzle holder
assembly, use tool J to remove it.
* Be careful not to let dirt or dust get into the
nozzle holder assembly mount.

INSTALLATION OF NOZZLE
HOLDER ASSEMBLY

D3 1 E-20 Serial No.: 42714 and up


D31P, PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up

l Carry out installation in the reverse order to


removal.

w Fuel injection tube sleeve nut (nozzle


holder end):
30.01 +. 5.00 Nm I3.06 z 0.51 kgm}
w Fuel injection tube sleeve nut (fuel injec-
tion pump end):
24.03 z 4.02 Nm 12.45 + 0.41 kgm)
m Mounting bolt of fuel injection tube in-
termediate clamp:
24.03 2 4.02 Nm 12.45 +. 0.41 kgm}

w Spill tube joint bolt: 8.04 Nm IO.82 kgm}

w Nozzle holder mounting bolt:


60.02 + 8.92 Nm 16.12 + 0.91 kgm}
* When assembling the nozzle holder, clean
the nozzle holder mount, and check that there
is no dirt or dust inside the sleeve before
assembling.

30-l 3-l
a
DISASSEMBLY AND ASSEMBLY TURBOCHARGER

REMOVAL OF
TURBOCHARGER ASSEMBLY
D31E-20 Serial No.: 42714 and up
D31P, PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up

1. Remove left and right engine side covers.

2. Remove exhaust pipe (I).

3. Remove air cleaner mounting bolts (2) and


(3).
* Support the air cleaner with block 0.

4. Lift off engine hood (4).

Engine hood: 30 kg

5. Disconnect wiring (AS1 and AS2) (5).

30- 13-2
a
DISASSEMBLY AND ASSEMBLY TURBOCHARGER

6. Remove clamps (6) and (71, then remove air


cleaner assembly (8) together with intake hose.

7. Remove adiabatic plate (9).

8. Sling muffler assembly (IO).

9. Loosen clamp (II).

IO. Remove muffler assembly together with exhaust


connector (12).

&I kg Muffler assembly: 35 kg

11. Loosen clamp and move hose (13) towards in-


take connector. a

12. Disconnect lubrication inlet hose (14). a

13. Disconnect lubrication outlet tube (15). 113

30-13-3
0
DISASSEMBLY AND ASSEMBLY TURBOCHARGER

14. Remove bracket (161, then remove turbocharger


assembly (17). m

INSTALLATION OF
TURBOCHARGER ASSEMBLY

D31E-20 Serial No.: 42714 and up


D31P, PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
% D37P-5A Serial No.: 3661 and up
z
0
l Carry out installation in the reverse order to
removal.

w Hose clamp:
10.00 f 1.96 Nm Il.02 r 0.2 kgml

w Lubrication inlet hose:


35.30 f 4.90 Nm I3.6 z 0.5 kgm}

w Lubrication outlet tube mounting bolt:


24.03 f 4.02 Nm 12.45 z 0.41 kgm}

w Turbocharger mounting nut:


43.05 = 5.98 Nm 14.39 = 0.61 kgm1

30-13-4
a
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD

REMOVAL OF CYLINDER HEAD


ASSEMBLY

D31 E-20 Serial No.: 42001 - 42713


D31P, PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660

1. Remove water pump assembly.


For details, see REMOVAL OF WATER PUMP AS-
SEMBLY.

2. Remove exhaust manifold (1).

3. Disconnect wiring of air cleaner clogging sensor,


then remove air cleaner assembly (2).

4. Remove fuel filter assembly (3) from cylinder head.

5. Disconnect heater wiring (4).

6. Remove clamps (5), then disconnect 6 fuel injection


pipes (6). 1

7. Disconnect spill hose (7).

6. Remove nozzle holder assembly (8). m

9. Remove head cover (9). m

10. Loosen adjustment screw (10) 2 - 3 times, then


remove rocker arm assembly (11). i

11. Remove push rod (12).

12. Lift off’cylinder head assembly (13). m

&I kg Cylinder head assembly: 76 kg

30-14
a
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD

INSTALLATION OF CYLINDER
HEAD ASSEMBLY

D3 1 E-20 Serial No.: 42001 - 42713


D31P, PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660

. Carry out installation in the reverse order to removal.

m Sleeve nut:
22.06 t 24.52 Nm (2.25 2 0.25 kgml
a
w Nozzle holder mounting bolt:
44.13 + 4.90 Nm 14.5 L 0.5 kgm1

m
w Head cover mounting bolt:
8.83 z 0.98 Nm IO.9 z 0.1 kgm}

Check that the ball of the adjustment screw is


fitted properly into the socket of the push rod,
then tighten the rocker arm assembly.

w Rocker arm mounting bolt:


24.52 2 4.90 Nm (2.5 z 0.5 kgm)

Adjust the valve clearance.


For details, see TESTING AND ADJUSTING.

Make mark on idler


Check that the grommet does not come out
when installing the gasket, and install with the
stamped mark facing up.

& Head mounting bolt:


Anti-friction compound (LM-P)

w Cylinder head mounting bolt: I I 6215FOl43

1st step 1 68.6 2 9.8 Nm {7 5 1 kgm}


~~~9Nm{ll~O.5kgmI Order for tightening bolts

Make mark on bolt head and cylinder Exhaust side


head with a felt pen, then tighten

Rear

* After tightening, mark one punch mark on the


bolt head to indicate the number of times that Intake side
the bolt has been used.
l If any bolt has 5 punch marks, do not reuse
it. Replace it with a new bolt. 6206F401

30-l 5
a
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD

REMOVAL OF CYLINDER HEAD


ASSEMBLY
I
D3 1 E-20 Serial No.: 42714 and up
D31P, PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up

1. Remove hydraulic pump assembly.


For details, see REMOVAL OF WORK EQUIP-
MENT ASSEMBLY.

2. Set No. 1 cylinder to compression top dead


center.
For details, see INSTALLATION OF FUEL INJEC-
TION PUMP ASSEMBLY.

3. Remove left and right side covers.

4. Remove exhaust pipe (1).

5. Remove air cleaner mounting bolts (2) and (3).


* Support the air cleaner with block 0.

6. Lift off engine hood (4).

f?l ks Engine hood: 30 kg

7. Disconnect wiring (AS1 and AS2) (5).

30-l 5-l
a
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD

8. Remove clamps (6) and (71, then remove air


cleaner assembly (8) together with intake hose.

9. Remove adiabatic plate (9).

%
:
0

IO. Sling muffler assembly IO).


\ I I
11. Loosen clamp (II).

12. Remove exhaust connector (12) together with


muffler assembly.

&I kg Muffler assembly: 35 kg

13. Remove engine stop solenoid (13).


* Be careful not to drop the spacer.

14. Remove air supply connector (14).

15. Remove delivery tubes (15).

16. Remove fuel tube (16).

30-15-2
0
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD

17. Remove brackets (17) and (18).

18. Remove tube (19) and adiabatic plate (20).

19. Remove brackets (21) and (22).

20. Disconnect lubrication inlet hose (23). a

21. Disconnect lubrication outlet tube (24). m

22. Remove bracket (25).

23. Sling turbocharger and exhaust manifold assem-


bly (26), then remove mounting bolts, and re-
move. m

&I kg Turbocharger, exhaust manifold assem-


bly: 25 kg

30- 15-3
0
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD

24. Disconnect radiator inlet hose (27) at cylinder


head end.

25. Using ratchet handle @ (insertion angle: 9.5


mm), raise tensioner (28) and remove fan belt
(29).
a Be extremely careful not to get your fingers
caught between the tensioner and pulley
when removing the fan belt.

26. Loosen bolt (30), then remove bolt (31) and tip
alternator assembly (32) to outside. m

27. Remove spill tube (33). m

28. Remove nozzle holder assembly (34). m


DISASSEMBLY AND ASSEMBLY CYLINDER HEAD

29. Remove head cover (35).

30. Remove rocker arm assembly (36). m


* Loosen the locknut, then loosen the adjust-
ment screw 2 - 3 turns.

31. Remove push rod (37).

32. Remove mounting bolts of cylinder head in or-


der shown in diagram on right. m

30-15-5
a
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD

33. Lift off cylinder head assembly (38).

elkg Cylinder head assembly: 40 kg 38

34. Remove cylinder head gasket (39). m

39

I \

I CED02294

30-15-6
a
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD

INSTALLATION OF CYLINDER
HEAD ASSEMBLY
D31E-20 Serial No.: 42714 and up
D31P, PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up

. Carry out installation in the reverse order to


removal.

* Adjust the engine stop solenoid.


For details, see TESTING AND ADJUSTING,
Adjusting engine stop solenoid linkage.

m Air supply connector mounting bolt:


24.03 2 4.02 Nm I2.45 2 0.41 kgm}

m
m Nozzle holder sleeve nut:
30.01 + 5.00 Nm j3.06 L 0.51 kgm}
m Fuel injection pump sleeve nut:
24.03 2 4.02 Nm I2.45 = 0.41 kgm}
m Intermediate clamp mounting bolt:
24.03 2 4.02 Nm I2.45 + 0.41 kgm}

m Fuel tube l-joint:


24.52 2 4.90 Nm 12.5 + 0.5 kgm}

m Lubrication inlet hose:


35.30 + 4.90 Nm 13.6 = 0.5 kgm}

116
m Lubrication outlet tube mounting bolt:
24.03 2 4.02 Nm 12.45 2 0.41 kgml

Tighten the mounting bolts in the order shown


in the diagram on the right.
m Turbocharger, exhaust manifold assem-
bly mounting bolt:
43.05 f 5.98 Nm j4.39 = 0.61 kgm1

CED02295

30-15-7
0
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD

w Alternator assembly mounting bolt:


42.95 I 5.98 Nm j4.38 f 0.61 kgm1

w Spill tube l-joint:


24.52 + 4.90 Nm I2.5 = 0.5 kgm)

w Nozzle holder assembly:


60.90 + 8.92 Nm I6.21 + 0.91 kgm}

w Head cover mounting bolt:


24.03 + 4.02 Nm I2.45 + 0.41 kgm}

. Install the rocker arm assembly and cylinder


head assembly as follows.

* Check that there is no dirt or dust inside the


cylinder or on the cylinder head mounting
surface.

1) Set cylinder head gasket (39) to cylinder


% , \
block.
z CED02294
0 + Check that the gasket is correctly aligned
with the holes in the block.

2) Raise cylinder head assembly (38) and set to


cylinder block.

3) Assemble push rod (37).


6 Add engine oil to the push rod
socket.

4) Fit rocker arm assembly (36) and tighten


mounting bolts by hand.
* Check that the ball of the adjustment
screw is fitted securely in the socket of
the push rod.
Add engine oil to the thread and seat
of the 8 mm and 12 mm diameter
mounting bolts.

30-15-8
0
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD

5) Tighten cylinder head mounting bolts in or-


der shown in diagram.
6 Add engine oil to the thread and seat
of the mounting bolts.

m Cylinder head mounting bolt:

1st pass: Tighten to 90.03 rt 5.00 Nm 19.18 *


0.51 kgm1 in the order 0 - @
2nd pass: Tighten to 120.03 2 5.00 Nm j12.24
k 0.51 kgm1 in the order 0, @,@I,
02 CLPO2095
3rd pass: I) When using tool A4
. Using angle tightening wrench
(tool A4), tighten bolts 90+5”
in the order @ - @.
2) When not using tool A4
. Make mark with felt pen on
bolt and head, then tighten
bolt 9O-c5”.

CLPO2121

6) Tighten rocker arm assembly mounting bolts


Make star t marks
(diameter: 8 mm). on the SY,linder head
and bolt
w Rocker arm mounting bolt (diameter:
8 mm):
24.03 f 4.02 Nm 12.45 t 0.41 kgm}

* Adjust the valve clearance.


For details, see TESTING AND ADJUSTING,
Adjusting valve clearance.

DKP00451

. Refilling with water


Add water through the water filler to the speci-
fied level.
Run the engine to circulate the water through
the system. Then check the water level again.

. Bleeding air
Bleed the air from the fuel line.
For details, see TESTING AND ADJUSTING,
Bleeding air from fuel circuit.

30-15-9
a
DISASSEMBLY AND ASSEMBLY RADIATOR GUARD

REMOVAL OF RADIATOR
GUARD ASSEMBLY

D31 E-20 Serial No.: 42001 - 42713


D31P, PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660

* The steps 1 and 2 show D31 PL, PLL-20.

1. Remove pin (1) and start engine, then retract lift cy-
linder piston rod fully.
* Stop the engine and operate the work equip-
ment control lever several times to release the
pressure inside the piping.

2. Disconnect hoses (2) from left cylinder.

3. Loosen radiator drain valve and drain cooling water.

4. Remove exhaust pipe (3) and left and right engine


side covers (4), disconnect reserve tank hose, then
remove engine hood (5).

&I kg Engine hood assembly: 40 kg

5. Disconnect wiring (6) and radiator hoses (7) and (8),


and remove fan guard (9).

6. Remove grille (10).

30-l 6
a
DISASSEMBLY AND ASSEMBLY RADIATOR GUARD

7. Remove plate (II), then disconnect oil cooler hoses [ , , , I ,/


(12).

I Il4FO21 I6

8. Lift off radiator guard assembly (13).

PI kg Radiator guard assembly: 210 kg


(With lift cylinder)

lI5lkg Radiator guard assembly: 110 kg


(Without lift cylinder)

Il4FO21 I7

INSTALLATION OF RADIATOR
GUARD ASSEMBLY

D31 E-20 Serial No.: 42001 - 42713


D31P, PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660

l Carry out installation in the reverse order to removal.

l Refilling with water


* Add water to the specified level from filler port,
and run the engine to circulate the water
through the system. Then check the water level
again.

l Refilling with oil (transmission)


* Add engine oil to the specified level, and run
the engine to circulate the engine oil through
the system. Then check the oil level again.

30-17
0
DISASSEMBLY AND ASSEMBLY RADIATOR

REMOVAL OF RADIATOR
ASSEMBLY
D31 E-20 Serial No.: 42001 - 42713
D31P, PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660

Loosen radiator drain valve and drain cooling water.

Remove exhaust pipe (1) and left and right engine


side covers (2), disconnect reserve tank hose, then
remove engine hood (3).

PI kg Engine hood assembly: 40 kg

Disconnect hoses (4) and (5), then remove fan guard


(6).

Il4FO21 IS

4. Remove shroud (7) of lower end.

5. Remove bracket (8). 8 y--m-_

Il4FO21 IS Il4FO2120

6. Remove grille, then remove plate (9).

7. Remove mounting bolts of oil cooler (IO), and move


towards front.

IY .
i’liFO2121

30-18
a
DISASSEMBLY AND ASSEMBLY RADIATOR

8. Remove mounting bolt of radiator.

9. Lift off radiator assembly (11).

&I kg Radiator assembly: 45 kg

INSTALLATION OF
RADIATOR ASSEMBLY
D31 E-20 Serial No.: 42001 - 42713
D31P, PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
D31P-20A Serial No.: 45001 - 47616
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660

l Carry out installation in the reverse order to removal.

. Refilling with water


* Add water to the specified level from filler port,
and run the engine to circulate the water
through the system. Then check the water level
again.

. Refilling with oil (transmission)


* Add engine oil to the specified level from filler
port, and run the engine to circulate the engine
oil through the system. Then check the oil level
again.

30-l 9
0
DISASSEMBLY AND ASSEMBLY RADIATOR, RADIATOR GUARD

REMOVAL OF RADIATOR,
RADIATOR GUARD ASSEMBLY

D3 1 E-20 Serial No.: 42714 and up


D31P, PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up

* It is impossible
individual part.
to remove the radiator as an
7
\\
CED02.269
* Steps 6 and 7 are for the D31PL, PLL-20 only.
1. Loosen radiator drain valve and drain coolant.

2. Remove left and right engine side covers.

3. Remove exhaust pipe (1).

4. Remove air cleaner mounting bolts (2) and (3).


* Insert block @ between the air cleaner and
the intake connector.

5. Lift off engine hood (4).

r+ kg Engine hood: 30 kg

6. Remove pin (5), then start engine and retract


piston rod of lift cylinder fully.
g Tie the piston rod with wire to prevent it
from coming out.
A Release the remaining pressure in the hy-
draulic circuit.
For details, see TESTING AND ADJUSTING,
Releasing remaining pressure in hydraulic
circuit.

7. Disconnect hoses (6) from lift cylinder.

30-l 9-l
0
DISASSEMBLY AND ASSEMBLY RADIATOR. RADIATOR GUARD

8. Remove reservoir tank (7).

9. Remove bolt (8) and spacer (91, and install lift-


ing tool.

10. Remove wiring (HL) (IO).

11. Remove radiator inlet hose (I I) and outlet hose


(12).

12. Remove fan guard (13).

30- 19-2
0
DISASSEMBLY AND ASSEMBLY RADIATOR, RADIATOR GUARD

13. Remove radiator guard (14).

14. Remove cover (15).

15. Disconnect 2 hydraulic cooler hoses (16).

16. Remove light guard (17).

17. Sling radiator and radiator guard assembly (181,


then remove mounting bolts, and lift off radia-
tor and radiator guard assembly.

elkg Radiator, radiator guard assembly


(without lift cylinder) : 110 kg
(with lift cylinder) : 210 kg

30-19-3
a
DISASSEMBLY AND ASSEMBLY RADIATOR. RADIATOR GUARD

INSTALLATION OF RADIATOR,
RADIATOR GUARD ASSEMBLY

D31E-20 Serial No.: 42714 and up


D31P, PL-20 Serial No.: 47617 and up
D31PLL-20 Serial No.: 47653 and up
D31S, Q-20 Serial No.: 41184 and up
D31P-20A Serial No.: 47617 and up
D37E-5 Serial No.: 3731 and up
D37P-5A Serial No.: 3661 and up

. Carry out installation in the reverse order to


removal.