D31E 20 - Sn42001and Up PDF

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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10-56-I @ 20-12 @ 20-34 20-72-4 @ 20-99
10-56-2 @ 20-12-I @ 20-35 20-72-5 @
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10-59-I @ 20-13-2 @ 20-39 20-72-g @ 0 30- 4
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IO-60 20-15 @ 20-41 20-72-11 @ 0 30- 5-1
lo-61 20-15-1 @ 20-42 20-72-12 @ 0 30- 5-2
IO-62 @ 20-15-2 @ 20-43 20-72-13 @ 0 30- 5-3
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IO-72 @ 20-23-l @ 20-57 20-80 0 30- 9-5
10-73 @ 20-23-2 @ 20-58 20-81 0 30-10
10-74 @ 20-24 @ 20-59 20-82 0 30-10-I
20-25 @ 20-60 20-83 0 30-10-2
20- 1 @ 20-26 @ 20-61 20-84 0 30-I 1
20- 2 @ 20-27 @ 20-62 20-85 0 30-12
20- 3 @ 20-28 @ 20-63 20-86 0 30-13
20- 4 @ 20-29 @ 20-64 20-87 0 30-13-I
20- 5 @ 20-29-I @ 20-65 20-88 0 30-I 3-2
20- 6 @ 20-30 @ 20-66 20-89 0 30-I 3-3
00-J-2
Time 01 Time 01 Time of Time of Time of
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L/ 30-115-2 @ 40-18
30-20 30-53 c 30-88-I c 30-115-3 @ 40-19
30-21 30-54 0 30-88-2 n

i/ 30-115-4 @ 40-20
30-21-I 30-55 30-89 0 30-115-5 @ 40-22 @
30-21-2 30-56 30-90 C 30-115-6 @ 40-23 @
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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 welding 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.
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
TIGHTENING TORQUE OF O-RING BOSS CONNECTOR

Use these torques for O-ring boss connector

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

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
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
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
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
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
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
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
Unit: mm
D31P-20A Serial No.: 45001 - 47616
. .
oszz
.
OS91
I-
0911 * OEPI
Il4FO2187
01-4
0
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
Unit: mm
D37E-5 Serial No.: 3001 - 3730
I
0611
I- -
I -
9% OLZI SL9Z
Il4FO2189
01-6
Unit: mm
D37P-5A Serial No.: 3001 - 3660
I
S69Z
Il4FO2190
01-7
0
D31E-20 Serial No.: 42714 and up Unit: mm
0611
I_ _I
956 OLZl
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.
D31P-20A Serial No.: 47617 and up Unit: mm
i- oszz
049 I
-
7 , f-
SBD02174
01&l0
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.
D37E-5 Serial No.: 3731 and up Unit: mm
I-
06Ll
09PI
SED02176
01612
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)
-
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
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
Piston stroke mm 145 120 145 120 120
Max. distance between pins mm 613 790 613 790 790
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

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

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

(to drain port of steering case) mm 315 380
O&l8
T
Serial No. 41001 - 41183 41001 - 41183
Name 6D95L-1
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}
Alternator 24V, l5A

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
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
01&O
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

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
Stability deg 35 35
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
2,185 2,185
330 600
315 380
01622
Machine model D37E-5 D37P-5A
Serial No. 3001 - 3730 3001 - 3660
Name 6D95L-1
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}
Low idling rpm 700
Min. fuel consumption ratio g/kWh {g/HPt 217 (162)

_


Steering clutch
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
Serial No. 3001 - 3730 3001 - 3660

f
In/, assembly typl e IDry, assembly type
Single Arc shoe
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

0
Min. distance between pins mm 716 716
Max. distance between pins mm 613 613

I

Serial No. 3001 - 3730 3001 - 3660

f
Hydraulic type Hydraulic type
Type angle tiltdozer angle tiltdozer
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
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

mm 315 380 380 380 380
01626
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)
Low idling rpm 800
Min. fuel consumption ratio j/kWh {g/I-K? 217 {I621


Steering clutch
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

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

2
F
0
Piston stroke mm 393 850 393 850 850
Max. distance between pins mm 1,109 1,350 1,109 1,350 1,350
Piston stroke mm 145 120 145 120 120
Max. distance between pins mm 613 790 613 790 790
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

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
: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

D31S. 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
Forward deg 30 31
Stability Reverse deg 35 35
(Right/Left) 26 28
deg
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

(to drain port of steering case) mm 315 380
01630
Machine model D31S-20 D31 Q-20
Name S4D102-1

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)
Low idling rpm 800
Min. fuel consumption ratio gikWh Ig/HPt 217 {162}

Wet type, multiple disc clutch, spring boosted,

Steering clutch
foot operated, PPC actuated
Steering brake Wet type, band type, PPC actuated, interconnected with clutch
Suspension Rigid
Carrier roller (each side)

I 1
I 1
I
-r
Serial No. f 41184 and up 41184 and up
In/, assembly type Integrated rubber

crawler
Semi-double grouser Arc shoe

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
0122
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
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

D37E-5
D37P-5A
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
Stability deg 35 35
2.3 2.3
4.1 4.1
6.9 6.9
Reverse 1st km/h 2.5 2.5
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

mm 315 380
0124
I I
Name S4D102-1
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)

I


Steering clutch
Steering brake Dry type, band type, PPC actuated, interconnected with clutch
Suspension
Carrier roller (each side)

Dry, assembly type Dry, assembly type
Single Arc shoe
MPa
Max. pressure 17.2 (1751 17.2 {175}
kg/cm
Gear type (SAR(2)-045)
Q/min
95.5
Double-acting, piston type
Max. distance between pins mm 613 613

Machine model D37E-5 D37 P-5A
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
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
D31S, 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
Unit: kg
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
D37E-5
D37P-5A
Unit: kg
Serial No. 3001 - 3730 3001 - 3660
l Modulating valve assembly 6 I 6
l Steering clutch assembly (each side) 48 48
l Brake band assembly (each side) 9 9
l Bevel gear 15 15
I
l Track roller assembly (each) 27 27
l Carrier roller assembly (each) 20 20
Cross bar 106 132

Unit: kg

I
Serial No. 3001 - 3730 3001 - 3660

I

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

I
l Blade 412 412
l U-frame 261 261
%
z Engine underguard 42 42
0
Transmission underguard 39 39
Hood 26 26
Canopy assembly - 50
01-.&43
D31E, P, PL, PLL-20

D3 1 P-20A
Unit: kg
42714 47617 47617 47617 47653

Serial No.
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
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.
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 - - -
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
D31S, Q-20
Unit: kg
Machine model D3 1S-20 D31 Q-20


Steering clutch assembly (each side) 48 48
l
%
l Brake band assembly (each side) 9 9 ;;
l Bevel gear 15 15
Cross bar 107 127
01-&a
Unit: kg
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
Engine underguard 42 42
% Transmission underguard 36 36
z
0 Hood 28 28
Canopy assembly 50 50
D37E-5
D37P-5A
Unit: kg



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

Sprocket (each side) 41 4;
Main frame assembly 660



Cross bar 106 132
0128
Unit: kg
I
I I

I
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
* Blade 412 412
U-frame 261 261

l
I
%
c Engine underguard 42 42
z
Transmission underguard 39 39
Hood 26 26
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
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
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

D31P-20 Serial No.: 47617 and up

D31PL-20 Serial No.: 47617 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
Steering clutch case 30 30

ingine oi

(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
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
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
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
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
-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
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
0
SBD01175

2. Transmission pump 8. R.H. brake cylinder
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

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-
the steering case.
0: Neutral
0: Reverse When steering and directional lever (2) is oper-
@: 3rd valve spool is actuated at the same time. A set of
@I: Lock the machine travels.
0: Inching When inching ,pedal (5) is operated, the inching
lo-~‘-’
STRUCTURE AND FUNCTION TRANSMISSION CONTROL

D31P, PL-20 Serial No. 47617 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
transfer drive gear (32) and transfer driven gear (34).
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
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
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
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

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
8. Left brake . If the steering and directional lever is moved
10. Left brake cylinder tially disengaged and the machine turns slowly
to the left.
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: Brake locked
’O-i9-*
STRUCTURE AND FUNCTION STEERING CONTROL
D3 1 E-20 Serial No. 42714 and up

SE002140

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
8. Left brake . If the steering, directional gear shift lever is moved
10. Left brake cylinder tially disengaged and the machine turns slowly
to the left.
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.
@: 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
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
(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
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
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

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
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
OPERATION
1) At neutral
Ports A and B of the steering clutch cylinder (1)
nected to drain chamber D. (Fig. 1)

SADOI
181
(Fig. 1)
retainer (9) is pushed; spool (1) is also pushed
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.
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)
(1).
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
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)
OPERATION
1) At neutral
Ports A and B of brake cylinder (11) and ports
PI and P2 of the PPC valve are connected to
SAD01185
2) During fine control (neutral -fine control) (Fig. 1)
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
anced with the pressure at port Pl. The relation-
(1).
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
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
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
chamber A from port PI, and pushes the piston
of brake cylinder (II).
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
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

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
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-
hydraulic tank.

SBD02146
1. R.H. blade lift cylinder OUTLINE

2. Hydraulic pump . The oil in hydraulic tank (5) is sucked up by hy-
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.
tank.
’O-i9-’
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-
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.
hydraulic tank.
The hydraulic filter is a cartridge type.
1O-49-2
HYDRAULIC PIPING
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.
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

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

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”.


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


+ Engine running, hydraulic control lever in “HOLD”.
SBD02151

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
DOZER SHOVEL
D31 S, Q-20
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
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660
0
2
I
D31P-20A Serial No. 45825 and Up
D37E-5 Serial No. 3235 and UP
SRDOI 189
Lever positions
Blade control lever

Selector button (tilt/angle)
(Power tilt, angledozer)
Lock lever
Main control valve

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

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

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-’
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-*
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
6. Return spring 14. Plug 22. Suction valve
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
ENGINE OIL PRESSURE SENSOR
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
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
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)

{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)

(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)
@
?- 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
-
-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
-
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
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
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
-
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
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
-
Gate Measurement conditions Jnit Standard value Permissible value
Item
gorl I
.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)

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
-
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
-
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
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
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
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
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

D31P. PL-20 Serial No. 47617 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
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.

D31P, PL-20 Serial No.: 47617 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
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

D31S, Q-20 Serial No.: 41184 and up -Dl
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

g Be careful not to touch any hot parts when removing

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
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
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

1) Loosen air bleed plug (I).
D31P. PL-20 Serial No.: 47617 and up
2) Loosen the feed pump knob, pump it up and
down, and continue until no more bubbles come
out with the fuel from the air bleed plug.
3) Tighten the air bleed plug.
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

a Be careful not to touch any hot parts when removing

* 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

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

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
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

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

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

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
@
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’
v ‘\J TDD00835
20-31-l
8
f-l ‘)
1
C
d
BDD00385
2021-2
* 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
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
BED00396
20-33-l
8
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).
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).

li Dimension e between pins of rod (8) : 846 mm
6. Connect yoke (9).

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
@
@ 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
@
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
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
@
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
@
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
@
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
@
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
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
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
@
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
. 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
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
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
. 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
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
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
* 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
. 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
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
* 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
S-l Starting performance is poor (starting always takes time)

General causes why exhaust smoke comes out but
engine takes time to start
. 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”.
Legend
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
@
(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 : 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.

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
@
(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
. Improper selection of fuel and oil
Legend
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
@
S-3 Engine does not pick up smoothly (follow-up is poor)

Causes
General causes why engine does not pick up smoothly

. 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
@
S-4 Engine stops during operations

General causes why engine stops during opera-
tions
. Seized parts inside engie
. 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
a: Possible causes due to length of use (used for a long period)
l : Items to confirm the cause.
-
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
@
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
I Condition of hunting
2
7J
%
CI
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
. 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 : 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
Non-specified fuel is beinq used

Dust indicator is red
Black
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
:
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
@
S-7 Exhaust smoke is black

(incomplete combustion)
Causes
General causes why exhaust smoke is black

Legend
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
@
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
/ / -I
Confirm recent repair history I I I I I I I I I I I I I I
20-72-9
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 : Most probable causes (judgingfrom Queaions and Check items)
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
Legend
() : Possible 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

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
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
@ : Most probable causes (judgingfrom Queaions and Check items)
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
@
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
20-72-14
@
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
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
@
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 : 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 2 + Normal example 4
shows that
the cause is
a, b, or d.
Continue to the next troubleshooting item.

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

. 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

. Is the level of oil in the tansmission case correct?
. Is oil leaking from piping or valve joint?

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
Thermistor temperature gauge
H-4. Steering does not work properly

. 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

. 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

. Is oil level in hydraulic tank correct?
. Is stroke of work equipment lever and control
valve spool correct?

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
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

Yes = Parts seized, broken
pened? Where did the sound come from?
. Had there been any symptoms before (drop in
speed, etc.)?
Yes = Parts worn, spring deteriorated

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

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

Yes = Dirt caught in valve, parts broken
. Did this problem gradually become worse?
Yes = Parts worn

. 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

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

I Causes I
Yes Cause is a in toubleshooting

li%?‘re
11FH chart
No idling ? Carry out 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
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)
, 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’

. Was any abnormal sound heard when this hap- ///
Yes = Parts broken
speed, etc.)?

. Is stroke of. work equipment lever and control
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

Troubleshooting
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
Yes = Parts worn


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)


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)

Yes = Parts broken
speed, etc.)?

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)

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


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
Flowmeter kit
20690
H-20. Impossible to raise lift arm, impossible to raise chassis

I Causes I

Yes = Parts broken
speed, etc.)?


. Relief pressure
Troubleshooting
Flowmeter kit
20-9 1
H-21. Excessive hydraulic drift of lift arm

Yes = parts worn

. When rod of work equipment control lever is dis-
connected at control valve end, does hydraulic
drift come within standard value?

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

I Causes I
I ,ye: Normal
Bfly$ g$?“‘“/-o Ca;: out troubleshooting

No 1 idling ? 11 Carry out 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
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
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

. Did the problem start suddenly? I Causes I

Yes = Parts broken
speed, etc.)?

. 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

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

I Causes I
Checks for abnormalities Tank - Pump Control valve
abcdefg
m[[v[ ,iIut troubleshooting

Yes Et;? is a in toubleshooting
figi$q[ Carry out 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
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

Troubleshooting
toois A: Adjust C: Clean
Flowmeter kit
H-26. Excessive hydraulic drift of bucket dump circuit

. Did the problem start suddenly? I Causes I
Yes = Parts worn

Checks for abno,rmalities

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

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

30-5-l
a
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
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

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
. 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
* 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
D37P-5A Serial No.: 3661 and up I’
a Disconnect the cable from the negative (-) ter-

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
D31P-20A Serial No.: 47617 and up --u-Ji - J / CEtl02252

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

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
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
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
il4FO21 IO
REMOVAL OF FUEL INJECTION

PUMP ASSEMBLY

1. Drain fuel from fuel tank.
2. Remove engine left cover.

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
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
INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY


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
* 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}
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.
Adjusting fuel injection timing.
. Bleeding air
Sr Bleed the air from the fuel line.
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
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
1. Drain coolant.

For details, see REMOVAL OF ALTERNATOR AS-
SEMBLY.
3. Remove water pump assembly (I). m
INSTALLATION OF WATER
PUMP ASSEMBLY

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

again.
30- 1o-2
a
DISASSEMBLY AND ASSEMBLY THERMOSTAT
REMOVAL OF THERMOSTAT
ASSEMBLY
D31 P, PL-20 Serial No.: 47617 and up
D31 PLL-20 Serial No.: 47653 and up
D31 P-20A Serial No.: 47617 and up
1. Drain coolant.

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
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}

* Add water through the water filler to the
specified level.
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
/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
REMOVAL OF NOZZLE
HOLDER ASSEMBLY
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

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


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}

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
1. Remove left and right engine side covers.
2. Remove exhaust pipe (I).
3. Remove air cleaner mounting bolts (2) and

(3).
4. Lift off engine hood (4).
Engine hood: 30 kg
30- 13-2
a
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
14. Remove bracket (161, then remove turbocharger

assembly (17). m
INSTALLATION OF
TURBOCHARGER ASSEMBLY

% D37P-5A Serial No.: 3661 and up
z
0
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
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
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
m Sleeve nut:
22.06 t 24.52 Nm (2.25 2 0.25 kgml
a
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.

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
REMOVAL OF CYLINDER HEAD

ASSEMBLY
I

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).

f?l ks Engine hood: 30 kg
30-l 5-l
a
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
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
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
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

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
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
INSTALLATION OF CYLINDER
HEAD ASSEMBLY

removal.
* Adjust the engine stop solenoid.

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
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
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.

Adjusting valve clearance.
DKP00451

Add water through the water filler to the speci-
fied level.
. Bleeding air
Bleed the air from the fuel line.
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

&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

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

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

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

* 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).

* Insert block @ between the air cleaner and
the intake connector.
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.
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).
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


removal.

* Add water through the water filler to the
specified level.
. Refilling with oil (hydraulic tank)

* Add oil through the oil filler to the specified
level.
Run the engine to circulate the oil through
30-19-4
a
DISASSEMBLY AND ASSEMBLY ENGINE
REMOVAL OF ENGINE
ASSEMBLY
I
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
A Disconnect the
cable from the negative (--) ter-
z b-I 1
I14FO2123
1. Remove the radiator guard assembly.

For details, see REMOVAL OF RADIATOR GUARD
ASSEMBLY.
2. Remove the cover, then remove drain plug and

drain oil from hydraulic tank.
:
u Hydraulic tank: Approx. 33 P
3. Disconnect alternator wiring (1) and oil pressure

gauge sensor wiring (2).
4. Disconnect hydraulic pump hoses (3).

Il4FO2124 ll4FO2125
5. Disconnect stop motor wiring connector (4).
7. Disconnect water temperature wiring (6) and air

cleaner clogging wiring (7).
+I ‘5Tj-gn+-f Il4FO2120
8. Disconnect starting motor wiring (8) and heater

switch wiring (9).
”
Il4FO2127
30-20
a
9. Disconnect fuel control rod (10) and fuel hose (11). 1

10. Disconnect ground connection (12).
11. Remove floor plate, then remove universal joint as-
sembly (13). m
12. Remove mounting bolts, then lift off engine assem-
bly (14). m
* When raising the engine assembly, be careful of
the position of the center of gravity, and check
again that all wiring and piping has been
removed.
r+lkg Engine assembly: 450 kg

Il4FO2128
* Mark the positions of the left, right, front, and
rear engine mount cushions.
INSTALLATION OF ENGINE
ASSEMBLY
D31 E-20 Serial No.: 42001 - 42713
D31 P, PL-20 Serial No.: 45001 - 47616
D31 PLL-20 Serial No.: 45001 - 47652
D31S, Q-20 Serial No.: 41001 - 41183
%
z D31P-20A Serial No.: 45001 - 47616
0 D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3660
m
Jr Adjust the control lever. For details, see TESTING
AND ADJUSTING, ADJUSTING FUEL CONTROL
LEVER.
m
w Universal joint mounting bolt:
30.89 + 3.43 Nm (3.15 + 0.35 kgm)
& Fill bearing portion (2 places) of universal
joint with grease (G2-LI).
m
& Mounting bolt thread: Thread tightener (LT-2)
m Mount bolt:
277.04 2 31.87 Nm (28.25 2 3.25 kgm)

again.
l Refilling with oil (transmission case, hydraulic tank)
* 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.
30-21
0
REMOVAL OF ENGINE
ASSEMBLY

g Disconnect the cable from the negative (-) ter-

1. Remove radiator and radiator guard assembly.

For details, see REMOVAL OF RADIATOR, RA-
DIATOR GUARD ASSEMBLY.
2. Drain oil from hydraulic tank.
- : Hydraulic tank: Approx. 33 .k!
3. Drain fuel from fuel tank.
4. Remove air cleaner assembly.

1) Remove wiring (AS1 and AS2) (I).
2) Remove clamps (2) and (3), then remove air

cleaner assembly (4) together with air sup-
ply hose.
5. Remove starting motor wiring clamps (5).
!I
CED02309
30-21-l
a
6. Remove wiring (+I (SSI) (6) and wiring (-1 (SS2)

(7).
7. Remove clamp (8) and wiring (9).
8. Remove fuel outlet hose (IO).
9. Remove fuel control linkage (11). E-ii
CED0.2311
10. Disconnect wiring (12) (PSA: female side; PSB:

male side)
11. Remove fuel outlet hoses (13).
12. Remove clamp (141, then remove piping (15).
13. Remove engine rear right end clamp (16).

-
T
--A
’ /
-T
30-21-2
14. Remove starting motor terminal B (STB) (17).

m
15. Disconnect terminal C (l-pin connector) (18).
16. Remove ground cable (19) at chassis end.
17. Remove alternator terminal B (ALB) (20) and ter-

minal R (ALR) (21).
19. Remove floor rubber and floor plate.
19. Remove drive shaft (22) at engine end.
20. Sling engine assembly (23).
21. Remove 4 mounting bolts, then move engine

assembly slowly to front and remove. a
* When removing the engine assembly, check
that all the wiring and piping has been dis-
connected.
&I kg Engine assembly: 500 kg
30-21-3
0
INSTALLATION OF ENGINE
ASSEMBLY


removal.
* Adjust the fuel control cable.

For details, see TESTING AND ADJUSTING, Ad-
justing fuel control cable.
w Starting motor terminal B:

17.65 z 1.96 Nm Il.8 t. 0.2 kgm1
w Drive shaft:
30.89 + 3.43 Nm I3.15 i: 0.35 kgm}
%
:
0
w Engine mount bolt:

277.04 + 31.87 Nm 428.25 f 3.25 kgml
& Thread of engine mount bolt:
Thread tightener (LT-2)
30-21-4
a
DISASSEMBLY AND ASSEMBLY DAMPER
REMOVAL OF DAMPER
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. Jack up the machine, and insert blocks (height: ap-

prox. 300 mm) under the tracks.
2. Using transmission jack 0, remove underguard (1).
& kg Underguard: 35 kg
3. Remove floor plate.
4. Remove universal joint assembly (2). 1
I 1 I r*,
II 1 ’
Il4FO213C
5. Remove yoke (3). /3EG2j
6. Using forcing screws 0 (Thread dia. = 10 mm,

Pitch = 1.5 mm), remove cover (4). m
+ Oil will come out, so catch it with a pad.
:
u Damper case: Approx. 0.8 P
-’ 11 I’ 114F02131
7. Remove damper assembly (5). m
30-22
0
INSTALLATION OF DAMPER
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
Universal joint mounting bolt:

30.89 + 3.43 Nm {3.15 + 0.35 kgm)
Bolt wit
Fill bearing portion (2 places) of universal
joint with grease (G2-LI).
Yoke spline: Grease (G2-LI)
Lip of oil seal: Grease (G2-LI)
Il4FO2132
Mounting surface of cover:

Gasket sealant (LG-1)
Thread of bolt with * mark:

Fill empty portion at end face of crankshaft

with grease (G2-LI) from inside of flywheel
bearing.
* Tighten damper mounting bolts in the order 1 -

8.
Il4FO2133
w Damper disc mounting bolt:

66.19 f 7.35 Nm l6.75 f 0.75 kgm)
l Refilling with oil

Supply engine oil to the specified level from filler
port.
% Damper case: Approx. 0.8 Q
30-23
a
REMOVAL OF DAMPER
ASSEMBLY

D31 P, PL-20 Serial No.: 47617 and up
1. Raise the chassis with jack and set the block

(height: approx. 300 mm), under the chassis.
2. Remove floor rubber and floor plate.
3. Using transmission jack 0, remove underguard

(I) (rear end).
4. Remove universal joint assembly (2) at damper

end. m
5. Remove yoke (3). m
6. Loosen drain plug (4), and drain oil from damper

case. m
& Damper case: Approx. 1.6 8
7. Using guide bolts @ and forcing screws 0, dis-

connect damper cover (5) at engine end. m
30-23- 1
a
8. Install lifting tool 0, sling damper cover (51,

then remove mounting bolts, and lift off.
f3 kg Damper cover: 20 kg
9. Remove damper assembly (6).
30-23-2
0
INSTALLATION OF DAMPER
ASSEMBLY

removal.
Universal joint mounting bolt:

30.89 + 3.43 Nm 13.15 + 0.35 kgm}
Fill the bearing portion (2 places) of the
universal joint with grease (G2-LI).
Yoke spline portion: Grease (G2-LI)

Lip of oil seal: Grease (G2-LI)
Drain plug: Gasket sealant (LG-1)

Drain plug:
26.97 f 10.30 Nm i2.75 t 1.05 kgm}
Cover mounting surface:

From the inside of the flywheel bearing,
fill the space at the end face of the crank-
shaft with grease (G2-LI).
Ir Align the dowel pin securely with the hole

at the engine end.
* Tighten the damper mounting bolts in the
order 1 - 8.
DED03164
w Damper mounting bolt:
66.19 f 7.35 Nm 16.75 + 0.75 kgm)
. Refilling with oil

I) Remove oil filler plug (7) and add oil (E030-
CD) to the specified level.
I& Damper case: Approx. 1.6 I!.

2) Coat the oil filler plug with gasket sealant
(LG-I), and tighten to the specified torque.
w Oil filler plug:
109.34 2 36.77 Nm Ill.15 + 3.75 kgm}
30-23-3
a
REMOVAL OF HYDROSHIFT
TRANSMISSION ASSEMBLY

prox. 300 mm) u,nder the tracks.
2. Using transmission jack 0, remove underguard (1). I
63 Underguard: 35 kg
3. Remove drain plug and drain oil from transmission

case and transfer case.
:
u Transmission case: Approx. 13 P
:
u Transfer case: Approx. I7 II
4. Remove operator’s seat frame.

For details, see REMOVAL OF OPERATOR’S SEAT
FRAME.
5. Remove oil filler tube (2).
6. Remove springs (3) and (4).
7. Disconnect rods (5) and (6), and remove link (7). m
8. Disconnect brake cylinder (8). 133f
-\ -“,/I
-I 14FO2135
9. Disconnect rod (9), and remove lever and bracket

assembly (10). m
I Il4FO2136
30&24
IO. Remove universal joint (11). m
11. Remove spring (12), and disconnect tube (13) be-

tween modulating valve and cooler.
12. IDisconnect hose (14) between modulating valve and

IPPC valve, and hose (15) between transmission case
and PPC valve.
13. Disconnect speed control rod (16) and F-R control

rod (17). m
14. Disconnect inching rod (18). m
- I’ I I 4FOi I ‘38
15. Using 2 eyebolts (Thread dia. = 10 mm, Pitch = 1.5

mm), sling transmission assembly (19), then remove
mounting bolts, and remove.
& kg Transmission assembly: 220 kg
16. Lower transmission assembly on pallet truck 0, then

pull out from under chassis.
INSTALLATION OF HYDROSHIFT
a Thread of mounting bolt for underguard:

/ ( ml
Bend the cotter pin securely.
* Adjust the rod. For details, see ADJUSTING

BRAKE PEDAL, STEERING BRAKE CYLINDER.
& Thread of mounting bolt for bracket, lever:

m Mounting bolt for bracket, lever:

58.8 f 14.7 Nm
(6.0 + 1.5 kgm)
m
m Mounting bolt: 30.9 + 3.4 Nm

(3.15 + 0.35 kgm)
& Universal joint:

Fill bearing portion (2 places) of universal joint
with grease (G2-LI).
* Adjust the rod. For details, see TESTING AND

ADJUSTING, ADJUSTING TRANSMISSION CON-
TROL LINKAGE.

ADJUSTING, ADJUSTING TRAVEL OF INCHING
PEDAL.
. Refilling with oil (transmission, transfer case)

DISASSEMBLY OF
ASSEMBLY
Special tool
Part No. Part Name Q’ty
A 799-301-I 600 Oil leak tester 1
GENERAL DISASSEMBLY
1. Remove bracket (l), (2) and (3) together with levers.
2. Remove transmission control valve assembly (4).

* The lengths of the mounting bolts are different,
so mark them clearly before removing them.
3. Screw in eyebolts (Thread dia. = 12 mm, Pitch =

1.75 mm), and lift off transfer assembly (5).
Transfer assembly: 40 kg
4. Remove modulating valve and pump assembly as

follows.
1) Remove cover (6) together with sleeve.
2) Remove holder (7), then remove coupling (8).
3) Remove tube (9).
4) Remove modulating valve and transmission
pump assembly (IO).
5. Using forcing screw (Thread dia. = 10 mm, Pitch =

1.5 mm), remove sleeve (11).
6. Remove left and right lock bolts (12), then remove
transmission case (13).
Transmission case: 50 kg
7. Using tool A, check the operating condition and

stroke of each piston.
t Air check pressure: 0.3 - 0.5 MPa (3 - 5 kg/cm’)
8. Remove 5 tie bolts (14).
9. Remove No. 1 housing and carrier assembly (15).

18. Remove No. 2, 3 carrier assembly (31).
19. Remove No. 3 ring gear (32).
20. Remove No. 4 housing assembly (33) together with

plate (34).
21. Remove springs (35), discs (36) and plates (37).

t Keep the plates and discs stored in a vertical or
horizontal position to prevent any deformation.
22. Remove No. 4 ring gear (38).
23. Remove snap ring (40), then remove No. 3 sun gear
(41).
24. Remove snap rings (42) and (43), then remove No.
4 sun gear (44).
25. Turn over No. 5 housing assembly (45), then

remove mounting bolts (46).
26. Turn over No. 5 housing assembly again, then put

copper rod in contact with end of shaft, and tap
shaft assembly (47) out.
Pi8140
27. Remove No. 5 clutch assembly (48).

DISASSEMBLY OF No. 1 CLUTCH HOUSING
AND CARRIER ASSEMBLY
1. Remove plate (I), then remove spring (2).
2. Remove discs (3) and plates (4).

* Keep the plates and discs stored in a vertical or
3. Remove ring gear (5) and piston (6).
%
1!3P18143
E
4. Remove snap ring (7), then tap out No. 1 carrier as-
sembly (8).
5. Using push tool 0 (outside diameter: 70 mm),

remove bearing (9) from housing (IO).
I Seal ring
I
113P18146
30632
6. Disassembly of No. 1 carrier assembly.
1) Tap in roll pin (11) to shaft, then tap out shaft
(12).
t Remove roll pin from shaft.
2) Remove washer (13) and gear (14).

3) Remove bearing (15) from gear.
DISASSEMBLY OF No. 2,3 CARRIER

ASSEMBLY 7
1. Remove seal ring (1).

6
2. Tap in roll pin (2) to shaft, then tap out shaft (3).
1
3. Remove pinion gears (4), (5) and thrust washer (6)
from carrier (7).
9
4 Remove snap ring (8), then remove bearing (9) from I IIu
L
carrier (7).
113F18214
113F18215
30633
DISASSEMBLY OF BEARING CAGE AND
OUTPUT SHAFT ASSEMBLY
1. Remove seal ring (1) from cage (2).
2. Remove spacer (3).
Il3Pl62
3. Remove snap ring (4).
4. Using puller 0, pull out bearing (5).
6. Remove gear (7).
8. Support cage (9) end, and push shaft (10) to

remove.
Il3Pl67
3OG34
9. Pull out bearing (11) from shaft (IO), remove collar
(12), then remove oil seal from collar.
ll3Pl68
DISASSEMBLY OF No. 5 CLUTCH HOUSING

ASSEMBLY
1. Remove mounting bolts (I), then remove housing (2)

together with clutch piston (3).
Il3Pl8151 I13P18152
2. Remove spring (4), plates (5), discs (6) and pins (7).
+ Keep the plates and discs stored in a vertical or
-I
Il3Pl8153
3. Remove gear (8).
4. Remove snap ring (9), then remove cover (10).
’ I w,,,,,,,,,,,, d, I&V
I l3Pl8154 Il3Pl8155
5. Disassembly of carrier assembly.
1) Knock in roll pin (12) of carrier assembly (II),
then remove shaft (13).
t Remove roll pin from shaft.
2) Remove washer (14), gear (15) and bearing (16).
Ei
d
14 ‘1612 13 13 14 ll3Pl8157
6. Disassembly of housing assembly.

1) Remove snap ring (17).
2) Using push tool 0 (outside diameter = 62 mm),
remove bearing (18).
ll3Pl8158 Il3PlSl59

remove cage (19).
Il3Pl8160 I13P18151
DISASSEMBLY OF TRANSFER ASSEMBLY
1. Remove cover (1) and holder (2).
2. Using forcing screws 0 (Thread dia. = 10 mm,

Pitch = 1.5 mm, Length = 100 mm), remove cage
(3).
t Check the number of shims, and keep in a safe
place.
3. Remove collar (4), and tap out shaft (5).

5. Remove gear (7) from case (8).
6. Using push tool @ (outside diameter = 115 mm),

pull out outer race (9).
7. Using push tool @ (outside diameter = 75 mm), pull

out outer race (10).
8. Using push tool @ (outside diameter = 75 mm), pull

out bearing (11).
9. Using puller 0, pull out bearing (12).
30638
ASSEMBLY OF HYDROSHIFT
Special tool
Part No. Part Name O’ty
A 799-301-I 600 Oil leak tester 1
ASSEMBLY OF TRANSFER ASSEMBLY

1. Using push tool @ (inside diameter: 55 mm), press
fit bearing (12).
2. Using push tool 8 (outside diameter: 90 mm), press

fit bearing (11).
3. Using push tool @I, press fit outer race (IO).
4. Using push tool 0, press fit outer race (9).
5. Set gear (7) in case (8).

6. Install cover (6).
7. Press shaft (5) through gear (7) and install, then in-
stall collar (4).
8. Using guide bolts @I (Thread dia. = 10 mm, Pitch =

1.5 mm, Length = 100 mm) and push tool @I (inside
diameter = 40 mm), press fit cage (3).
* Standard shim thickness: 2.0 mm
* Types of shim: t = 1.0 mm, t = 0.3 mm, t =
0.2 mm
* Assemble the same thickness of shim as was
removed during disassembly.
9. Install holder (2).

* Bend lock plate securely.
10. Install cover (1).

ASSEMBLY OF No. 5 CLUTCH HOUSING
ASSEMBLY
1. Assembly of housing assembly.

press fit cage (19).
PCI& Mounting bolt: Thread tightener (LT-2)
w Mounting bolt: 29.4 + 4.9 Nm

(3 k 0.5 kgm)
2) Using push tool @ (outside diameter = 68 mm),

press fit bearing (18).
3) Install snap ring (17).
181 I13P18182
2. Assembly of carrier assembly.

1) Assemble bearing (16) in gear (15), fit washer (14),
then set in position.
1 4 l13P18157
2) Align shaft (13) with roll pin hole of carrier (1 I),

then knock in roil pin (12), and lock.
Il3Pl8156
3. Install cover (IO), then install snap ring (9).
4. Turn over carrier assembly, then install gear (8).
Il3P18154
/13P18155
5. Install pins (7), discs (6), plates (5) and springs (4).
R
d
Il3P18153
6
6. Fit seal ring, install piston assembly (3) in housing (2).
7. Turn over housing assembly, and set in carrier assem-

bly, then tighten mounting bolts (1).
I13P18152 I13P18151
30642
ASSEMBLY OF BEARING CAGE AND
OUTPUT SHAFT ASSEMBLY
1. Press fit oil seal (13) to collar (12).

A Lip of oil seal: Grease (G2-LI)
2. Install collar (12) to shaft (IO), then press fit bearing

(11).
* Inside diameter of bearing: 40 mm
3. Support cage (9), push outside of collar, and install

output shaft assembly (IO) to cage.
4. Install snap ring (8).
5. Install gear (7).
Il3Pl66
7. Press fit bearing (5) to shaft (IO).

* Inside diameter of bearing: 45 mm
8. Install snap ring (4)

9. Install spacer (3).
IO. Install seal ring (1) to cage (2).
ASSEMBLY OF No. 2,3 CARRIER

ASSEMBLY
1. Using push tool (outside diameter = 85 mm), press

fit bearing (9) in carrier (7).
3. Assemble needle bearings (IO) and (11) in pinion

gears (5) and (4).
4. Assemble thrust washer (6) and pinion gears as one

unit in carrier (7).
113F18214
5. Align shaft (3) with roll pin hole of carrier, and

knock in shaft with a plastic hammer.
* Rotate the pinion gear when knocking in the
shaft.
6. Knock in roll pin (2).
7. Assemble seal ring (1).
113F18215
3024
ASSEMBLLY OF No. 1 HOUSING AND
CARRIER ASSEMBLY
1. Assembly of No. 1 carrier assembly

1) Assemble needle bearing (15) in pinion gear
(14).
2) Assemble thrust washers (13) and pinion gear
(14) as one unit in carrier.
li ,j i2 i4
Il3Pl8148
3) Align shaft (12) with roll pin hole of carrier, and

knock in shaft with a plastic hammer.
* Rotate the pinion gear when knocking in the
shaft.
4) Knock in roll pin (11).
Il3Pl8147
2. Using push tool @ (outside diameter: 90mm), press

fit bearing (9) in housing (10).
3. Put No. 1 housing (10) on No. 1 carrier assembly

(8), and assemble with bearing (11).
Seal ring
* Assemble seal ring on housing.
* Bearing (11) inside diameter: 55 mm
outside diameter: 90 mm
5. Assemble seal ring, and install piston (6).
6. Install ring gear (5).
7. Install plates (4) and discs (3) in turn.
%
113P18143 f 13Pl8142 z
0
8. Install springs (2).
9. Align plate (1) with dowel pin, and knock in plate.

GENERAL ASSEMBLY
Clean all parts, and check for dirt or damage. Coat

the sliding surfaces of the bearings, shafts, plates,
discs and other parts with greases (G2-LI) before in-
stalling.
-Seal ring
The piston ring must be installed facing in the cor-
rect direction. Install with the side receiving the
pressure facing the housing.
Install the snap ring as shown in the diagram.
Coat the seal ring with grease (G2-LI) before assem-

F23JTK1003
bling.
Coat the inside face of the housing hole and the

press-fitting face of the oil seal with gasket seal (LG-
5). After press fitting, wipe off all the gasket sealant
that is squeezed out.
I F23JTK1002
1. Set No. 5 housing (45) on block (height: approx.

200 mm).
2. Install output shaft assembly (47).
3. Turn over No. 5 housing.
4. Install No. 5 clutch assembly (48).

5. Assemble No. 4 sun gear (44), and install snap rings
(43) and (42).
6. Assemble No. 3 sun gear (41), and install snap ring

(40).
7. Assemble No. 4 ring gear (38).
8. Install plates (37) and discs (36) in turn, then springs

(35).
* Plates: 2
* Discs: 2
9. Assemble piston, and install No. 4 housing (33)

together with plate (34).
30648
10. Install No. 3 ring gear (32).
* Install with the wide stepped part of the outer
teeth at the bottom.
11. Install No. 2 and 3 carrier assembly (31).

* Secure the inner race of the bearing to the
shaft.
13. Install guide pin (26).
14. Install plates (29) and discs (28) in turn, then install
springs (27).
* Plates: 3
* Discs: 3
15. Assemble piston ring on piston, and install to No. 2,

3 housing assembly (24) together with plate (25).
16. Assemble spring (47) and transmission lubrication
valve (48) in housing (24).
Il3F
17. Mesh with pinion gear, and install No. 2 ring gear
(23).
* The wider stepped part of the external teeth is
at the bottom.
18. Install ring gear (22).

* The snap ring fits into the gear of the No. 2, 3
carrier. Lift up the ring gear by hand and check
that the ring gear does not come up. (If the ring
gear comes up, the snap ring is not properly
fitted.)
20. Install plates (18) and (19), discs (20) in turn, then
install springs (17).
* Plates: 4
Discs: 4
21. Install No. 1 sun gear and input shaft assembly (16).
22. Align planet gear with No. 1 sun gear and install
No. 1 housing and carrier assembly (15).
23. Tighten five tie bolts (14).

* Assemble O-ring under spacer.
It One of the bolts at the mounting surface of the
modulating relief valve is 5 mm shorter than the
other four.
w Tie bolt: 63.7 k 4.9 Nm (6.5 f 0.5 kgm)

24. Using tool A, check that pistons of each clutch func-
tion correctly.
* Air pressure when checking: 0.3 - 0.5 MPa
(3 - 5 kg/cm2)
Il3Pl8126
25. Using two eye bolts (Thread dia. = 8 mm, Pitch =

1.25 mm; Thread dia. = 12 mm, Pitch = 1.75 mm)
raise transmission case (13) vertically and install.
26. Fit washers and install lock bolts (12) (one each on
both sides).
& Both faces of washer: Gasket sealant (LG-1)
m Bolt: 176.5 k 19.6 Nm (18 k 2 kgm)
27. Fit Olring and install sleeve (11).
a Sleeve: Grease (G2-LI)
Il3Pl8123
28. Installation of modulating valve and pump assembly.

1) Fit O-ring to sleeve and put modulating valve
and pump assembly together.
2) Fit gasket and install modulating valve and
pump assembly (IO).
* Make sure that the gasket is not creased
when installing it.
Fit O-ring and install suction tube (9).
& Gasket: Gasket sealant (LG-1)

Assemble coupling (8), fit O-ring, and install
holder (7).
m Mounting bolt: 66.2 + 7.4 Nm

(6.75 + 0.75 kgm)
Fit O-ring, and install cover (6) together with
sleeve.
29. Fit gasket and install transfer assembly (5).
30. Fit gasket and install selector and inching valve as-
sembly (4).
* Make sure that the gasket is not creased when
installing it.
* There are three types of mounting bolt, so be
sure to install them in the correct positions.
* Mounting bolt: % = 4 bolts
@= 3 bolts
* = 5 bolts
& Mounting bolt: Gasket sealant (LG-5)
w Mounting bolt: 30.9 + 3.4 Nm

(3.15 f 0.35 kgm)
31. Align lever with yoke and install brackets (3), (2)
and (1).
REMOVAL OF MODULATING
VALVE AND PUMP ASSEMBLY

prox. 300 mm) under the track.
2. Using transmission jack 0, remove underguard (1).
m Underguard: 35 kg
3. Remove drain plug and drain oil from transmission

case.
:
u Transmission case: Approx. 13 P
4. Remove universal joint assembly (2). m
5. Remove spring (3), then disconnect tube (4).
6. Disconnect hose (5) and rod (6).
7. Remove suction tube (7) and coupling (8). m
8. Remove modulating valve and pump assembly (9).
0
2 - crrr‘s-
Il4FO2140 Il4FO2141
73 INSTALLATION OF
MODULATING VALVE AND
PUMP ASSEMBLY

m
m Universal joint mounting bolt: 30.9 f 3.4 Nm
(3.15 f 0.35 kgm)
& Universal joint:
Fill bearing portion (2 places) of universal joint
with grease (G2-LI).
/ I
\ Il4FO214i
m Coupling mounting bolt: 66.2 k 7.4 Nm
(6.75 f 0.75 kgm)
m
& Mounting surface of modulating valve and
pump assembly: Gasket sealant (LG-1)
w Mounting bolt of modulating valve, pump as-

sembly: 30.9 f 3.4 Nm (3.15 f 0.35 kgm)
l Refilling with oil (transmission)

DISASSEMBLY OF
MODULATING VALVE
ASSEMBLY
1. Remove 2 mounting bolts (1) and 2 mounting bolts

(2), then remove seat (3).
DISASSEMBLY OF QUICK RETURN VALVE

SPOOL
Remove plates (4) and (5) from body (6).
Remove stopper (7).
Pull out quick return spool (8).
lOlPl225
Remove stopper (9).
DISASSEMBLY OF MODULATING VALVE
6. Remove plates (4) and (5) from body (6).
7. Remove stopper (10).
8. Remove valve (11) and spring (12), and pull out

modulating spool (13) together with valve (14).
9. Remove stopper (15).
10. Pull out valve (16) and shim (17) as one unit, and
remove springs (18) and (19).
ASSEMBLY OF
MODULATING VALVE
ASSEMBLY
ASSEMBLY OF MODULATING VALVE
1. Assemble shim (17), and springs (18) and (19) in

valve (16), then assemble in body (6).
* Standard shim thickness: 1 .O mm
* Types of shim: t = 0.5 mm, t = 0.2 mm
* Coat the sliding surface of the spool with engine
oil before assembling.
2. Fit O-ring and install stopper (15).

t Install the stopper with the protruding part on 15-
the inside as shown in.
3. Assemble valve (14) in modulating spool (13), then

assemble in body, and install spring (12) and valve
(11).
* Coat the sliding surface of the spool with engine
oil before assembling.
* Be careful to assemble valves (14) and (11) in
the direction shown in figure.
5. Install plates (4) and (5).
% ASSEMBLY OF QUICK RETURN VALVE

z
7. Assemble quick return spool (8) in body (6).

t Coat the sliding surface of the spool with engine
oil before assemling.

t Install the stopper with the protruding part on
the inside as shown in.
9. Install plates (4) and (5).
10. Fit gasket and install seat (3), then tighten bolts (2)
and (1).
REMOVAL OF SELECTOR
AND INCHING VALVE
ASSEMBLY
1. Remove floor plate (1) and remove cover (2).
2. Disconnect speed control rod (3) and F-R control rod

(4), and remove lever. m
3. Disconnect spring (5).
4. Disconnect inching rod (6) and lever (7). m
5. Remove selector and inching valve assembly (8). m A--&$+--

l lAFO2101
I lAFO2lA!
INSTALLATION OF
SELECTOR AND INCHING
VALVE ASSEMLY
* Adjust the rod. For details, see TESTING AND

ADJUSTING, ADJUSTING TRANSMISSION CON-
TROL LINKAGE.

ADJUSTING, ADJUSTING TRAVEL OF INCHING
PEDAL.
& Bolt: Gasket sealant (LG-5)
m Mounting bolt: 31.4 + 2.9 Nm (3.2 + 0.3 kgm)

DISASSEMBLY OF
SELECTOR AND INCHING
VALVE ASSEMBLY
1. Disassembly of inching valve
1) Remove cover (1) and shims (2).
2) Pull out inching valve (3) from body (4), then
remove sleeve (5), spring (6), piston (7), spring
(8), and shim (9).
3) Remove plug (IO), then remove inching valve
(II).
4) Remove piston (12), spring (13), and piston (14)
from inching valve (11).
5) Remove oil seal (15) from cover.
2. Disassembly of F-R valve

I IOIFO713C
6) Remove- plug (16), then remove spring (17) and
ball (18) from body (4). Inching valve
7) Pull out F-R spool (19) from body (4).
8) Loosen nut (20), and remove yoke (21) from F-R
3 1 2 5 6 7 8 9 11 14 13 12 11
spool.
9) Remove plug (22) and oil seal (23) from body.
10) Remove ball (24), spring (25), and sleeve (26)
from body.
3. Disassembly of speed valve

11) Remove plug (27), then remove spring (28) and
ball (29) from body (4).
2 12) Pull out speed spool (30) from body (4).

A
d 13) Loosen nut (31), and remove yoke (32) from
IOIFO713l
z speed spool.
14) Remove plug (33) and oil seal (34) from body. F-R valve
16
17
18
A-A
IOIFO713i
Speed valve
ASSEMBLY OF SELECTOR
AND INCHING VALVE
ASSEMBLY
* Clean all parts, and check for dirt and damage.
Coat the sliding surface of all parts with engine
oil before installing.
1. Assembly of speed valve 3. Assembly of inching valve

I) Fit O-ring and install plug (33) to body (4). 17) Assemble piston (14), spring (13), and pis-
m Plug: 39.2 i 4.9 Nm (4 f 0.5 kgm) ton (12) to valve (II), then install to body
(4), fit O-ring and tighten plug (10).
2) Install oil seal (34) to body.
m Plug: 107.9 + 14.7 Nm (11 + 1.5 kgm)
& Lip of oil seal: Grease (G2-LI)
18) Install shim (9), spring (8), piston (7), spring
3) Install yoke (32) to speed spool (30).
(6), and sleeve (5) to valve and body (4),
* Mounting diameter a of yoke: 27 mm
and assemble inching spool (3) to body.
4) Tighten locknut (31) securely.
* Standard thickness of shim (9): 1 .O mm
w Nut: 7.8 & 2.0 Nm (0.8 f 0.2 kgm) 19) install oil seal (15) to cover (1).
5) Assemble speed spool to body. a Oil seal: Grease (G2-LI)
6) Assemble ball (29) and spring (28) to body.
20) Assemble O-ring, then fit shim (2), and in-
7) Assemble O-ring, and tighten plug (27).
stall cover (1) to body (4).
m Plug: 17.2 I 2.5 Nm (1.75 + 0.25 kgm) * Standard thickness of shim (2): 1.0 mm
8) Check operating force of speed spool.
* Operating force: 83.3 - 127.4 N
(8.5 - 13 kg)
2. Assembly of F-R valve

9) Assemble sleeve (26), spring (25), and ball
(24) to body.
IO) Assemble O-ring, and install plug (22) to
body.
w Plug: 39.2 + 4.9 Nm (4 k 0.5 kgm)

11) Install oil seal (23) to body.
a Lip of oil seal: Grease (G2-LI)

12) Install yoke (21) to F-R spool (19).
* Mounting dimension b of yoke: 27 mm
13) Tighten locknut (20) securely.
m Nut: 7.8 + 2.0 Nm (0.8 f 0.2 kgm)

14) Assemble F-R spool to body.
15) Assemble ball (18) and spring (17) to body,
then fit O-ring and tighten plug (16).
m Plug: 17.2 i 2.5 Nm (1.75 i 0.25 kgm)

16) Check operating force of speed spool.
* Operating force: 83.3 - 127.4 N
(8.5 - 13 kg)
REMOVAL OF MAIN RELIEF
VALVE ASSEMBLY
2. Remove main relief valve assembly (2). a
INSTALLATION OF MAIN
RELIEF VALVE ASSEMBLY
w Valve assembly: 68.6 f 9.8 Nm (7 + 1 kgm)

DISASSEMBLY AND ASSEMBLY STEERING PPC VALVE
REMOVAL OF STEERING PPC

VALVE ASSEMBLY
D31 E-20 Serial No.: 42001 - 42198
D31P, PL, PLL-20 Serial No.: 45001 - 45784
D31S, Q-20 Serial No.: 41001 - 41054
D31 P-20A Serial No.: 45001 - 45784
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3152
1. Remove left stand cover.
2. Disconnect wiring connector (1).

148
-
3. Disconnect 6 hoses (2). m
4. Disconnect rod (3). m
5. Remove steering PPC valve assembly (4) together

with bracket (5).
INSTALLATION OF STEERING
PPC VALVE ASSEMBLY
D31 E-20 Serial No.: 42001 - 42198
D31S. Q-20 Serial No.: 41001 - 41054
D31 P-20A Serial No.: 45001 - 45784
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3152
* Connect the hoses without twisting or inter-

ference.
@K
* If there is excessive play of the control lever,

adjust the PPC valve. For details, see TESTING
AND ADJUSTING, ADJUSTING PPC VALVE.
l Bleeding air
* Bleed the air from the steering circuit. For de-
tails, see TESTING AND ADJUSTING, BLEEDING AIR
FROM STEERING CIRCUIT.
30-60
0
REMOVAL OF STEERING PPC

VALVE ASSEMBLY
D3 1 P-20A Serial No.: 45785 and up
1. Remove left stand cover.
2. Disconnect 6 hoses (I).
3. Disconnect rod (2).
4. Remove steering PPC valve assembly (3).
PPC VALVE ASSEMBLY
0 D31P, PL, PLL-20 Serial No.: 45785 and up
2 D31S, Q-20 Serial No.: 41055 and up
z
0 D31 P-20A Serial No.: 45785 and up

removal.
Install the hoses without twisting or interfer-

ence.
If there is excessive play in the control le-

vers, adjust the PPC valve.
Adjusting PPC valve.
. Bleeding air
* Bleed the air from the steering circuit.
Bleeding air from steering circuit.
30-60- 1
0
DISASSEMBLY OF STEERING
PPC VALVE ASSEMBLY
D3 1E-20 Serial No.: 42001 - 42198
D31S, Q-20 Serial No.: 41001 - 41054
D31 P-20A Serial No.: 45001 - 45784
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3152
1. Remove nut (I), then remove disc (2).

2. Remove joint (3).
3. Remove plate (4).
4. Remove seal (5), then remove collar (6).
5. Remove piston (7).
6. Remove valve assembly (8) from valve body (9).
7. Remove collar (IO), then remove retainer (II),
springs (12) and (13), and shim (14) from piston
(15).
8. Remove snap ring (16), then remove retainer (17),
spring (18), and valve (19) from valve body (9).
::
w ASSEMBLY OF STEERING
z PPC VALVE ASSEMBLY
D31 E-20 Serial No.: 42001 - 42198
D31S, Q-20 Serial No.: 41001 - 41054
D31 P-20A Serial No.: 45001 - 45784
D37E-5 Serial No.: 3001 - 3730
D37P-5A Serial No.: 3001 - 3152
1. Assemble valve (19), spring (18), and retainer (17) in

valve body (9), and secure with snap ring (16).
* Check that the snap ring is fitted securely in the
ring groove.
2. Assemble shim (14). springs (13) and (12), and re-
tainer (11) to piston (15), and install collar (10).
t Check that the collar is fitted securely in the
cotter groove of the piston. F20903133
3. Assemble valve assembly (8) in valve body (9).

4. Install piston (7).
5. Fit O-ring and install collar (6) and seal (5).
6. Install plate (4).
7. Install joint (3).
8. Fit disc (2)‘and tighten nut (1).
* Adjust the clearance between disc (2) and piston
(7).
For details, see TESTING AND ADJUSTING, AD-
JUSTING PPC VALVE.
30-61
a
PPC VALVE ASSEMBLY
1. Remove nut (I), then remove disc (2) and boot

(3).
2. Remove joint (41, then remove plate (5).
3. Remove seal (6) and collar (7).
4. Pull out piston (87, and remove retainer (91,

springs (IO) and (II), and shim (12).
* Springs (IO) and (11) consist of two sets of
two types of springs, so check the mounting
position (oil pressure port) and mark with
tags to prevent mistakes when installing.
5. Pull out valve (13) and piston (14) from body

(15).
* Valve (13) insists of two sets of two types of
valves, so check the mounting position (oil
pressure port) and mark with tags to pre-
vent mistal <es when installing. -
6. Remove cover (171, then remove filter (16). a b
CED02332
30-61-l
0
ASSEMBLY OF STEERING PPC

VALVE ASSEMBLY

* Body (15), piston (141, valve (13), and piston (8)

are not available as individual parts, so if there
is any abnormality, replace the whole steering
PPC valve assembly.
1. Fit O-rings to filter (16) and cover (17), then in-

stall to body (15).
a b
CED0.2332
2. Assemble piston (14) and valve (13) to body

(15).
* There are two types of valve for valve (131,
so check the table below when installing.
1 Position of port 1 Dimension X (mm) 1
I a I 3.9 + 0.05 I
b 6 f 0.05
CED02333
30-6 1-2
a
3. Assemble shim (121, springs (II) and (IO), re-

tainer (9), and piston (8) to valve (13).
* There are two types of spring for spring (1 I)
(free height Y is different according to the
hydraulic port), so check the table below
when installing.
tii
CED02334
Ir There are two types of spring for spring (IO)
(the number of loops in the coil is different
according to the hydraulic port), so check
the table below when installing.
Ir When assembling piston (81, coat the out-

side of the piston and the inside of the hole
in the body with grease.
& Piston: Grease (G2-LI)
4. Fit O-ring to collar (7) and assemble to body

(151, then install seal (6).
5. Install plate (5).

m Mounting bolt:
13.24 + 1.47 Nm (I.35 + 0.15 kgml
6. Install joint (4).

& Sliding portion of joint: Grease (G2-LI)
& Joint: Thread tightener (LT-2)
m Joint: 44.13 z 4.90 Nm {4.5 t 0.5 kgm]
* Keep strictly to the tightening torque for the
joint.
7. Assemble boot (3) and disc (2), and tighten with

nut (I).
m Nut: 112.78 z 14.71 Nm Ill.5 = 1.5 kgm}
Ir After assembling the disc, adjust the clear-
ance.
Adjusting PPC valve.
30-61-3
0
REMOVAL OF STEERING
CLUTCH ASSEMBLY
1. Remove operator’s seat frame.

For details, see REMOVAL OF OPERATOR’S SEAT
FRAME.
\
2. Remove drain plug and drain oil from steering case.
& Steering case: Approx. 30 II
I
Il4FO2149
3. Disconnect 4 PPC hoses (1).
4. Disconnect rods (2) and (3), and remove link (4). m
5. Remove brake cylinders (5) and (6) together with

bracket (7). m
6. Remove springs (8) and (9).
\ ’ -I 14F6215C
7. Disconnect rods (10) and (II), and remove lever and

bracket assembly (12). m
12-U Il4FO2151
8. Remove cover (13), and loosen adjustment screw

fully. m
9. Using 2 eyebolts (Thread Dia. = 10 mm, Pitch = 1.5

mm), remove brake cover assembly (14). m
10. Remove spring (15).
11. Turn shoe assembly and remove mounting bolts

(16) and (17). 116/
t When removing outside bolts (16), remove the

frame plug, then insert a wrench through the
hole and remove the bolts.
* Outside bolts (16) are 5 mm longer.
12. Raise brake band (18), and remove steering clutch

assembly (19).
PI kg Steering clutch assembly: 50 kg
%
!
’ Il4FO2153
6
3Og53
CLUTCH ASSEMBLY
w/ /I ml m1
* Bend the cotter pin securely.
* Adjust the rod. For details, see ADJUSTING

BRAKE PEDAL, STEERING BRAKE CYLINDER.
If
a Thread of mounting bolt for bracket:

m Bracket mounting bolt: 58.8 + 14.7 Nm

(6.0 f 1.5 kgm)
& Cap mounting surface: Gasket sealant (LG-1)
a Thread of mounting bolt for cap:

m
& Cover mounting surface: Gasket (LG-1)
& Thread of mounting bolt for cover:

m Clutch mounting bolt: 66.2 k 7.4 Nm

(6.75 k 0.75 kgm)
* Tighten 2 or 3 mounting bolts temporarily on

opposite sides, and align the pilot and bolt
holes, then tighten on opposite sides in turn.
l Adjust the adjustment screw of yoke assembly (20)

as follows.
Draw center line d of the chassis on top of
cover (21).
* The center line between left and right cover
mounting bolts (22) is the center line of the
chassis.
Using a T-square or other tool, make a perpen-
dicular line, and measure horizontal dimension e
from here to the adjustment screw.
* Dimension e: 135 mm
Loosen nut (24) and turn screw (23) to adjust.
l Adding oil (steering case)
Add engine oil through the oil filler to the specified
level.
l Bleeding air
Bleed the air from the steering circuit. For details,
see TESTING AND ADJUSTING, BLEEDING AIR
FROM STEERING CIRCUIT.
DISASSEMBLY AND ASSEMBLY STEERING CLUTCH
CLUTCH ASSEMBLY
Special tools required
Part No. Part Name A
791-431-5000 Compressor 1
790-101-1102 1 Pump I ’
790-101-2102 1 Puller (294 kN {30 ton}) 1 1
790-201-2750 I Spacer I 1
1. Remove brake band (1).
2. Remove brake drum (2).
I24P492 I 24P493
3. Set steering clutch assembly on tool A.
4. Extend puller of tool A and compress clutch spring. 4
A
5. Remove mounting bolt (3).
6. Release hydraulic pressure slowly and release ten-

sion of clutch spring. Remove puller and spacer of
tool A.
7. Remove pressure plate (4).
8. Remove 9 plates (5) and 8 discs (6).

* Store the discs and plates flat in a level place to
avoid deformation.
I24P497
30-65
a
9. Remove clutch drum (7).
10. Remove springs (8) and (9) and pipe (10).
11. Remove retainer (II).
30-66
0
ASSEMBLY OF STEERING
CLUTCH ASSEMBLY
Part No. Part Name A
791-431-5000 Compressor 1
790-101-1102 Pump 1
790-101-2102 Puller (294 kN (30 ton}) 1
790-201-2750 1 Spacer I 1
1. Set retainer (11) on plug of tool A.
2. Assemble pipe (10) and springs (9) and (8), and set
on retainer.
* Check that there is no deformation of the springs
before installing.
* Free length of spring (8): 100.3 mm (outer)
Free length of spring (9): 94.0 mm (inner)
3. Set clutch drum (7) on springs. \\ \\

Ir Check that the springs are correctly fitted in the \ b ’\ \
\\
holes in the clutch drum.
4. Assemble plate (12) on clutch drum.

+ Plate (12) is thicker than the other plate.
5. Assemble 9 plates (5) and 8 discs (6).

* Before installing the plates and discs, clean them
and coat the contacting faces between the plates
and discs with engine oil.
I24P503
6’ 124P497
30-67
0
6. Align pressure plate (4) with match mark on clutch

drum and set in position.
7. Using guide bolt @ (12 mm, P = 1.751, align bolt

hoses of pressure plate and retainer.
8. Align internal teeth of brake drum (2) with external

teeth of discs, and install.
Ir Use a plate with a 5 mm chamfer and tap lightly
to align the discs.
9. Set spacer and puller of tool A in position and slowly

apply pressure so that pressure plate and retainer do
not slip, compress clutch spring.
10. Tighten mounting bolt (3).

w Mounting bolt:
66.19 t 7.35 Nm (6.75 z 0.75 kgm}
11. Remove tool A.
%
124P506 z
0
12. Install brake band (1).
I24P507
30-68
a
DISASSEMBLY AND ASSEMBLY BEVEL GEAR SHAFT AND BEVEL GEAR
REMOVAL OF BEVEL GEAR

SHAFT AND BEVEL GEAR
ASSEMBLY
Special tools
Part No. Part Name I Q’tv
A I 791-422-6000 1 Remove & installer 1 1
B 791-422-2001 Remover B 1
C 791-423-1501 Remover 1
C, 790-101-3201 Bearina Duller 1
D I 791-422-I 300 1Wrench I 1 Il4FO2154
E 791-423-I 800 Centering tool 1
1. Remove steering clutch assembly.

For details, see REMOVAL OF STEERING CLUTCH
ASSEMLY.
2. Remove drain plug and drain oil from bevel gear

case.
4. Remove lock (3), then using tool A, remove nut (4).

* Lock the flange to stop rotation.
5. Using tool B, remove flange (5).

* Lock the flange to stop rotation.
6. Remove yoke asssembly (6).
7. Remove eight mounting nuts (7).

* Install the flange temporarily to stop rotation.
30-70
a
8. Remove lock (8), then using tool D, remove nut (9) 0
*
from cage. P
e /
I I3P202 I I3P203
9. Raise gear (IO) with tool E and remove cage (11) of

right end.
* Be careful not to damage the oil sea) if it is to
be used again.
10. Using tool C, pull out bearing (13).
11. Push out cage (11) of left end with shaft and
remove.
* Be careful not to damage the oil seal if it is to
be used again.
Il3Fl43
30671
12. Remove dowel pin (14) on left side of case, then
disconnect gear (10) from shaft (15) and remove.
3P207
INSTALLATION OF BEVEL
GEAR SHAFT AND BEVEL
GEAR ASSEMBLY
Special tools
16
Part No. Part Name Q’ty
A 791-422-6000 Remover and installer 1
B 791-440-4000 Installer B 1
I
B, 790-I 01-l 102 Pump 1
B* 790-I 01-4200 Puller (30 t) 1
C 791-422-I 600 Seal guide 1
D- 791-422-I 300 Wrench 1 1.3
E 791-423-1800 Centering tool 1 I I3P208
1. Assemble eight bolts (16) in shaft (15) and shrink fit

bearing (13). c P
* Shrink-fitting temperature: 100°C for 30 minutes
2. Insert bevel gear (10) and nut (9) in case. Assemble

nut (9) of right end while installing shaft (15). $u
3. Assemble dowel pin (14) for left end case, install all
bevel gear mounting nuts (7) temporarily, then raise
with tool E.
-
4. Shrink fit bearing (13) of right end. i ,’
* Shrink-fitting temperature: 100°C for 30 minutes

5. Install oil seal (12) in cage (11).
t Outside dia.: 78 mm
6. Fit O-ring, align with dowel pin and install cage (11)
in case.
* Fit tool C on shaft side, guide oil seal and in-
stall.
7. Screw nut (9) into cage.

* On the left side, push the bevel gear fully to the
pinion side and leave a large clearane from the
case when installing.
8. Tighten mounting nuts (7) of bevel gear.

9. Adjust backlash and tooth contact of bevel gear.

Using tool D, rotate gear while watching back-
lash, and tighten nuts (9).
* Backlash: 0.18 - 0.23 mm
* Rotating torque of bevel gear shaft:
1.4 - 2.4 Nm (0.14 - 0.24 kgm)
(However, it should be about 137.3 N (14
kg) at the top of the bevel gear tooth when
the transmission is engaged.)
In this case, tighten adjustment nut at 392.3
- 490.3 Nm (45 f 5 kgm)
t To measure the backlash, put a fuse wire
between the gears. Rotate the gears and
measure the thickness of the crushed fuse
wire with a micrometer.
* Tighten nut (9) so that the lock groove is in
the correct position.
Check tooth contact.
After adjusting backlash and tooth contact, in-
stall lock (8).
l Adjusting tooth contact
Coat the tooth face of the bevel pinion lightly with
red lead (minimum). Rotate the bevel gear forward
and backward and inspect the pattern left on the
teeth.
* Tooth contact should be checked with no load
on the bevel pinion. The tooth contact pattern
should cover about 30% of the length of the
tooth, and should start near the small end. It
should be in the center of the tooth height.
If the gears are adjusted to this pattern, the
tooth contact will be correct when load is ap-
plied.
l If the result of the inspection shows that the correct
tooth contact is not being obtained, adjust again as
23P 2
follows.
1) If bevel pinion is too far from center line of
bevel gear.
Contact is at the small end of the convex tooth
face of the bevel gear and at the big end of the
concave tooth face.
t Procedure for adjustment
Reduce the thickness of the shims at the
mounting face of the bevel pinion assembly
cage and steering case to move the pinion
shaft in direction A, nearer to the bevel
gear. Using the adjustment nut, move the
bevel gear in direction B by the same
amount that the bevel pinion has moved in
direction A.
Check the tooth contact pattern and back-
lash.
2) If bevel pinion is too close to center line of
bevel gear.
Contact is at the small end of the concave tooth
face of the bevel gear and the big end of the
convex tooth face.
* Procedure for adjustment
Increase the thickness of the shims at the
mounting face of the bevel pinion assembly
cage and steering case to move the pinion
shaft in direction A, away from the bevel
gear. Using the adjustment nut, move the
bevel gear in direction B by the same
amount that the bevel pinion has moved in
direction A.
Check the tooth contact pattern and back-
lash.
* To insert shims, loosen the mounting bolt of the
bevel pinion assembly, and use a plastic ham-
mer to knock out the tip of the pinion gear
enough to extract shims.
* When adjusting the bevel gear, do not change
the preload of the bearing. Always turn the ad-
justment nuts at both ends the same amount in
the same direction.
* Count the movement of the notches to check
the amount of adjustment by the adjustment
nut.
10. Fit gasket and install cover (1).
* Do not install the front 4 mounting bolts.
a Gasket: Gasket sealant (LG-4)
& Cover mounting bolt:

w Cover mounting bolt: 58.8 + 14.7 Nm

(6 f 1.5 kgm)
Il4FO2154
11. Install yoke assembly (6).

* Be careful to install facing in right direction.
12. Align with tabs of collar and install flange (5).

t Only one place can be aligned.
a Serrated portion:
13. Using tool B, press fit flange (5).
14. After press fitting flange, measure distance a from

end face of shaft to end face of flange.
* Distance a: 8 + 0.7 mm
* When no measuring tool is available, measure
distance b of the shaft before press fitting the
flange.
After press fitting the flange, measure distance
C.
b-c=a
15. Using tool A, tighten nut (4).
& Nut thread: Anti-friction compound (LM-P)
m Nut: 343.2 + 49.0 Nm (35 k 5 kgm)
* After tightening to about 294.2 Nm (30 kgm),

check the position of the mounting hole of lock
plate (3).
If it is not in the correct position, tighten the nut
until it reaches the correct position.
16. Tighten lock plate (3).
17. Install steering clutch assembly.

For details, see INSTALLATION OF STEERING
CLUTCH ASSEMBLY.
18. Tighten drain plug and add engine oil through oil fil-
Il3Fl5E
ler to the specified level.
30-76
0
REMOVAL OF FINAL DRIVE
FIRST PINION ASSEMBLY
Special tools
A 791-422-6000 Remover and installer 1
B 1 791-422-2001 Remover I ’
1. Remove steering clutch assembly.

For details, see REMOVAL OF STEERING CLUTCH
ASSEMBLY.
2. Remove cover (I), then using tool A, remove nut

(2).
3. Using tool B, remove flange (3).
4. Using forcing screws @ (Thread dia. = IO mm,

Pitch = 1.5 mm), remove retainer (4).
5. Remove first pinion assembly (5).
5 INSTALLATION OF FINAL
6
DRIVE FIRST PINION
ASSEMBLY
Special tools
I Part No. I Part Name I Qw

A 1 791-422-6000 ) Remover and installer I 1
B 791-440-4000 Installer B 1
B, 791-I 01-I 102 Pump 1
790-I 01-4200 Puller (30 ton) 1
1. Press fit bearing (7) and inner races (8) to pinion

gear (6).
* Inside diameter of inner race (8): 40 mm
* Inside diameter of bearing (7): 55 mm
2. Press fit oil seal (9) and inner races (IO) to retainer
(4).
* Outside diameter of inner race: 120 mm
t Outside diameter of oil seal: 105 mm
& Lip of oil seal: Grease (G2-LI)

3. Install first pinion assembly (5).
4. Fit O-ring and install retainer assembly (4).
5. Press fit flange (3) with tool B.

* Flange press-fitting force: 39.2 - 117.7 KN
(4 - 12 tons)
& Serration: Anti-friction compound (LM-P)
6. After press fitting flange, measure dimension a from

end face of shaft to end face of flange.
* Dimension a: 3 & 0.7 mm
* When no measuring tool is available, measure
distance b of the shaft before press fitting the
flange.
After press fitting the flange, measure distance
C.
b-c=a
7. Measure face runout and radial runout of flange (3)

from bevel gear shaft flange end.
* Set dial gauge in position, rotate the bevel gear
shaft flange end, and measure the movement of
the dial gauge indicator.
* Face runout: 0.3 mm (reading of dial gauge)
* Radial runout: 0.4 mm (reading of dial gauge)
II Il3Fl62
8. Using tool A, align nut (2) with bolt hole of cover

(I), then install.
m Nut: 343.2 + 49.0 Nm (35 _+ 5 kgm)
a Nut thread: Anti-friction compound (LM-P)
9. Fit O-ring and install cover (1).
a Gasket: Gasket sealant (LG-1)
10. Install steering clutch assembly

For details, see INSTALLATION OF STEERING
CLUTCH ASSEMBLY.
Il3Fl6Z u Il3Fl64
DISASSEMBLY OF FINAL
DRIVE ASSEMBLY
Special tools
A 791-522-7110 Socket 1
B 791-521-I 002 Remover 1
B, 1 791-101-1102 1 Pump I 1
B* 790-I 01-1600 Cylinder (70 ton) 1
1. Remove track shoe assembly.

For details, see REMOVAL OF TRACK SHOE ASSEM-
BLY.
2. Jack up machine and put stands @ under steering

case and equalizer bar.
3. Remove drain plug and drain oil from final drive

case.
:
u Final drive case:
Approx. 9.5 Q (D31 E, P, S-20, D37E-5)
Approx. 12 Q (D31 P-20A, D31 Q-20, D37P-5A)
Approx. 15 Q (D31PL. PLL-20)
%
6
5. Remove cap (2).
6. Using tool A, remove nut (3).

t Width across flats: 95 mm
7. Using tool B, B, and B,, pull out sprocket and hub
assembly (4).
A When removing the sprocket and hub assembly,

there is danger that it may fly out, so tempo-
rarily fit a nut.
8. Leaving 2 or 3 mounting bolts in position, sling

sprocket and final drive assembly, then remove re-
maining mounting bolts, and lift off sprocket and
final drive assembly (5) as one unit.
+ When removing the final drive assembly, the
shaft assembly will come out of the final drive
case, so leave sprocket hub assembly (4) and
nut (3) fitted together temporarily.
& kg Sprocket * final drive assembly: 190 kg
9. Remove nuts (3), then remove sprocket (6).
A kg Sprocket: 45 kg
10. Remove hub (7).
11. Remove floating seals (8) and (9).
Il3Pl8224 ’
30680
12. Remove mounting bolts, then remove cover (10) and
shims (11).
* Check the number and thickness of the shims,
and keep in a safe place.
13. Using eyebolts @ (Thread dia. = 12 mm, Pitch =

1.75 mm), remove case (12).
kg
rE?l Case: 40 kg
14. Pull out bearing (13) and outer race (14) from final
drive case.
%
z
0
15. Using puller 0, pull out bearing (15) from sprocket

shaft.
16. Using puller @I, pull out bearing (16) from sprocket
shaft.
17. Remove lock plates and nuts, then remove gear

(17).
18. Pull out outer race (18) from steering case end.
ASSEMBLY OF FINAL
DRIVE ASSEMBLY
Special tools
A 791-522-7110 Socket 1
C ) 791-521-2001 1 Installer I 1
* Clean all parts, and check for dirt or damage.

Coat the sliding surfaces of all parts with engine oil
before installing.
1. Using push tool @ (outside diameter: 130 mm),

press fit outer race (18) to steering case.
2. Install driven gear (17) to shaft, and fit lock plate,

then tighten nut.
* Bend the lock plate securely.
3. Using push tool 0 (inside diameter: 80 mm), press

fit bearing (16) to shaft.
4. Using push tool 8 (inside diameter: 100 mm), press

fit bearing (15) to shaft.
30682
5. Using push tool 0 (outside diameter: 170 mm),
press fit outer race (14) to case.
6. Using push tool @ (outside diameter: 85 mm), press

fit bearing (13) to case.
7. Using eyebolts @ (Thread dia. = 12 mm, Pitch =

1.75 mm), install case (12).
8. Assemble shim (11) temporarily, and fit cover (IO)

temporarily.
* Standard shim thickness: 1.5 mm
9. Install hub and nuts temporarily.
10. Using guide bolts 8 (Thread dia. = 16 mm, Pitch =

2.0 mm), fit gasket and set final drive assembly (5)
in position, then tighten mounting bolts.
a Mounting bolt: Thread tightener (LT-2)

11. Adjust preload of bearing.
Remove temporarily installed nut and sprocket
hub.
Remove shim (II), then tighten mounting bolts
marked % (4 places) of cover (10) uniform to a
tightening torque of 9.8 - 14.7 Nm (1 - 1.5
kgm).
Rotate the track on the other side with a jack to
rotate shaft 4 - 5 times to settle in the roller of
the bearing, then tighten the mounting bolts
evenly to a torque of 9.8 - 14.7 Nm (1 - 1.5
kgm).
Il3Fl821
Using feeler gauge 0, measure clearance be-
tween cover (10) and case in at least four
places, and calculate average value a.
t Shim thickness: a + 0.5 mm
Decide thickness of shim (11) as a i- 0.3 mm
and install.
12. Using tool D, install floating seals (9).
13. Using tool D, install floating seals (8).
30684
14. Using tool C, C, and C,, press fit hub (7).
& Serrated portion:

* Press-fitting force: 147.1 - 441.3 kN (15 - 45 tons)
15. After press fitting, use gauge 0 to measure dis-

tance b from end face of shaft to end face of
sprocket hub.
* Distance b: 1.5 ?I:: mm
* If the value is too large, press fit again at the

maximum press-fitting force within the permitted
range.
If the value is too small, replace the hub.
13Fl61
16. Using tool A, tighten nut (3).
& Nut: Anti-friction compound (LM-P)
m Nut: 1152.3 k 73.4 Nm (117.5 f 7.5 kgm)
17. Fit gasket and install cap (2).
e Gasket: Gasket sealant (LG-1)
18. Install sprocket (6).
& Mounting bolt: Thread tightener (LT-2)

21. Using work equipment and jack, jack up chassis, then
remove stand 0 from steering case and equalizer bar,
and lower machine to ground.
22. Install track shoe assembly.

For details, see INSTALLATION OF TRACK SHOE AS-
SEMBLY.
DISASSEMBLY AND ASSEMBLY TRACK FRAME
REMOVAL OF TRACK FRAME

ASSEMBLY
D31E-20 Serial No.: 42001 - 42713
D31 P-20 Serial No.: 45001 - 47616
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

BLY.
g Apply the brake securely.
2. Jack up machine and put stands under steering case

and equalizer bar.
3. Sling track frame assembly (2) and remove mounting

bolts (I) and (3). m
4. Raise track frame assembly, and pull out at an angle

to the front to remove.
r&lkg Track frame assembly:

D31E, S, Q-20 : 500 kg
D31P-20, D31P-20A : 550 kg
%
z
D37E-5 : 550 kg
0 D37P-5A : 700 kg
INSTALLATION OF TRACK
FRAME ASSEMBLY
D31E-20 Serial No.: 42001 - 42713
D3 1 P-20 Serial No.: 45001 - 47616
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
m
30-87
0

ASSEMBLY

For details, see REMOVAL OF TRACK SHOE AS-
SEMBLY.
a Apply the brake securely.
2. Jack up chassis and set stand under equalizer

bar and steering case.
3. Sling track frame assembly (2) and remove

mounting bolts (I) and (3). m
4. Raise track frame assembly and pull out diago-

nally to front to remove.
&I kg Track frame assembly:

D31E, S, Q-20 : 600 kg
D3 1 P-20A : 650 kg
D37E-5 : 550 kg
D37 P-5A : 700 kg
FRAME ASSEMBLY

removal.
30-88
0

ASSEMBLY
D31PL-20 Serial No.: 45001 - 47616

D31PLL-20 Serial No.: 45001 - 47652
1. Remove work equipment assembly.

For details, see REMOVAL OF WORK EQUIPMENT
ASSEMBLY.

BLY.
A Apply the brake securely.
3. Jack up machine and put stands under steering

case and equalizer bar.
4. Remove cover (1). m
5. Remove clamps (2) and (3), then remove tilt hoses

(4) and (5).
6. Sling track frame assembly (6), and remove mount-

ing bolts (7) and (8), then pull out at an angle to
the front to remove. m
&I kg Track frame assembly: D31PL-20 : 550 kg

D31PLL-20: 700 kg
FRAME ASSEMBLY
D31PL-20 Serial No.: 45001 - 47616
D31PLL-20 Serial No.: 45001 - 47652
m
6 Mounting bolts (7), (8):
30-88-l
a

ASSEMBLY
1. Remove work equipment assembly.

For details, see REMOVAL OF WORK EQUIP-
MENT ASSEMBLY.

For details, see REMOVAL OF TRACK SHOE AS-
SEMBLY.
a Apply the brake securely.
3. Jack up chassis and set stand under equalizer

bar and steering case.
4. Remove side cover. a
5. Remove clamps (2) and (31, then remove tilt

hoses (4) and (5).
6. Raise track frame assembly (61, then remove

mounting bolts (7) and (81, and pull out diago-
nally to front to remove. m
&I kg Track frame assembly:

D31P, PLL-20: 650 kg
D31 PLL-20 : 800 kg
FRAME ASSEMBLY

removal.
Mounting bolt: Thread tightener (LT-2)
Mounting bolts (71, (8): Thread tightener (LT-2)
30-88-2
a
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
DISASSEMBLY OF RECOIL
SPRING ASSEMBLY
Special tools
-~
[ 790-201-2760 1 Spacer I 1
791-635-3160 Extension 1
1. Set recoil spring assembly (1) in tool A.
2. Operate pump slowly to compress spring then

remove plate (2).
3. Release hydraulic pressure in pump slowly, then

gradually extend spring and turn nut (14) to extend
spring fully.
4. Remove cylinder (4) and spring (5) from bracket (3).
5. Remove piston (6) from cylinder (4).

5
113F1821:
30-91
a
ASSEMBLY OF RECOIL
SPRING ASSEMBLY
1. Fit packing (7) on piston (6), then install snap ring

(8) and ring (9).
2. Insert bar (10) in cylinder (4), then install piston (6).

* Push in from packing side.
3. Fit seal (11) and spacer (12) in cylinder (4), then in-
stall snap ring (13).
4. Set spring (5) and cylinder (4) together with the

bracket to tool A.
9 8
Il3Fl70
5. Operate pump of tool A, then compress spring and
tighten nut (14), and install plate (2) when spring is
compressed fully.
It Using guide bolt, align mounting holes of plate.
6. Release hydraulic pressure in pump and remove re-

coil spring assembly (1) from tool A.
TT==!=
12 4
Il3Fl71
30692
REMOVAL OF IDLER
ASSEMBLY

* For details, see REMOVAL OF TRACK SHOE AS-
SEMBLY.
2. Remove four bracket mounting bolts (I). m
3. Raise idler assembly (2) and pull forward to remove.
6 ks Idler assembly: 95 kg
INSTALLATION OF IDLER
ASSEMBLY
& Thread of mounting bolt for yoke:

30693
DISASSEMBLY OF IDLER
ASSEMBLY
1. Remove plug (I) and drain oil

:
u Idler: Approx. 80 cc
2 46 ?f
2. Remove bolt (2), then remove cover (3), and remove
shim.
t Check the number and thickness of the shims,
and keep in a safe place in sets for the left and
right side.
lOlFO7134
3. Remove nut (4). and knock out dowel bolt (5), then
remove support (6).
7\ n
5. Remove bushing mounting bolt (9).
%
lOlFO7135
6
6. Turn over idler, and set on block 0.
7. Remove bolt (IO), remove cover (ll), then remove

shim.
and keep in a safe place in sets for the left and
right side.
8. Remove nut (12), and knock out dowel bolt (13),

then remove support (14).
F07 I36
10. Remove bushing mounting bolt (17).
lOlFO7137
30694
11. Push end face of shaft (18), and remove bushing
(19).
12. Turn over idler, and push end face of shaft (18),
then remove bushing (20).
13. Remove shaft (18).

ASSEMBLY OF IDLER
ASSEMBLY
1. Set idler on block 0.
2. Assemble O-ring to bushing (20), then fit guide bolt

0, and using push tool @, press fit to idler.
a Press-fitting portion of bushing:

Engin oil (EOSO-CD)
* Press-fitting force of bushing: 49 - 58.8 kN
(5 - 6 ton)
\ I IOIFO714C
3. Turn over idler, and assemble shaft (18).
4. Assemble O-ring to bushing (19), then fit guide bolt

0, and using push tool @, press fit to idler.
& Press-fitting portion of bushing:

Engine oil (EOBO-CD)
* Press-fitting force of bushing: 49 - 58.8 kN
(5 - 6 ton)
IOIFO7l4l
5. Fit bushing mounting bolt (17), and install floating 1

seals (16) and (15).
Sr Clean the seal ring mating surface with a
sponge, coat thinly with engine oil (E030-CD), fit
the seal rings in tight contact with each other,
then push in the O-ring on the collar side, tak-
ing care not to let it twist, align the center, then
assemble the seal ring and O-ring.
lOlFO7137
6. Taking care that matching surface of floating seal

does not move out of position, assemble support
(14), then align with notched portion of shaft, knock 12
in dowel bolt (13), and tighten nut (12).
14
m Nut: 53.9 + 9.8 Nm (5.5 + 1 kgm)
n
$-_ 13 /l
m n
& Dowel bolt: Thread tightener (LT-2)
7. Assemble shim, and fit cover (II), then tighten with

bolt (10).
* Standard shim thickness: 3 mm
lF0713t
and install them in the correct place.
8. Turn over idler, and fit bushing mounting bolt (9),
then install floating seals (8) and (7).
* Clean the seal ring mating surface with a
the seal rings in tight contact with each other,
then push in the O-ring on the collar side, tak-
ing care not to let it twist, align the center, then
assemble the seal ring and O-ring.
* Fill the idler with oil before installing the floating
seal.
& Idler: Approx. 80 cc (EOSO-CD)

lOlFO7135
9. Taking care that matching surface of floating seal

does not move out of position, assemble support
(6), then align with notched portion of shaft, knock
in dowel bolt (5), and tighten nut (4).
& Dowel bolt: Thread tightener (LT-2)
w Nut: 53.9 + 9.8 Nm (5.5 + 1 kgm)
10. Assemble shim, and fit cover (3), then tighten with
bolt (2).
t Standard shim thickness: 3 mm
and install them in the correct place.
11. Tighten plug (1).
30697
REMOVAL OF CARRIER
ROLLER ASSEMBLY
1. Raise track shoe assembly using hydraulic jack 0.
2. Remove mounting bolt from inside, then remove
carrier roller assembly (1).
INSTALLATION OF CARRIER
ROLLER ASSEMBLY I I3P279

DISASSEMBLY OF CARRIER
ROLLER ASSEMBLY
1. Remove cap (I) from carrier roller assembly.
2. Remove bolt (2), then remove plate (3).
3. Remove roller assembly (4).
4. Disassembly of roller assembly

1) Remove floating seal (5) from roller assembly
(4).
2) Set roller assembly on block 0, and using push
tool 0, remove bushing (6).
Il4FO2156 I14FO2157
5. Disassembly of shaft, support assembly

1) Remove floating seal (8) from shaft and support
assembly (7).
2) Set shaft and support assembly (7) on block 0,
and using push tool @, remove shaft (10) from
support (9) with press.
Il4FO2156
30699
ASSEMBLY OF CARRIER
ROLLER ASSEMBLY
1. Assembly of shaft, support assembly.

1) Set support (9) on block 0, and using push tool
8, press fit shaft (10).
* Press-fitting force:
19.6 - 106.8 kN (2 - 10.9 ton)
& Shaft: Anti-friction compound (LM-P)
“4FO216C
2) Install floating seals (8) and (5).

It Clean the seal ring mating surface with a
sponge, coat thinly with engine oil (E030-
CD), fit the seal rings in tight contact with
each other, then push in the O-ring on the
collar side, taking care not to let it twist,
align the center, then assemble the seal ring
and O-ring.
“4FO2161
2. Assembly of roller assembly.

Using push tool 0, press fit bushing (6).
3. Set shaft and support assembly (7) in position, and

assemble roller assembly (4).
4. Assemble plate (3), and tighten with bolt (2).
w Mounting bolt: 176.5 + 19.6 Nm (18 + 2 kgm)
Il4FO216i Il4FO216C
5. Fill roller with oil.
& Carrier roller: Approx. 70 cc (Engine oil EOBO-CD)
6. Fit O-ring to cap (1) and install to carrier roller as-

sembly.
Il4F0215E
REMOVAL OF TRACK
ROLLER ASSEMBLY
1. Loosen lubricator (1) one turn to relieve track ten-

sion. m
* If the track tension is not relieved, move the
machine backwards and forwards.
2. Remove roller guards (2) and (3). 1121
3. Remove track roller mounting bolts (4). m
4. Using work equipment at front and hydraulic jack at

rear, raise machine and remove track roller assem-
bly (5).
I I3P280
ROLLER ASSEMBLY
m
z
d a Tighten lubricator (I), then pump in grease
2 (G2-LI) to adjust track tension.
t Track tension: 20 - 30 mm
& Thread of mounting bolt for guard:

& Thread of mounting bolt for track roller:

DISASSEMBLY OF TRACK
ROLLER ASSEMBLY
D3 1 E-20 Serial No. 42001 - 42539
D3 1 P-20A Serial No. 45001 - 46854
D31S, Q-20 Serial No. 41001 - 41134
D37E-5 Serial No. 3001 - 3616
D37P-5A Serial No. 3001 - 3489
1. Remove plug (2) from track roller (I), and drain oil.
:
u Track roller: 80 cc
2. Set track roller assembly (1) on block 0.
3. Press collar (3) and turn it, remove lock ring (4),
then remove collar (3).
4. Remove floating seal (5) from collar (3).
5. Remove floating seal (6), then remove bushing lld /

mounting bolt (7).
6. Turn over track roller assembly (I), press collar (8)

and turn it, remove lock ring (9), then remove collar
(8).
8. Remove floating seal (II), then remove bushing

mounting bolt (12).
9. Using push tool 0, push shaft (13) with press, then

remove bushing (14) from roller (15).
. Reverse the set, push the end of the shaft in
the same way, and remove bushing (16) on the
opposite side from roller (15).
30-Ao2
ASSEMBLY OF TRACK
ROLLER ASSEMBLY
D31E-20 Serial No. 42001 - 42539
D3 1 P-20A Serial No. 45001 - 46854
D31S, Q-20 Serial No. 41001 - 41134
D37E-5 Serial No. 3001 - 3616
D37P-5A Serial No. 3001 - 3489
1. Set roller (15) on block 0.
2. Fit O-ring to bushing (16), then fit guide bolt 0, and

using push tool 0, press fit bushing (16) to roller
(15).
a Press-fitting surface of bushing:

lOlFO7148
Engine oil (E030-CD)
* Press-fitting force of bushing:
49 - 68.8 kN (5 - 6 ton)
3. Turn over roller (15), and assemble shaft (13).
4. Fit O-ring to bushing (14), then fit guide bolt 8, and

using push tool 0, press fit bushing (14) to roller
(15).
& Press-fitting surface of bushing:

* Press-fitting force of bushing:
49 - 58.8 kN (5 - 6 ton)
5. After installing bushing mounting bolts (7) and (12),

install O-ring.
6. Install floating seals (11) and (10).

* Clean the seal ring mating surface with a
the seal rings into tight contact with each other,
then install floating seal (11) on the bushing
side, taking care not to let the O-ring @twist,
then assemble seal ring @ and install O-ring @
on the collar side.
Be careful not to let dirt or dust stick to the
IOIFO7l51 IOlFO715i
seal ring mating surface.
7. Install collar (8) straight, taking care not to let seal
ring come out of position.
8. Using hand press or puller, push in collar and install

lock ring (9).
IOIFO7154
9. Turn over roller (15), and fill with oil.
& Track roller: Approx. 80 cc (Engine oil E030-CD)
IO. Install floating seals (6) and (5).

* For details, see Step 6.
11. Using hand press or puller, push in collar (3) and in-
stall lock ring (4).
12. Install plug (2) to track roller assembly (1).
lOIFO7155
30-JO4
DISASSEMBLY OF TRACK
ROLLER ASSEMBLY
D31P. PL, PLL-20 Serial No. 46855 and up
D31S. Q-20 Serial No. 41135 and up n n
1. Remove plug (1) and drain oil.
- : Track roller: Approx. 150 cc
2. Set roller assembly (2) to block 0.
3. Push collar (3) and pull out ring (41, then remove
collar (3).
%
6
5. Pull out roller (6) from shaft.
CED00930 CED00931
6. Remove floating seals (7) and (8) from roller (6).
7. Remove bushings (9) and (10) from roller (6).
SED00933
8. Remove ring ill), then remove collar (12) from shaft
(13).
II 12 13
CED00934
10. Remove O-ring from shaft (13). J

c
_
/O-ring
O-ring
CEO00935 CEO00936
30-E4-2
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
ASSEMBLY OF TRACK ROLLER

ASSEMBLY
No. 1 Part No. I Part Name I Q’w QIJ CED00937

B 1 791-601-1000 1 Oil pump I 1
1. Fit O-ring to shaft (13) and assemble collar (12),

then install ring (11).
* After assembling, tighten plug (I) temporar-
ily.
2. Install floating seal (14) to collar (12) and shaft

(13).
* Precautions when assembling floating seal
1) When assembling the floating seal, wash
the hatched portion in Fig. A (O-ring and
O-ring contact surface), remove all grease
and oil, and dry it. CED02341
2) After assembling the floating seal, check
that the angle of the seal is less than 1
mm. Fig. A 'ig. B
3) After assembling, check that protrusion Remove oil and
grease.
@ of the floating seal is within a range
of 7 - 11 mm. (See Fig. B)
DED03165 DED03166
3. Using push tool 0, press fit bushings (9) and

(IO) to roller (6).
& Bushing press-fitting portion:
* Bushing press-fitting force:
29.4 = 3.92 kN I3.0 2 0.4 ton}
CEDO0939
4. Install floating seal (8) to roller (6).

* For details of the precautions when install-
ing the floating seals, see Step 2, * Precau-
tions when assembling floating seal.
I CErJ02342
5. Set shaft (13) and collar (12) assembly on block

0, then assemble roller (6).
* Coat the sliding surface of the floating seal
with engine oil, and make sure that no dirt
or dust sticks to the surface.
Ir When assembling the roller, coat the shaft
or bushing with engine oil.
CED00941
6. Refilling with oil

Pour oil through clearance between shaft (13)
and roller (6).
I& Roller: Approx. 150 cc (E030-CD)

* When using tool B to add the oil, add the oil
after completing the total assembly.
7. Install floating seal (8).

ing the floating seals, see Step 2, Sr Precau-
CED02343
30- 104-4
a
8. Install floatingseal (5) to collar (3).

ing the floating seals, see Step 2, Sr Precau-
Sr Coat the sliding surface of the floating seal
with engine oil, and make sure that no dirt
or dust sticks to the surface.
CED02344
9. Fit roller (2) to collar (3), then install ring (4).
-2
--a
CED00929
10. Using tool B, apply basic pressure to roller oil

filler port, and check for leakage of air from
seal.
* Basic pressure: 0.1 MPa {I kg/cm?
+ Method of checking
The basic pressure shall be maintained for
10 seconds and the indicator of the gauge
shall not go down.
\
CED00945
11. If oil was not added in Step 6, use tool B to fill

track roller assembly with oil.
Track roller oil:

Approx. 150 cc (E030-CD)
To oil
'i
To vacu~rn tank
DED03167
30-104-5
0
REMOVAL OF TRACK SHOE
ASSEMBLY
1. Loosen lubricator (1) one turn to relieve track ten-

sion. Illj
* If the track tension is not relieved, move the
machine backwards and forwards.
2. Move machine forward so that grouser mounts

block 0.
Stop machine and apply brake.
* When laying out the track to the rear, the ma-
chine moves about 2 m in reverse, so a space
of at least 3 m should be available.
I I3P285
3. Remove shoe bolt (3) of master link (2), then
remove shoe (4). m
4. Screw in shoe bolt (3) again and separate link (2).
5. Support front of track shoe with bar and move ma-

chine in reverse to separate track shoe assembly.
%
z SHOE ASSEMBLY
a Tighten lubricator (I), then pump in grease

(G2-LI) to adjust track tension.
* Move the machine slowly backwards and for-
wards while pumping in grease. Finally, drive
forward, stop the machine without using the
brake, and check the track tension.
w Shoe bolt:
Initial tightening: 147.1 f 19.6 Nm
(15+2kgm)
Additional tightening angle: 180” + 10
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
REMOVAL OF HYDRAULIC
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
A Loosen the oil filler cap slowly to release the

pressure inside the hydraulic tank.
Il4FO2164
Remove drain plug and drain oil from hydraulic

tank.
:
u Hydraulic tank: Approx. 33 L
Remove engine side cover.
Disconnect pump tubes (1) and (2).
Remove mounting bolts, and remove hydraulic

pump assembly (3).
INSTALLATION OF HYDRAULIC
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
l Refilling with oil (Hydraulic tank)

30-106
0
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
PUMP ASSEMBLY

A Loosen the oil filler cap slowly to release the

pressure inside the hydraulic tank. 2 CED02254
1. Drain oil from hydraulic tank.
- : Hydraulic tank: Approx. 33 e
2. Remove left engine side cover.
3. Disconnect fuel control linkage (I). m
4. Remove clamp (2) of fuel hose.
5. Disconnect 2 pipes (3) from hydraulic pump.
%
6. Remove hydraulic pump (4). \ / \\ CED02255
z
0
PUMP ASSEMBLY


removal.
* Adjust the fuel control cable.

For details, see TESTING AND ADJUSTING, Ad-
justing fuel control cable.

* Add oil through the oil filler to the specified
level.
the system.- Then check the oil level again.
30- 106- 1
a
DISASSEMBLY AND ASSEMBLY HYDRAULIC CONTROL VALVE
CONTROL VALVE ASSEMBLY
D31 E-20 Serial No.: 42001 - 42713
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
A Lower
ground
the work
and stop the engine.
equipment completely
Operate the control
to the
levers several times to release the remaining

pressure in the hydraulic piping. Then loosen
the oil filler cap slowly to release the pressure
inside the hydraulic tank.
1. Remove floor plate and bottom cover of work

equipment lever.
2. Disconnect control rods (1). m
3. Disconnect connecting hose (2) of hydraulic control
valve and tubes (3). m
4. Remove hydraulic control valve assembly (4)
together with bracket. m
0
v CONTROL VALVE ASSEMBLY ‘02 I 66
b
D31 E-20 Serial No.: 42001 - 42713
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

jlll
* Operate the work equipment control lever and
check that the spool moves smoothly.
Check also that there is no interference with the
notched part of the box.
m
* When connecting the piping, clean all dirt and
dust from the sleeve nut and nipple contact sur-
face.
* Connect the tubes in order from the bottom of
the valve.
pcj
* If the mounting bolts are tightened fully, it may
be impossible to align the sleeve nuts of each
tube, so tighten the nuts fully after connecting
the sleeve nuts of the tubes.

t Add engine oil to the specified level, and run
30- 107
0
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
REMOVAL OF MAIN CONTROL

VALVE ASSEMBLY

g Lower the work equipment to the ground and

stop the engine. Operate the control levers sev-
eral times to release the remaining oressure in
the hydraulic piping. Then loosen-the oil filler
cap slowly to release the pressure inside the
hydraulic tank.
1. Remove drain plug and drain oil from hydraulic

tank.
- : Hydraulic tank: Approx. 33 t
2. Open hydraulic tank cover.
3. Disconnect 3 control rods (1). [I
4. Remove pipes Q), (31, (41, (5). (6), (7), and (8)
connected to main control valve. m
5. Remove main control valve assembly (9) to-

gether with bracket. 113
30-107-l
0
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
INSTALLATION OF MAIN

removal.
M
* Operate the work equipment control lever
and check that the spool moves smoothly.
Check also that there is no interference with
the notched portion of the box.
When connecting the piping, remove all dirt

and dust from the connecting surfaces of
the sleeve nut and nipple.
Connect the piping in order from the bottom
of the valve.
If the mounting bolts of the main control

val’ve are tightened fully at the beginning, it
will be impossible to connect the sleeve nuts
of the tubes. To prevent this, connect the
sleeve nuts first, then tighten the mounting
bolts of the valve.

Ir Add oil through the oil filler to the specified
level.
30- 107-Z
0
DISASSEMBLY OF HYDRAULIC
D31P, PL-20 Serial No.: 45001 and up D37E-5 Serial No.: 3001 - 3730
D31PLL-20 Serial No.: 45001 and up D37P-5A Serial No.: 3001 - 3660
LIFT CONTROL VALVE ASSEMBLY FINE DISASSEMBLY OF MAIN RELIEF

VALVE ASSEMBLY
1. Remove case (1) together with detent (Z), plate
(3), and snap ring (4). 19. Remove cap (37).
2. Remove ball (5). 20. Loosen locknut (38), then remove adjustment
screw (39).
3. Loosen plug (11). * To make the set dimension when assem-
* Loosen the plug while the spool is still in- bling the same as when disassembling,
serted in the body. check the set dimension of the adjustment
screw (39) and end face of holder (41) be-
4. Pull out lift spool (6) from body (7). fore removing the nut.
5. Remove plug (S), then remove ball (9) and 21. Loosen locknut (40), then remove holder (41)
spring (10).
22. Remove poppet (42), spacer (43), spring (44)
6. Remove plug (II), then remove retainer (12), and retainer (45) from holder (41).
spring (13) and spacer (14).
23. Remove seat (47) from sleeve (46).
7. Remove plates (15).
24. Remove plug (48), then remove valve (49) and
8. Remove plate (16) and collar (17). spring (50) from sleeve (46).
t If there is any abnormality in the valve or
9. Remove plug (18), then remove spring (19) and sleeve, replace the ‘whole assembly. These
check valve (20). parts are not available individually.
10. Remove suction valve assembly (21).

LIFT SUCTION VALVE ASSEMBLY
TILT CONTROL VALVE ASSEMBLY 25. Remove screw (51).
11. Remove case (22). 26. Remove spring (52) and ball (53) from sleeve
(54).
12. Loosen bolt (23). * If there is any abnormality in these parts,
* Loosen the bolts while the spool is still in- replace the whole valve assembly. These
serted in the body. parts are not available individually.
13. Pull out tilt spool (27) from body (28).
14. Remove bolt (23) from tilt spool, then .remove

collar (24), retainer (25) and spring (26).
16. Remove plate (30) and collar (31).
17. Remove plug (32), then remove spring (33) and

check valve (34).
18. Remove main relief valve assembly (35).
30-108
0
Il3Fl822E
0
45-@
44----z 8
24-8 Y
43-a
kid
5o\g
49+--..._
49.
63
8
0
0
0
Il3Fl8224 A I l3Fl822’j
51
52
53 \
54- Q \\,oeQ
0
0
B Il3F18227
30-109
0
ASSEMBLY OF HYDRAULIC
D31P, PL-20 Serial No.: 45001 and up D37E-5 Serial No.: 3001 - 3730
D31PLL-20 Serial No.: 45001 and up D37P-5A Serial No.: 3001 - 3660
* Clean all parts, and check for dirt or damage. TILT CONTROL VALVE ASSEMBLY
Coat the sliding surfaces of all parts with en- 11. Assemble spring (33) and check valve (34) in
gine oil before installing. body (28), then fit O-ring and install plug (32).
m Plug: 107.9 + 14.71 Nm {II 2 1.5 kgm)

12. Press fit dust seal to plate (30), then fit O-ring
1. Assemble ball (53) and spring (52) in sleeve
and install collar (31) and plate (30).
(54).
13. Fit dust seal to body (28), then fit O-ring and
2. Tighten with screw (51).
install plate (29).
14. Assemble retainer (25), spring (26) and collar

FINE ASSEMBLY OF MAIN RELIEF VALVE
(24) to tilt spool (27), then tighten bolt (23) tem-
ASSEMBLY
porarily.
* Tighten the bolt fully after installing the
3. Assemble spring (50) and valve (49) in sleeve
spool to the body.
(46), and install plug (48).
15. Assemble tilt spool (27) in body (28).

4. Fit O-ring and back-up ring, then assemble seat
(47) in sleeve (46).
16. Tighten bolt (23).
5. Assemble retainer (45), spring (44), spacer (43) m Bolt: 34.37 + 4.90 Nm (3.5 + 0.5 kgm)
and poppet (42) in holder (41).
17. Install case (22).
6. Fit O-ring and assemble holder (41) in sleeve
(46), then tighten locknut (40). LIFT CONTROL VALVE ASSEMBLY
18. Fit O-ring and install suction valve assemly (21).
m Holder: 39.2 t 9.8 Nm 14 z 1 kgm}
m Suction valve assembly:
m Locknut: 68.6 z 9.8 Nm I7 z 1 kgm}
51.98 t 6.86 Nm (5.3 = 0.7 kgm)
7. Screw adjustment screw (39) in holder (41).

19. Assemble check valve (20) and spring (19) in
body (7), then fit O-ring and install plug (18).
8. Adjust set dimension of adjustment screw (39)
and end face of holder (41) to same dimension B Plug: 107.9 2 14.71 Nm 111 z 1.5 kgm}
as when disassembling, then tighten nut (38).
f Make the final adjustment after installing to 20. Fit U-packing. to body (7), press fit dust seal to
the machine, and adjust so that the set plate (16), then fit O-ring and install collar (17)
pressure is 17.2 I!:” MPa I175 - 183 kg/cm21. and plate (16).
* For details of the adjustment procedure, see
TESTING AND ADJUSTING. 21. Press fit U-packing, then fit O-ring and install
plate (15).
9. Fit O-ring and install cap (37).
22. Assemble spacer (14), retainer (12) and spring
m Cap: 34.37 f 4.90 Nm I3.5 2 0.5 kgm}
(13) to lift spool (6), then install plug (11) tem-
porarily.
10. Fit O-ring and install main relief valve assembly
t Tighten the plug fully after installing the
(35).
spool in the body.
m Main relief valve assembly:
83.36 +. 14.7 Nm 18.5 2 1.5 kgm1 23. Assemble spring (10) and ball (9) to plug (II),
* When installing the main relief valve assem- then install plug (8).
bly, fix with grease (G2-LI) so that the
m Plug: 7.35 + 2.45 Nm IO.75 2 0.25 kgm}
backup ring does not protrude from the
outside circumference of the sleeve.
30-l 10
a
B
30---l@
0
I3F I8229
37.
0
39-e
39- 8
41
25----f??
26-8 0
45--8
25-8
24-8 0 1 44---g
a @ z s
14 43-a
23- d 12--0 o 42-
8 c
13-
12- is
0
ll- Q
10.
-w---5 8
i-z
--l
f?
f-a 8
.O
4-@
0
0
0
Il3Fl8228 A Il3Fl8230
24. Assemble lift spool (6) in body (7). 51

52
53
25. Tighten plug (11). \
m Plug: 14.7 z 4.9 Nm (1.5 2 0.5 kgm} \\,ob@
54-
26. Install ball (5). Q
0
27. Assemble detent (2), plate (3), and snap ring (4) 0
to case (I), then install to body.
B Il3Fl8231
30-l 11
0
DISASSEMBLY OF HYDRAULIC
LIFT CONTROL VALVE ASSEMBLY FINE DISASSEMBLY OF MAIN RELIEF

1. Remove case (I) together with detent (2), plate VALVE ASSEMBLY
(3), and snap ring (4).
20. Remove cap (37).
2. Remove ball (5).
21. Loosen locknut (38), then remove adjustment
3. Loosen plug (11). screw (39).
* Loosen the plug while the spool is still in- * To make the set dimension when assem-
serted in the body. bling the same as when disassembling,
check the set dimension of the adjustment
4. Pull out lift spool (6) from body (7). screw (39) and end face of holder (41) be-
fore removing the nut.
5. Remove plug (8), then remove ball (9) and
spring (10). 22. Loosen locknut (40), then remove holder (41).
6. Remove plug (II), then remove retainer (12), 23. Remove poppet (42), spacer (43), spring (44)
spring (13) and spacer (14). and retainer (45) from holder (41).
7. Remove plate (15). 24. Remove seat (47) from sleeve (46).
8. Remove plate (16) and collar (17). 25. Remove plug (48), then remove valve (49) and
spring (50) from sleeve (46).
9. Remove plug (18), then remove spring (19) and * If there is any abnormality in the valve or %
check valve (20). sleeve, replace the whole assembly. These z
0
parts are not available individually.
10. Remove suction valve assembly (21).
DUMP CONTROL VALVE ASSEMBLY LIFT SUCTION VALVE ASSEMBLY

11. Remove case (22).
26. Remove screw (51).
12. Loosen bolt (23).
* Loosen the bolts while the spool is still in- 27. Remove spring (52) and ball (53) from sleeve
serted in the body. (54).
13. Pull out dump spool (27) from body (28). * If there is any abnormality in these parts, re-
place the whole valve assembly. These parts
14. Remove bolt (23) from dump spool (27), then are not available individually.
remove collar (24), retainer (25) and spring (26).
15. Remove plate (29). DUMP AND TILT BACK SUCTION SAFETY
VALVE ASSEMBLY
16. Remove plate (30) and collar (31).
* Do not disassemble the suction safety valve as-
17. Remove plug (32), then remove spring (33) and sembly because a test stand is required to ad-
check valve (34). just the set pressure if the valve has been dis-
assembled.
18. Remove main relief valve assembly (35).
19. Remove dump and tilt back suction safety valve

assemblies (36).
30-l 12
0
Il3Fl8233
37---
@
0
38------@
39- I
41
49, 0
GJ
0
45--8
44-----g
Y
43-a
42-
1
47-q
c3
0
4 -a
I13Fl8232 A I13Fl8234
B Il3Fl8235
30-113
0
* Clean all parts, and check for dirt or damage. * When installing the main relief valve assem-
Coat the sliding surfaces of all parts with en- bly, fix with grease (G2-LI) so that the
gine oil before installing. backup ring does not protrude from the
outside circumference of the sleeve.
1. Assemble ball (53) and spring (52) in sleeve DUMP CONTROL VALVE ASSEMBLY
(54). 12. Assemble spring (33) and check valve (34) in
2. Tighten with screw (51).
m Plug: 107.9 2 14.71 Nm 111 L 1.5 kgml
FINE ASSEMBLY OF MAIN RELIEF VALVE 13. Press fit dust seal to plate (30), then fit O-ring
ASSEMBLY and install collar (31) and plate (30).
3. Assemble spring (50) and valve (49) in sleeve
(46), and install plug (48).
14. Fit dust seal to body (28), then fit O-ring and
install plate (29).
4. Fit O-ring and back-up ring, then assemble seat
(47) in sleeve (46).
15. Assemble retainer (25), spring (26) and collar
(24) to dump spool (27), then tighten bolt (23)
6. Assemble retainer (45), spring (44), spacer (43)
temporarily.
* Tighten the bolt fully after installing the
spool in the body.
6. Fit O-ring and assemble holder (41) in sleeve
(46), then tighten locknut (40).
16. Assemble dump spool (27) in body (28).
m Holder: 39.2 z 9.8 Nm I4 + 1 kgm}
17. Tighten bolt (23).
w Locknut: 68.6 z 9.8 Nm I7 z 1 kgm)
w Bolt: 34.37 z 4.90 Nm 13.5 2 0.5 kgm)
7. Screw adjustment screw (39) in holder (41).
18. Install case (22).
8. Adjust set dimension of adjustment screw (39)
and end face of holder (41) to same dimension LIFT CONTROL VALVE ASSEMBLY
as when disassembling, then tighten nut (38). 19. Fit O-ring and install suction valve assembly
* Make the final adjustment after installing to (21).
the machine, and adjust so that the set m Suction valve assembly:
pressure is 17.2 ?i.” MPa {I75 - 183 kg/cm21.
51.98 z 6.86 Nm I5.3 z 0.7 kgm}
* For details of the adjustment procedure, see
TESTING AND ADJUSTING.
20. Assemble check valve (20) and spring (19) in
9 Fit O-ring and install cap (37).
m Plug: 107.9 z 14.71 Nm {II z 1.5 kgm}
m Cap: 34.37 2 4.90 Nm 13.5 2 0.5 kgm}
21. Fit U-packing to body (7), press fit dust seal to

IO. Fit O-ring and install dump and tilt back suction
plate (16), then fit O-ring and install collar (17)
safety valve assembly (36).
and plate (16).
m Dump and tilt back suction safety valve
assembly: 51.98 = 6.86 Nm i5.3 t 0.7 kgm) 22. Press fit U-packing, then fit O-ring and install
plate (15).
11 Fit O-ring and install main relief valve assembly
(35). 23. Assemble spacer (14), retainer (12) and spring
(13) to lift spool (6), then install plug (11) tem-
w Main relief valve assembly: porarily.
83.36 z 14.71 Nm 18.5 t 1.5 kgm1 * Tighten the plug fully after installing the
spool in the body.
30-l 14
0
@
31--@
@
0 -36
27,
8
Il3F18237
0
45-0
44------_g
Y
43-a
3.0”
4-@ Il3F I 8231
A Il3Fl823E I
24. Assemble spring (IO) and ball (9) to plug (II),

then install plug (8).
51
m Plug: 7.35 2 2.45 Nm IO.75 2 0.25 kgm} 52
53
\
25. Assemble lift spool (6) in body (7).
\\,o@*@
26. Tighten plug (11).

54-----
Q
w Plug: 14.71 t 4.9 Nm Il.5 2 0.5 kgm)
0
0
27. Install ball (5).
8 I13Fl823! 3
28. Assemble detent (2), plate (3), and snap ring (4)
to case (I), then install to body.
30-115
0
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE
DISASSEMBLY OF CONTROL VALVE ASSEMBLY

D31E-20 Serial No.: 42714 and up D37E-5 Serial No.: 3731 and up
D31P-20A Serial No.: 47617 and up D37P-5A Serial No.: 3661 and up
&! fiy’
0
>I0 -52
77-g cp----64
76
p-36
20-1)
24----+@
37
36
25M
33
39
CEO02336
30-115-l
a
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
Angle control valve assembly Disassembly of angle suction valve assembly

1. Remove cover (I). 1. Loosen sleeve (30) and remove spring (31).
2. Loosen bolt (2). 2. Loosen nut (321, and remove piston (34),
* Always loosen the bolt with the spool still backup ring (351, spring (36), seal (37), and
installed inside the body. poppet (38) from valve (33).
3. Pull out angle spool (3) from body (4). 3. Remove seal (39) from valve (33).
* Except for sleeve (30) and spring (31), the
4. Remove bolt (2) from angle spool, then re- parts cannot be supplied as individual
move retainer (5), collar (6), and spring (7). parts, so if there is any abnormality, re-
place the whole valve assembly.
Tilt control valve assembly
6. Remove plate (9) and dust seal (IO). 1. Remove cover (40).
7. Remove plug (II), then remove spring (12) 2. Loosen bolt (41).
and valve (13). * Always loosen the bolt with the spool still
installed inside the body.
8. Remove plug (14).
3. Pull out tilt spool (42) from body (43).
9. Remove main relief valve assembly (A) and
angle suction valve assembly (B). 4. Remove bolt (41) from tilt spool, then remove
retainer (44), collar (45). and spring (46).
Disassembly of main relief valve assembly
%
7 1. Remove cover (15). 5. Remove plate (47) and seal (48).
z
2. Loosen locknut (161, and remove adjustment 6. Remove plate (49) and dust seal (50).
screw (17).
* To make sure that the set dimension is 7. Remove plug (51), then remove ring (52).
the same after assembly as before disas-
sembly, check the set dimension of the Lift control valve assembly
end face of holder (18) and adjustment 1. Remove case (53) together with detent (54),
screw (17) before removing the nut. plate (551, and snap ring (56).
3. Loosen locknut (191, and remove holder (18). 2. Remove ball (57).
4. Remove poppet (20), spacer (21), spring (22), 3. Loosen plug (58).
and retainer (23) from holder (18). Ir Always loosen plug (58) with the spool
still installed inside the body.
5. Remove seat (24) and backup ring (25) from
sleeve (26). 4. Pull out lift spool (59) from body (60).
6. Remove plug (271, then remove valve (28) and 5. Remove plug (61), then remove ball (62) and
spring (29) from sleeve (26). spring (63).
* Valve (28), sleeve (261, and plug (27) can-
not be supplied as individual parts, so if 6. Remove plug (58), then remove retainer (64),
the result of disassembly shows that there spring (651, and spacer (66).
is an abnormality in these parts, replace
the whole valve assembly. 7. Remove plate (67) and packing (68).
8. Remove plate (69) and seal (70).
30-115-2
0
9. Remove plugs (71) and (72).
10. Remove plug (731, then remove spring (74) and

va Ive (75).
11. Remove plug (761, then remove ring (77).
12. Remove lift suction valve assembly (Cl.
Disassembly of lift suction valve assembly

1. Loosen sleeve (78), and remove spring (80) from
valve (79).
* Valve (79) and seal (81) cannot be supplied
as individual parts, so if there is an abnor-
mality in these parts, replace the whole valve
assembly.
30-115-3
0
ASSEMBLY OF CONTROL VALVE ASSEMBLY
D31E-20 Serial No.: 42714 and up D37E-5 Serial No.: 3731 and up
D31P-20A Serial No.: 47617 and up D37P-5A Serial No.: 3661 and up
-37
%38
k
33
\0
39
CEO02336
30-115-4
0
* Clean all parts, and check for dirt or damage. 10. Tighten plug (58).
Coat the sliding surfaces of all parts with en- w Plug (58):
gine oil before installing. 14.71 = 4.90 Nm Il.5 + 0.5 kgm}
Assembly of lift suction valve assembly 11. Install ball (57).

1. Fit O-ring to valve (79) and assemble spring
(80), then tighten sleeve (78). 12. Fit detent (54), plate (55), and snap ring (56)
to case (53), and install to body.
Lift control valve assembly w Case mounting bolt:
1. Install lift suction valve assembly (C). 13.24 + 1.47 Nm II.35 f 0.15 kgm}
w Lift suction valve assembly:
139.74 +. 22.06 Nm I14.25 f 2.25 kgm}
Tilt control valve assembly
2. Fit O-ring and ring (77) to plug (761, and 1. Fit O-ring to plug (511, assemble O-ring and
tighten. ring (52) in body (43), then tighten.
w Plug: m Plug:
139.74 2 22.06 Nm {14.25 +. 2.25 kgm} 139.74 2 22.06 Nm 114.25 + 2.25 kgm)
3. Assemble valve (75) and spring (74) in valve 2. Assemble dust seal (50) to plate (491, and in-
(60), then fit O-ring and tighten plug (73). stall to body (43).
m Plug: m Plate:
105.42 + 17.16 Nm I10.75 + 1.75 kgm} 13.24 = 1.47 Nm {I.35 t. 0.15 kgm}
4. Fit O-rings to plugs (71) and (72), and tighten. 3. Assemble dust seal (48) in body (43), and in-
w Plug: 53.94 z 4.90 Nm I5.5 2 0.5 kgm} stall plate (47).
%
z
5. Assemble seal (70) in body (60), and install 4. Assemble retainer (44), spring (46). and collar o
plate (69). (45) to tilt spool (42), and tighten bolt (41)
w Plate mounting bolt: temporarily.
13.24 + 1.47 Nm Il.35 2 0.15 kgm} * Tighten the bolt fully after assembling the
spool to the body.
6. Assemble O-ring and packing (68) in body
(60), and install plate (67). 5. Assemble tilt spool (42) in body (43).
7. Assemble spacer (661, retainer (64), and spring 6. Tighten bolt (41).
(65) in lift spool (591, and tighten plug (58) w Bolt: 17.16 2 2.45 Nm Il.75 + 0.25 kgm}
temporarily.
* Tighten the plug fully after assembling 7. Install cover (40).
the spool to the body. w Cover mounting bolt:
13.24 z 1.47 Nm Il.35 f 0.15 kgml
8. Assemble spring (63) and ball (62) to plug
(61), and tighten plug (61) temporarily.
w Plug (61):
7.35 f 2.45 Nm jO.75 t 0.25 kgml
9. Assemble lift spool (59) in body (60).
30-115-5
0
Assembly of angle suction valve assembly 2. Assemble seal (39) and install angle suction
1. Assemble poppet (381, seal (371, O-ring, spring valve assembly (B).
(361, backup ring (35), and piston (34) in valve w Angle suction valve assembly:
(33), then tighten nut (32). 139.74 f 22.06 Nm 114.25 + 2.25 kgm}
2. Assemble spring (31) and fit O-ring, then 3. Fit O-ring and tighten plug (14).
tighten sleeve (30). w Plug: 68.6 = 9.8 Nm {7 = 1 kgml
4. Assemble valve (13) and spring (12) in body

Assembly of main relief valve assembly (4), then fit O-ring and tighten plug (II).
1. Assemble spring (29) and valve (28) in sleeve w Plug:
(26), then install plug (27). 105.42 d 17.16 Nm I10.75 f 1.75 kgml
2. Fit O-ring and backup ring (25), then assem- 5. Assemble dust seal (IO) to plate (9). and in-
ble seat (24) to sleeve (26). stall to body (4).
m Plate:
3. Assemble retainer (23), spring (221, spacer (211, 13.24 + 1.47 Nm Il.35 z 0.15 kgml
6. Assemble dust seal (IO) to body (4), and in-
4. Fit O-ring, assemble holder (18) in sleeve (26), stall plate (8).
then lock with locknut (19).
w Holder: 39.2 = 9.8 Nm I4 + 1 kgml 7. Assemble retainer (51, spring (71, and collar
w Locknut: 68.6 + 9.8 Nm I7 + 1 kgm} (6) to angle spool (3), then tighten bolt (2)
temporarily.
5. Screw adjustment screw (17) into holder (18). * Tighten the bolt fully after assembling the
%
spool to the body.
5
0 6. Adjust so that set dimension of end face of
holder (18) and adjustment screw (17) is same 8. Assemble angle spool (3) in body (4).
as before disassembly, then tighten nut (16).
* Make the final adjustment after installing 9. Tighten bolt (2).
to the chassis, and adjust so that the set w Bolt:
pressure is 17.2+$’ MPa (175 +E kg/cm2). 17.16 2 2.45 Nm (I.75 t 0.25 kgml
Ir For details of the adjustment procedure,
see TESTING AND ADJUSTING, Measur- 10. Install cover (I).
ing and adjusting work equipment main w Cover mounting bolt:
relief pressure. 13.24 + 1.47 Nm (I.35 f 0.15 kgml
7. Fit O-ring and install cap (15).

w Cap: 34.32 + 4.90 Nm 13.5 + 0.5 kgml
Angle control valve assembly

1. Fit O-ring and install main relief valve assem-
bly (A).
m Main relief valve assembly:
83.36 f 14.71 Nm 18.5 f 1.5 kgm}
* After installing the main relief valve, fix
the backup ring with grease (G2-LI) so that
it does not protrude from the outside di-
ameter of the sleeve.
30-115-6
0
REMOVAL OF BLADE LIFT
CYLINDER ASSEMBLY
D31 E, P-20, D31 P-20A, D37E-5, D37P-5A
A Lower the work

ground and stop the engine.
equipment completely to the
1. Sling lift cylinder assembly (I), and remove lock

plate, then pull out pin (2). m
2. Start engine and retract rod, then disconnect hose

(3).
A Stop the engine. Operate the control levers se-

veral times to release the remaining pressure in
the hydraulic piping. Then loosen the oil filler
Il4FO2167
cap slowly to release the pressure inside the hy-
draulic tank.
3. Remove lock plate, and pull out pin (4), then lift off
lift cylinder assembly (1). m
& kg Lift cylinder assembly: 30 kg
INSTALLATION OF BLADE
LIFT CYLINDER ASSEMBLY
D31 E, P-20, D31 P-20A. D37E-5, D37P-5A
ml ml
A When aligning the position

never insert your fingers in the pin hole.
of the pin hole,
l Bleeding air
* Bleed the air from the hydraulic cylinder circuit.
BLEEDING AIR FROM HYDRAULIC CYLINDER.
. Refilling with oil (Hydraulic tank)

* Add oil to the specified level from filler port,
and run the engine to circulate the oil through
REMOVAL OF BLADE LIFT
CYLINDER ASSEMBLY
D31 PL, PLL-20
A Lower
grouna
the work
1. Pull out pin (1). 1
2. Start engine and retract rod, then disconnect hose
12).
Stop the engine. Operate the control levers se-

A
draulic tank.
3. Sling lift cylinder assembly, remove cap (3), then

remove lift cylinder assembly (4).
Lift cylinder assembly: 35 kg

& kg
% LIFT CYLINDER ASSEMBLY
z D31 PL, PLL-20
A When aligning the position of the pin hole,

l Bleeding air

REMOVAL OF BLADE TILT
CYLINDER ASSEMBLY
D31 E, P-20, D31 P-20A. D37E-5, D37P-5A
A Lower
ground
the work
equipment completely
Operate the control
to the
levers several times to release the remaining

pressure in the hydraulic piping. Then loosen
the oil filler cap slowly to release the pressure
inside the hydraulic tank.
1. Disconnect hoses (1) and pull out pin (2) of cylinder

bottom end. Iflj
2. Pull out pin (3) and remove tilt cylinder assembly

(4). m
-
TILT CYLINDER ASSEMBLY
D31 E, P-20, D31 P-20A. D37E-5, D37P-5A
/ [a

. Bleeding air

t Add oil to the specified level from filler port,
REMOVAL OF BLADE TILT
CYLINDER ASSEMBLY
D31 PL, PLL-20
A Lower
ground
the work
1. Remove covers (1).
2. Remove cap (2), then start engine and retract rod. m

* When retracting the rod, support the cylinder
assembly by hand to prevent it from falling, or
place a block on top of the frame.
* Check the number and thickness of removed
shims, and keep in a safe place.
A Stop
veral
the
times
engine.
to release
Operate
the
the control
remaining
levers
pressure
se-
in
draulic tank.
3. Disconnect hoses (3) and (4).
4. Remove lock plate, and pull out pin (5), then

remove tilt cylinder assembly (6). m
TILT CYLINDER ASSEMBLY
D31 PL, PLL-20
t Insert shims securely.

l Bleeding air
For details, see TESTING AND ADJUSTiNG,

30-A19
REMOVAL OF BLADE ANGLE
CYLINDER ASSEMBLY
D31 E, P-20, D31 P-20A. D37E-5, D37P-5A
A Lower
ground
the work
2. Pull out pin (2). m
3. Start engine and retract rod, then disconnect hoses

(3).

draulic tank.
4. Pull out pin (4), then lift off angle cylinder assembly
(5). m
&I kg Angle cylinder: 25 kg
ANGLE CYLINDER ASSEMBLY
D31 E, P-20, D31 P-20A, D37E-5, D37P-5A
1111 /I

l Bleeding air

302 20
REMOVAL OF BUCKET LIFT
CYLINDER ASSEMBLY
D31 S, Q-20
A Lower
grouno
the work
I ano 3stop the engine.
I. Place stand 0 (height: approx. 800 mm) under the

cross bar of lift arm securely.
2. Sling lift cylinder assembly, then pull out pin (1). m

(2).

draulic tank.
4. Pull out pin (3), then lift off lift cylinder assembly
(4). m
& kg Lift cylinder assembly: 45 kg
0
2
6
INSTALLATION OF BUCKET
LIFT CYLINDER ASSEMBLY
D31 S, Q-20
mm

. Bleeding air

3oiA21
REMOVAL OF BUCKET DUMP
CYLINDER ASSEMBLY
D31 S, Q-20
A Lower the work equipment completely to the

ground and stop the engine.
1. Sling dump cylinder assembly, then pull out pin (1). m

(2).
A Stop
veral
the
times
engine.
to release
Operate
the
the control
remaining
levers
pressure
se-
in
draulic tank.
3. Pull out pin (3), then lift off dump cylinder assembly
(4). m
&_Ikg Dump cylinder: 35 kg
INSTALLATION OF BUCKET
DUMP CYLINDER ASSEMBLY
D31 S, Q-20
11 m2]

. Bleeding air

DISASSEMBLY OF
HYDRAULIC CYLINDER
ASSEMBLY
Special tools
A 790-502-I 003 Stand 1
B 1 790-330-I 100 1 Wrench I 1
Set cylinder assembly (I) in tool A, then using tool

B, loosen cylinder head assembly (2).
Remove piston rod assembly (3) from cylinder as-

sembly (I).
Remove nut (4), then remove piston assembly (5)

and cylinder head assembly (2) from piston rod.
E
d
E
4. Remove wear ring (6) and piston ring (7) from pis-
ton assembly (5).
PI 1318167
5. Disassembly of cylinder head assembly

1) Remove snap ring (8). then remove dust seal
(9).
2) Remove rod packing (10).
3) Pull out bushing (11) from cylinder head.
CYLINDER ASSEMBLY
Special tools
I Part No. I Part Name I Q’tv

A 1 790-502-1003 1 Stand I 1
B 790-330-I 100 Wrench 1
D 790-720-I 000 Expander 1
E, 1 07281-01029 I Clamp I 1
F 796-720-I 650 Ring 1
Clean all parts, and check for dirt or damage. Coat

the sliding surfaces of all parts with engine oil be-
fore installing. Be careful not to damage the rod
packings, dust seals, or O-rings when assembling.
Assembly of cylinder head assembly.

1) Using push tool, press fit bushing (11) to cylin-
der head.
t Be careful not to deform the bushing when
press fitting.
2) Assemble rod packing (10).
t Be careful to install the rod packing facing
in the correct direction.
3) Using push tool, install dust seal (9) to head.
4) Install-snap ring (8).
Assembly of piston assembly

1) Using tool D, expand piston ring (7).
t Set the piston ring on the expander and
turn the handle 8 - 10 times to expand the
ring.
2) Remove piston ring (7) from tool D, and as-
semble to piston (5).
3) Using tools E, and F, compress piston ring.
4) Assemble wear ring (6).
Assemble cylinder head assembly (2) and piston as-

sembly (5) to piston rod, then fit nut (4). PI 1318171
Blade
Blade lift
Bucket
dE;;;P;;:_;& (D31 PL, PLL-20)
Width across flats

41 36 50
of nut 14) fmm)
Nut tightening 617.8 f 61.8 411.9 rt 41.2 1078.7 zt 107.9
toraue Nm (kam) (63 f 6.3) (42 f 4.2) (110 i 11)
PI 1318167
4. Set cylinder (1) to tool A.
5. Assemble piston rod assembly (3) to cylinder (1).
6. Using tool B, tighten cylinder head assembly (2).
w Cylinder head:
Cylinder
bottom (mm) 90 1 70 1 100 1 80
Head tighten-
ing torque 676.7 k 67.7 539.4 k 53.9 588.4 i 58.8 588.4 + 58.8
(69 k 6.9) (55 It 5.5) (60 k 6.0) (60 rt 6.0)
Nm (kgm)
REMOVAL OF WORK
EQUIPMENT ASSEMBLY
D31 E, P-20, D31 P-20A, D37E-5, D37P-5A
Stop machine on level ground, place block 0

(height: apparox. 200 mm) under U-frame, then
lower blade to ground.
Sling lift cylinder assembly (I), then pull out pin (2).
Start engine and retract piston rod fully.

draulic tank.
4. Remove cover (3), then disconnect hoses (4).
5. Pull out pin (5).
6. Start engine, then move machine slowly in reverse

to separate work equipment assembly (6) from ma-
chine.
INSTALLATION OF WORK
EQUIPMENT ASSEMBLY
D31 E, P-20, D31 P-20A, D37E-5, D37P-5A
l Greasing
& Connecting pins: Grease (G2-LI)
Il4FO2175
REMOVAL OF WORK
EQUIPMENT ASSEMBLY
D31 PL, PLL-20
1. Stop machine on level ground, lower blade to

ground, and place block under right and left sides
of straight frame (near trunnion boss).
2. Remove covers (I), (2) and (3).
3. Start engine and retract piston rod fully.

draulic tank.
4. Disconnect hoses (4) and (5) at tilt cylinder end, and

gather together at rear of machine.
5. Pull out pin (6).
6. Remove trunnion cap (7).
7. Start engine, move machine slowly in reverse and

separate straight frame from trunnion to remove
work equipment assembly.
E
d
z
0
EQUIPMENT ASSEMBLY
D31 PL, PLL-20
l Greasing

REMOVAL OF BLADE
D31 E, P-20, D31 P-20A, D37E-5, D37P-5A
1. Stop machine on level ground, place block 0

(height: approx. 200 mm) under U-frame, then lower
blade to ground.
2. Pull out pin (1) on tilt cylinder bottom end.
3. Pull out pins (2) of angle cylinder.
4. Sling blade assembly, then pull out pin (3) of pitch-

ing rod.
5. Start engine and retract piston rod fully.
A Stop
veral
the
times
engine.
to release
Operate
the
the control
remaining
levers
pressure
se-
in
draulic tank.
6. Disconnect hose (4).
7. Remove cap (5). m
8. Lift off blade assembly (6).
m Blade assembly: 730 kg
D31 E, P-20, D31 P-20A. D37E-5, D37P-5A
& Cap mount: Grease (LC-G)
&& Mounting bolt: (LT-2)
m Mounting bolt: 931.6 * 98.1 Nm (95 k 10 kgm)
l Greasing
30228
REMOVAL OF BLADE
D31 PL, PLL-20
A Lower
curely.
work equipment assembly to ground se-
1. Pull out pin (1) of lift cylinder, then run engine and
retract rod fully.
2. Sling tilt cylinder assembly, remove mounting bolts,

then disconnect tilt cylinder assembly (2). m
3. Start engine and retract rod of tilt cylinder fully.
4. Disconnect center brace (3) at straight frame end.
5. Sling blade assembly and disconnect tilt braces (4).

m
6. Pull out pin (5), then lift off blade assembly (6).
& kg Blade assembly: 350 kg
%
: D31 PL, PLL-20
mi Wj
t Standard shim thickness: 5 mm
l Greasing
a Connecting pins: Grease (G2-Ll)
30-A29
REMOVAL OF WORK
EQUIPMENT ASSEMBLY
D31S. Q-20
1. Place stand (height: approx. 800 mm) under the

cross bar of lift arm securely.
2. Remove dump cylinder assembly.

For details, REMOVAL OF BUCKET DUMP CYLINDER
ASSEMBLY.
3. Sling lift cylinder assembly, then pull out pin (1) and
disconnect lift cylinder assembly (2).
4. Sling work equipment assembly (4), then pull out

pin (3) and lift off.
& kg Work equipment assembly: 800 kg
EQUIPMENT ASSEMBLY
D31S, Q-20
l Greasing
30230
REMOVAL OF BUCKET
D31 S, Q-20
A Lower work equipment assembly to ground.
l Greasing
a Connecting pins: Grease (G2-LI)
PI 1318191
REMOVAL OF OPERATOR’S
SEAT FRAME
1. Remove canopy assembly (1). m
kg
rE?l Canopy assembly: 50 kg
2. Remove rear cover (2).
3. Remove floor plate (3), cover (4), and operator’s

seat assembly (5).
I14F0217E
4. Disconnect rods (6) and (7). m
Il4FO2180
5. Disconnect battery cables (8) and (9), and remove

battery (IO).
6. Disconnect rear lamp wiring (11).
7. Disconnect wiring (12) and (13).
8. Disconnect suction safety valve assembly (14) from

frame.
9. Remove operator’s seat frame (15). m
& kg Operator’s seat frame: 30 kg
* When removing the operator’s seat frame, dis-

connect the PPC hose clamp under the frame.
INStALLATlON OF
OPERATOR’S SEAT FRAME
m Canopy mounting bolt: 66.2 + 7.4 Nm

(6.75 f 0.75 kgm)
m
* Bend the cotter pin securely.
a Thread of mounting bolt for frame:

40 MAINTENANCE STANDARD
Damper and universal ...................

joint 40- 2
HYDROSHIFT transmission ................... 40- 4
Transmission control valve ................... 40- 6
Transmission and steering pump ............. 40- 8
PPCvalve .................................... 40- 9
Steering cylinder ............................. 40-I 0
Bevel gear shaft ............................. 40-I 1
Steering clutch .............................. 40-I 2
Steering brake ............................... 40-I 4
Final drive ................................... 40-I 6
Track frame ................................. 40-I 8
Idler cushion ................................. 40-20
% Idler ......................................... 40-22
Track roller .................................. 40-24
6
Carrier roller ................................. 40-25
Track (lubricated track link)
D31 E, P, PL, PLL-20, D31 P-20A, D37E-5,
D37P-5A ............................. 40-26
Track (dry type track link)
D31 E, P, PL, PLL-20, D31 P-20A, D37E-5,
D37P-5A ............................. 40-28
Track (lubricated track link)
D31S, Q-20 .............................. 40-30
Track (dry type track link)
D31S, Q-20 .............................. 40-32
Hydraulic pump.............................. 40-34
Hydraulic control valve ....................... 40-36
Hydraulic cylinder ............................ 40-40
Work equipment ............................. 40-46
40-l
DAMPER AND UNIVERSAL JOINT
31.4 * 2.9 Nm
(3.2 ? 0.3 kgm)
5
r
I
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit

Outside diameter of oil seal contact
1 Replace
surface on coupling
0
60 59.9
-0.074
Max. , ,. Take coupling at transmission end as fulcrum and measure

2 Face runout of output coupling
( surface of coupling at damper end )
Adjust
Take coupling at transmission end as fulcrum and measure
3 Radial runout of output coupling Max. 3.0
surface of coupling at damper end
40-2
16
66.2 * 7.4 Nm
/
(6.75 k 0.75 kgm)
-6
/ /
m 63.7 + 4.9 Nm 17 + 4.9 Nm ‘)j’
(6.5 +_0.5 kgm) (3 i 0.5 kgm) 113Fl8052
Unit: mm
Standard size Repair limit

, Backlash between No.1 sun gear and
’ planetary gear
I 0.12 - 0.22
2 Backlash between No.2 sun gear 0.14 - 0.24

and planetary gear
Backlash between No.3,4 sun gear

3 0.13 - 0.23
and planetary gear
Replace
4 Backlash between each planetan/ gear -
0.15 - 0.27
and ring gear
5 Backlash between transfer drive gear and

0.18 - 0.33
driven gear
Backlash between bevel pinion and bevel 0.18 - 0.23

6
gear
J Clearance between each planetray gear and 0.55 - 0.95 -

thrust bearing
40-4
Unit: mm
No Check item Criteria Remedy

-

8 Thickness of a disc
2.7
9 Thickness of a plate 3.2 2.9
10 Thickness of a pressure plate 3.2 3.05

- Replce
Overall thickness of four discs and
11 24.8 22.4
four plates for No.1 and No.2 clutches
Overall thickness of three discs and

12 18.6 16.8
three plates for No.3 clutch
Overall thickness of two discs and two

13 12.4 11.2
plates for No.4 clutch
Overall thickness of three discs and four

14 21.8 19.7
plates for No.5 clutch
-

Outside diameter of oil seal contact
15
surface on input coupling
0
65.0 64.9
-0.074
Repair or
Outside diameter of oil seal contact replace
16 48.0 47.9
surface on output shaft -:.062
-0.01
Width 4.0 3.76
-0.03
Wear of seal ring on
17
No.1 carrier
Thickness 4.9 20.12 4.70
- I I
% -0.01
Width
z0 Wear of seal ring on
3.0
-0.03
2.82
18
No.4 carrier
Thickness 3.8 -c 0.12 3.65
Tolerance
Standard Standard Clearance
size clearance !imit
Clearance between lubrication valve spool
19 Shaft Hole
and clutch housing
12.0 -0.020 -1-0.027 0.020 - 0.08

-0.030 0 0.057
Replace
Free Installation Installation Free Installation

20 No.1 clutch spring
length length load length load
29.13 27.8 84.87 N 27.4 72.5 N

(8.66 kg) (7.4 kg)
No.2 clutch spring 18.65 77.22 N 65.7 N

21 16.5 17.5
(7.88 kg) (6.7 kg)
No.2 clutch spring 22.93 10.3 77.22 N 65.7 N

22 21.6
(7.88 kg) (6.7 kg)
-
23 27.3
(12.33 kg) (10.5 kg)

24 (12.14 kg) 35.3
(10.3 kg)

25 27.3
(6.02 kg) (5.1 kg)
18.91 N 16.07 N
26 Lubrication valve spring 25.4 23.6 23.9
(1.93 kg) (1.64 kg)
Thickness of shim for bevel pinion

27 2.0 Adjust
bearing cage
40-5
TRANSMISSION CONTROL VALVE
T 39.2f4.9Nm
(4.OfO.5kgm)
&?& 39.2+4.9Nm i
(4.0&0.5kgm) A-A
lb 1'1 112 & 107.8k14.7Nm

(ll.OF1.5kgm)
B-B
5 14 13 6 7
15
18
c-c
114FO2051
40-6
Unit: mm
I I
Check item Criteria Remedy
Clearance between F-R and speed valve

1
spool and body
-
14.0 -0.020 +0.011 0.020 0.06
-0.030 0 0.041
Clearance between inching spool and 0 +0.027 O-

2 sleeve 14.0 -0.027 0 0.054 0.07
Clearance between inching valve spool -0.035 +0.013 0.035 -

3 and body 25.0 -0.045 0 0.058 0.08
Clearance between inching valve spool -0.020 +0.015 0.020 -

4 and piston 10.0 -0.030 0 0.045 0.07
2 5
Clearance between modulating load -0.035 +0.013 0.035 -
d piston and bodv 26.0 -0.045 0 0.058 0.08
6
Clearance between modulating valve -0.035 +0.013 0.035 -
6 suool and bodv 22.0 -0.045 0 0.058 0.08
Clearance between modulating valve -0.020 +0.018 0.020 -

7 spool and piston 15.0 -0.030 0 0.048 0.07
Clearance between quick return valve -0.100 +0.033 0.100 -

8 25.0 -0.200 0 0.233 0.25 Replace
spool and body
Clearance between quick return valve -0.035 +0.011 0.035 -

9 spool and body 14.0 -0.045 0 0.056 0.08
c
I I
Free installation Installation
10 Inching valve spring
length length load
20.727 N
27.0 18.0
(2.115 kg)
55.66 N
11 Inching valve spring 34.19 20.0
(5.68 kg)
Piston spring 26.0 19.0 5.693 N 25.2 5.39 N

12
(0.581 kg) (0.55 kg)
Modulating valve spring (Large) 62.0 39.02 204.8 N 60.1 195.0 N

13
(20.9 kg) (19.9 kg)
Modulating valve spring (Small) 53.9 39.88 142.1 N 51.2 127.89 N

14
(14.5 kg) (13.05 kg)
Piston spring 26.0 19.0 5.68 N 25.2 5.39 N

15
(0.58 kg) (0.55 kg)
- -
16 Thickness of shim for inching valve / 1.0 (One shim of 0.5 mm will charge the pressure by 0.025 MPa (0.255 kglcm2) 1
-
17 Thickness of shim for inching valve sleeve

I
1 0 (One shim of 0.5 mm will charge the pressure by 0.092 MPa (0.094 kg/cm*) 1 Adjust
-
18 Thickness of shim for modulating valve 1 1.0 (One shim of 0.5 mm will charge the pressure by 0.054 MPa (0.55 kg/cm*) I
40-7
TRANSMISSION AND STEERING PUMP
C--.- 29.4 * 4.9 Nm

(3 & 0.5 kgm)
q
\
A-A
Unit: mm
Standard clearance Clearance limit

Top clearance between gear case
1
and gear
0.140 - 0.1 JO 0.2 Repalce
2 Side clearance between gear case

0.060 - 0.070 0.1
and gear
Standard Repair limit
Revolution Pressure
discharge discharge
(rpm)
- Discharge (Q/min) (Q/min) -
(Class-CD SAE 1OW, 50 - 55°C) 2.9 MPa
2.700 54.9 45.8
(30 kg/cm*)
40-8
PPC VALVE
D3 1 E-20 Serial No. 42001 - 42198
D3 1 P-20A Serial No. 45001 - 45784
D31S, Q-20 Serial No. 41001 - 41054
D37E-5 Serial No. 3001 - 3234
D37P-5A Serial No. 3001 - 3152
44.lf4.9Nm
(4.5+0.5kgm)
17.7+3.9Nm
m 31.4+2.9Nm
-1 (3.220.3kgm)
114FO2052
Unit: mm

I I
Free length Installed Installed Free Installed
1 Metering spring x O.D. length load length load
Replace spring
36.3 N 29.0 N if any
32.8 x 7.6 29.4 23.5 damages or
(3.7 kg) (2.96 kg)
deformations
are found
44.8 N 35.9 N
2 Metering spring 35.7 x 7.4 29.4 23.5
(4.57 kg) (3.66 kg)
-
3 Return spring 1 28.3 x 11.5 1 17.5 1 ,::;7,;, 1 14 / (:;fk;) 1

FOR STEERING AND BRAKE
2.7* 14.7Nm
.5* 1.5bm)
13.23* 1.47Nm
(1.35*0.15km)
A-A c-c
%
6
SAD01 191
Unit: mm
1 Centering spring (for P3 and P4 ports)
Replace
spring if any
damage or
-
deformations
2 Metering spring (for P3 and P4 ports) are found
3 Centering spring (for Pi and Pz pans)

-
4 Metering spring (for PT and P2 ports)
4o&9-1
STEERING CYLINDER
114FO2053
Unit: mm
Clearance between cylinder and piston
40-l 0
BEVEL GEAR SHAFT
m 343+49Nm
(35 * 5 kgm) 3 2
\ \
6 5 4 I13Fl8054
Unit: mm

1 Backlash between bevel gear and pinion
0.18 - 0.23 - &djust
2 Face runout of back of bevel gear Max. 0.1

3 Outside diameter of oil seal contact Repair or
surface on bevel gear shaft replace
0
55 54.9
-0.074
1.34 - 2.4 Nm (0.14 - 0.24 kgm) (Rotating torque of bevel gear shaft)
Preload of tapered roller bearing on (For details, see INSTALLATION OF BEVEL GEAR
4
bevel gear shaft
SHAFT AND BEVEL GEAR ASSEMBLY.)
Adjust
Fitting pressure of hub of bevel gear 39.2 - 117.7 kN (4- 12 ton)
5
shaft I
Clearance between bevel gear

6 8 -c 0.7
shaft and hub
40-11
STEERING CLUTCH
W 66.4 k 6.9 Nm
CZd 66.4 + 6.9 Nm
Il3Fl8055
40-l 2
Unit: mm

1 Thickness of clutch plate
6.8 5.3 Repalce
Thickness of clutch plate 2.6 2.4

I I
2 Tolerance Repair limit

Repair or
Strain of clutch plate
replace
0.3 0.3
5 -
6 Thickness of clutch disc Replace
4.2 3.6
3
Tolerance Repair limit
Repair or
Strain of clutch disc
replace
0.2 0.2
Strandard size Repair limit

4 Thickness of clutch disc assembly
63.8 61.8
5 Wear of brake drum of outside diameter 330.0 329.0
6 Clutch spring
Replace
686.5 N 583.5 N
7 Clutch spring 94.0 65.0 88.4
(70.0 kg) (59.5 kg)
Tolerance
size clearance limit
Clearance between release yoke ball and
8 Shaft Hole
bushing
-
30 -0.100 +0.200 0.100 1 .o
-0.200 0 0.400
Clearance between pin for release yoke -

20 -0.050 +0.021 0.050 0.2
and bearing cage -0.070 0 0.091
40-13
STEERING BRAKE
Il3Fl8057
Unit: mm

1 Thickness of brake lining
6.0
Thickness of lining and brake band 12.3

2 14.0
assembly I
Standard size Repair limit Replace
I I
3 Brake band spring for rearward
80.4 N 68.6 N
72.0 76.5 67.7
(8.2 kg) (7.9 kg)
85.3 N 72.6 N
4 Brake band spring for forward 72.0 77.0 67.7
(8.7 kg) (7.4 kg) I
5 Clearance between brake drum and lining 0.3
Adjust
6 Brake lining adjustment nut Tighten adjustment nut to 39.2 N (4 kgm) and turn back 2.5 rotation
40-14
FINAL DRIVE
* The diagram shows the D31 E, S-20, final drive.
-.
-_
/-.- /
343 + 4.9 Nm
(35 f 0.5 kgm)
f
7
-.
_-
A-
40-16
Unit: mm
Tolerance Repair limit

1 Backlash between pinion and gear
0.18 - 0.53
2 Interference between boss of sprocket

shaft and reamer bolt

3 Outside diameter of oil seal contact Repair or
surface on final drive flange replace
0
80 79.9
-0.074
4 1Face runout of final drive flange I 0.3 (Datum point: Center of bevel gear shaft at 4 248))
5 Radial runout of final drive flange 0.4 (Datum point: Center of bevel gear shaft)
6 Fitting pressure of final drive flange 39.2 - 117.7 kN (4- 12 ton)

I
Adjust
7 Clearance between final drive flange and
3 kO.7
pinion shaft
8 Fitting pressure of sprocket shaft 147.1 - 441.3 kN (15 - 45 ton)
g Clearance between sprocket shaft

1.5 -0.1
+0.5
I andsprocket boss
,o Clearance between sprocket boss

2.5
and ring I
1.5
11 Thickness of shim for ring
(For details, see ASSEMBLY OF FINAL DRIVE ASSEMBLY.)

12 Wear of tips of sprocket teeth
636.4 624.5
Repair or
13 Wear of roots of sprocket teeth 571.9 560.0
I I replace
,4 Wear of teeth crest width of sprocket

38.0 32.0
teeth
,5 Wear of bottom land width of sprocket

47.5 42.0
teeth
40-17
TRACK FRAME
D31 E, P, PL, PLL-20, D31 S, Q-20
* The diagram shows the D31 E, S, Q-20 track.
114FO2054
Unit: mm

1 sending of track frame
7 (In length of 3,000 mm)
-
2 rorsion of track frame 3 (In length of level of 300 mm)
Repair or
3 Nidth of idler portion 198 203
replace
Max. 6 (Difference of forward and

D31 E, P, S-20 1,450
rearward)
Distance between
Max. 6 (Difference of forward and
A .right and left D31Q-20 1,650
rearward)
track frame center
D31 PL, PLL-20 Max. 6 (Difference of forward and

1,900
rearward)
40-18
D31 P-20A
D37E-5
D37P-5A
j, The diagram shows the D31 P-20A. D37P-5A track.
113F18316
Unit: mm
NO._ Check item / Criteria Remedy
1 Bending of track frame

7 (In length of 3,000 mm)
2 / Torsion of track frame

I - 3 (In length of level of 300 mm)
Repair or
3 Width of idler portion 198 203
replace
Max. 6 (Difference of forward

D37E-5 1,450
Distance between and rearward)
4 right and left
track frame center
D31 P-20A Max. 6 (Difference of forward
1,650
D37P-5A and rearward)
40-19
IDLER CUSHION
* The diagram shows the D31 E, P, PL, S, Q-20, D31 P-20A. D37E-5, D37P-5A.
‘i i‘1
\\ // \\ ‘/ \\ //
113F18317
--
Unit: mm
1 Recoil spring Free Installation Installation Free Installation

68647 N 61095 N
465 379 454
(7,000 kg) (6,230 kg)
Replace
Tolerance
Clearance between
2 Shaft Hole
yoke shaft and bushing
50 4.1 +0.164 0.007 - 0.5

+0.007 0.264
;yrnay between bracket 5 5 Adjust

3
40-20
MAINTENANCE STANDARD IDLER
IDLER
9
_\\\\\_\\\\
I -i
I
SBD02158
40&22
MAINTENANCE STANDARD IDLER
Unit: mm

Outside diameter of protruding section
1
on idler
548 536
2 Outside diameter of idler tread face 520 508

I I
3 Thickness of idler tread 20 14 Repair by

I I build-up
-
% welding or
4 Width of protruded section on idler 52 40 replace
z
0 -
5 Width of idler tread face 33 39
6 Overall width of idler I 118 I 110
7 Width of collar on shaft 10 9

I I
Standard
size
8 _,_I._..__-_...__.. _.._.._.._ ___ ~ t- Shah
Replace
Tolerance
Standard Standard Interference
size interference limit
9 Interference between roller and bushing Shaft Hole
+0.072 +0.054 -0.072 -

88
+0.037 0 -0.017 -
10 Free play of shaft in the axial direction

0.40 - 0.85 1.5
I
Clearance between guide plate
11 1.0 5.0
and support

12 0.5 3.0
and side mate
13 Thickness of shim for guide plate 5.0

I
MAINTENANCE STANDARD TRACK ROLLER
TRACK ROLLER
D3 1 E-20 Serial No. 42001 - 42539 D31S. Q-20 Serial No. 41001 - 41134
D3 1 P-20A Serial No. 45001 - 46854 D37E-5 Serial No. 3001 - 3616
D31P, PL, PLL-20 Serial No. 45001 - 46854 D37P-5A Serial No. 3001 - 3489
k
t- -i
IO SBDOl192
Unit: mm
Outside diameter of flange

198.0
I 188.0
Outside diameter of track roller

170.0 160.0
tread face
Thickness of track roller tread 41 36 Repair by

build-up
welding or
4 Overall width of track roller 151.0 replace
lNidth of track roller tread face 34.5 40.5
Nidth of flange 14.0 8.0
Nidth of collar on shaft 10.0

I 9.0
8 Clearance between shaft and bushing
55 -0.250 +0.074 0.250 -

-0.300 0 0.374 1.5
Replace
Interference between roller and bushing
Standard clearance I Clearance limit

Free play of shaft in the axial direction
0.40 - 0.85 1.5
I
MAINTENANCE STANDARD TRACK ROLLER
D31E-20 Serial No. 42540 and up D31S, Q-20 Serial No. 41135 and up
D31 P-20A Serial No. 46855 and up D37E-5 Serial No. 3671 and up
D31P, PL, PLL-20 Serial No. 46855 and up D37P-5A Serial No. 3490 and up
Unit: mm
-
% No Check item Criteria Remedy
7
0 -
1 Outside diameter of flange (outside)

198 186
-
2 Outside diameter of tread 170 160
Rebuild or
replace
3 Thickness of tread 56.5 51.5
4 Width of tread 34.5 40.5

I I
5 Width of flange 14 8
I I
Replace
Tolerance bushing
Standard Standard Interference
7 Interference between roller and bushing Shaft Hole
+0.117 +0.040 - 0.047 -

57
+0.087 0 -0.117 -

8 Side clearance of roller Replace
0.21 - 0.62 1.5
40-&4-’
MAINTENANCE STANDARD CARRIER ROLLER
CARRIER ROLLER
SBD02161 Unit: mm

-
1 Outside diameter of flange

%
170 160
Outside diameter of carrier roller

142 130 Repair by
tread face
build-up
welding or
Thickness of carrier roller tread 71 65 replace
I I
I I
5 Width of carrier roller tread face 35 42
I I
Clearance
limit
I 40 -0.119
-0.080 +0.039
0 0.080
0.158-
1.0
I I I
Tolerance
Standard Standard Interference Replace
Interference between carrier roller
7 Shaft Hole
and bushing
+0.062 +0.030 -0.062 -

52
+0.032 0 -0.002 -
+O.OJO +0.039 -0.070 -

8 Interference between shaft and support 40
+0.050 0 -0.011 -
9 Free play of roller in the axial direction

0.525 - 0.700 1.5
10 Fitting pressure of shaft 39 - 118 kN (4 - 12 ton1 Adjust

MAINTENANCE STANDARD TRACK SHOE
TRACK SHOE
LUBRICATED TRACK LINK (l/2)
SINGLE GROUSER SHOE, TRIPLE GROUSER SHOE, SWAMP SHOE
b I - II
2 i Ii 1’8 i5
I I I
* P portion shows the link of bushing press fitting end. SElDO2141
%I. Single-grouser shoe

%2. Triple-grouser shoe (for D31S, Q-20)
%3. Swamp shoe
Unit: mm

1 Link pitch
154.25 157.25
Reverse or
When turned replace
Standard size
Bushing outside diameter Normal load Impact load
47 42.2 44.2

Repair or
3 Link height replace
87 80
Thickness of link metal

4 23.5
(bushing press-fitting portion) I
%
z 5 112.4
0 - Replace
6 Shoe bolt pitch 82.4
7 57
I
8 Inside width 52.4
Repair or
9 Link Overall width 35 replace
10 Tread width 30.1
11 Protrusion of pin 4
12 Protrusion of regular bushing 2.75

I
13 Overall length of pin 170
Adjust or
replace
14 Overall length of bushing 92.3
15 Thickness of bushing metal 9.3

I
16 Thickness of spacer I 8.4
17 Bushing 19.6 - 49 kN {2 - 5 ton}
18 Press-fitting force Regular pin 78.4 - 117.6 kN I8 - 12 ton} -

3%
19 Master pim -
I
% : Dry type track link ,
9 0 23 22 21 6 13 )4
I
I I/
\ \ h \ \ III I I I /
\:I
IO 2 7 17 18 I5
u u u
I
2oll
\
20a
SBD02141
Ir P portion shows the link of bushing press fitting end.

z-3. Swamp shoe
Unit: mm
Tightening torque Additinal tightening

(Nm {kgml) I angle (deg.)
a. Regular link
147.1 5 19.6 I15 + 2) 60 + 10

Shoe bolt
I
Retighten
Tightening torque Additinal tightening Lower limit torque
20
(Nm IkgmH angle (deg.) (Nm {kgm))
b. Master link
%
z 147.1 + 19.6 {15 -c 2) 180 + 10 255 126)
0
D31E-20, D31S. Q-20: 37
No., of shoes (each side) D31P, PL-20, D37E-5: 41
D31 PLL-20: 46
Standard
Interference between size w in%ZEe
21
bushing and link
+0.287 +0.062
47 0.185 - 0.287
I +0.247 I 0
Interference between
22 regular pin and link
Clearance between
23
regular pin and bushing
+O.lOO +0.785 Adjust or
28 0.185 - 0.785
i 0 +0.285 replace
Standard
% size -1 ir%ZZe
24
master pin and link
-
I - I - I -
% Clearance between
25
master pin and bushing
% : Dry type track link

DRY TYPE TRACK LINK (l/2)
0 2 21 22 0 II 5 14 24 16 13
L- I /
I
\ I i\ / J F? II
12 17 23 18 7 2i is i5
x2 %3
+ P portion shows the link of bushing press fitting end.
Xl. Single-grouser shoe

~3. Swamp shoe
4o-%-’
Unit: mm

1 Link pitch
154.25 157.25
Reverse or
When turned replace
Standard size
2 Bushing outside diameter Normal load Impact load
47 42.2 44.2

I Repair or
3 Link height
replace
87 80
I
4 23.5
(bushing press-fitting portion)
%
5 112.4
Z
0 -
6 Shoe bolt pitch 57
7 15
8 Inside width 52.4

I
Repair or
9 Link Overall width 35
replace
10 Tread width 30.1

:-

Adjust or
replace

I
16 Thickness of spacer I -
17 Bushing 49 - 147 kN 15 - 15 ton}
18 Press-fitting force Regular pin 88.2 - 235.2 kN 19 - 24 ton1 -

E
19 Master pim 49 - 137.2 kN {5 - 14 ton)
I
4029-2
B 2 21 22 II 5 14 24 16 13
I I
1 \. I A
9
\ 0
I
12 17 23 I8 7 25 i!
I
20a
* P portion shows the link of bushing press fitting end.
El. Single-grouser shoe

~2. Triple-grouser shoe (for D31S, Q-20)
~3. Swamp shoe
40-%3
Unit: mm

-
(Nm {kgm)) angle (deg.)
147.1 * 19.6 {I5 * 2) 60 ? 10

Shoe bolt
I
Retighten
20
(Nm {kgm}) angle (deg.) (Nm Ikgm))
b. Master link
%
F - - -
0
D31E-20, D31S. Q-20: 37
No. of shoes (each side) D31P, PL-20, D37E-5: 41
D31PLL-20: 46
Tolerance
Standard Standard
Interference between size interference
21 Shaft Hole
bushing and link
+0.287 +0.062
47 0.185 - 0.287
I +0.247 I 0
nterference between
22 -egular pin and link
Clearance between
23
*egular pin and bushing
+0.830 -0.200 Adjust or

28 0.530 - 1.230
I +0.330 I -0.400 replace
3%
24
master pin and link
% Clearance between
25 master pin and bushing
4029-4
SINGLE GROUSER SHOE
SED01627
Unit: mm

1 Height
47 20
-
Rebuild or
2 Thickness 8.5 replace
3 Length of base 19.6

-
4 Length at tip 7
-
40&30
TRIPLE GROUSER SHOE
SDDOl629
Unit: mm

1 Height
20 10
2 Thickness 9
3 19
Rebuild or
- Length of base replace
4 16
5 15
6 Length at tip 10
7 16
SWAMP SHOE
2
SED01630
Unit: mm
D31S, Q-20, D37E-5

1 Height 74.5 62.5
D37?-5A
Rebuild or
D31E. P, PL, PLL-20
74.5 67.5 replace
D31 P-20A
D31S. Q-20, D37E-5

17 5
D37 P-5A
2 Thickness
D31E. P, PL, PLL-20
12 5
D31 P-20A
-
4022
MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
SAL( 2)-036
D31E-20 Serial No. 42001 - 42713
D31 P-20A Serial No. 45001 - 47616
D31 P, PL-20 Serial No. 45001 - 47616
D31PLL-20 Serial No. 45001 - 47653
D31S, Q-20 Serial No. 41001 - 41163
D37E-5 Serial No. 3001 - 3730
D37P-5A Serial No. 3001 - 3660
4
\
m 110.3+12.3Nm
{11.25+1.25kgmI
SED01052
Unit: mm
I
Clearance between gear case and
1
side plate, gear
0.10 - 0.15 0.19
Clearance between inside diameter of

2 ptla;ths$ng and outside diameter of 0.06 - 0.125 0.20 Replace
g
0
3 Pin insertion depth 12
-0.5
4 Rotating torque of spline shaft 2.9 - 6.9 Nm IO.3 - 0.7 kgm}

I
I
Delivery Standard Delivery

Delivery Speed @pm) pressure delivery limit
EOlOCD (MPa (kg/cm3 Wmin.) @/min.) -
45 - 55°C
3,000 20.6 12101 113 106
MAINTENANCE STANDARD HYDRAULIC PUMP
SAR(2)-040
4 2 3 3 I
SAD02157
Unit: mm
NO. Check item Criteria Remedy
I
Clearance between gear case and
1
side plate, gear
0.10 - 0.15 0.19
Clearance between inside diameter of

2 p;la;t;;;ing and outside diameter of 0.06 - 0.125 0.20 ~ Replace
9
3 Pin insertion depth 12 -:.5
4 Rotating torque of spline shaft 2.9 - 6.9 Nm {0.3 - 0.7 kgm)

I I
Delivery Standard Delivery

Delivery Speed (rpm) pressure delivery limit
EOIOCD (MPa {kg/cm’1 Wmin.) @/min.) -
45 - 55°C
3,000 20.6 12101 121 111
40&35
MAINTENANCE STANDARD HYDRAULIC CONTROL VALVE

D31E-20 Serial No. 42001 - 42713
D31 P-20A Serial No. 45001 - 47616
D37E-5 Serial No. 3001 - 3730
D37P-5A Serial No. 3001 - 3660
4 m IiS* 15Nm
(11 k 1.5 kgm)
8f2Nm
i & Q 15k5Nm
(1.5 * 0.5 kgm)
(0.8 + 0.2 kgm)
f5*5Nm
(3.5 f 0.5 kgm)
I13F18071
40&36
(7 f 1 kgm) W69klONm39+10Nm m34+5Nm
IONm m 69klONm
W 52j:7Nm w 52*7Nm
(5.3 + 0.7 kgm) (5.3 + 0.7 kgm)
%
6
Il3Fl8072
Unit: mm

1 Spool return spring
132 N 106 N
74.5 45.2 68.7
(13.5 kg) (10.8 kg)
2 Spool return spring 68.8 36.0 127 N 62.3 102 N

(13.0 kg) (10.4 kg)
3 Detent spring 15.9 12.5 49 N 15.3 39 N

Replace
(5.0 kg) (4.0 kg)
4 Check valve spring 38.5 26.0 4.9 N 36.0 3.9 N

(0.5 kg) (0.4 kg)
5 Poppet spring for main relief valve 41.1 34.0 216 N 173 N
39.7
(22.0 kg) (17.6 kg)
6 Main relief valve spring 24.2 18.3 31 N 23.0 25 N

(3.2 kg) (2.6 kg)
7 Suction valve spring 15.5 8.0 1.57 N 13.9 1.27 N

(0.16 kg) (0.13 kg)
Height of main relief pressure

8 8.35 (One turn of the screw oil charge the pressure: 2.43 MPa (24.8 kg/cm21 Adjust
adiustment screw
40-37

m
107.9*14.7Nm
a=
F87.6;;8,Nm
5 ~11*1.5kml * m
’ %EiNm %iNm
2 %!E!.9Nm
(1.8*0.2komI (1.5*0.5lamI ~0.6~0.2kPml
SAD02163
4o-F1
m 53.9*4.9Nm
(5.5*0.5koml
-
52t6.9Nm
(5.3+0.7bml
SAD02170
Unit: mm

-
Standard size I Repair limit

Spool return spring length length load length load
81.2 45.2 68.6 N 54.9 N

17.0 kg) 15.6 kg1
74.5 45.2 132.4 N 105.9 N

Spool return spring
13.5 kg1 110.8 kg)
68.8 36.0 127.5 N - 102 N

Spool return spring
113.0 kg} 110.4 kg1
Replace
17 12.5 68.6 N 54.9 N
17.0 kg} 15.6 kg)
39.5 26.0 27.5 N 21.6 N

Check valve spring
12.8 kg1 (2.2 kg1
41.1 34.0 215.7 N 172.6 N

Poppet spring for main relief valve
122.0 kg) 117.6 kg)
24.2 18.3 31.4 N 25.5 N

Main relief valve spring
13.2 kg) 12.6 kg1
4.5 N 3.6 N
Suction valve spring 38.9 17.0
(0.46 kg) 10.37 kg)
Height of main relief pressure 8.35 (One turn of the screw oil charge the pressure: Adjust
adjustment screw 2.4 MPa 124.8 kg/cm?)
D31 S, Q-20
/ \
4 Qa 108515Nm
(11 + 1.5 kgm)
8f2Nm
1 633 Qa 15*5Nm (0.8 * 0.2 kgm)
34*5Nm (1.5 + 0.5 kgm)
(3.5 + 0.5 kgm)
lIZiF
40-38
Ai I, I
m 69+10Nm
(7 i: 1 kgm) ’ w
m 83+15Nm -69*lONmm 39+10Nm 34k5Nm
(8.5 2 1.5 kgm) 1 (7 ’ ’ “em) ,(4 * 1 kgmy (3.5 * 0.5 kgm)
B-I \ \ / /A&
m 59k IONm m 69+10Nm

(6*1 kgm)W 88klONm (7 + 1 kgm)
W 52+7Nm m 52+7Nm
(5.3 + 0.7 kgm)
(5.3 k 0.7 kgm)
\
I13Fl8074
Unit: mm
Check item Criteria
Spool return spring
Height of main relief pressure

8 8.35 (One turn of the screw oil charge the pressure: 2.43 MPa (24.8 kg/cm?) Adjust
adiustment screw
40-39
STRAIGHT TILTDOZER
031 P, PL, PLL-20
1) LIFT CYLINDER
* The diagram shows the D31 P, PL-20 lift cylinder.
(55 * 5.5 kgm) (42 * 4.2 kgm)

(Width across flats: 36 mm)
113F18076-1
2) TILT CYLINDER
m 676.7 + 67.7 Nm m
\
617.8 + 61.8 Nm
(69 * 6.9 kgm) (63 * 6.3 kgm) (Width across flats: 41 mm)
F11318100
40-40
Unit: mm
NO. Check Item Criteria Remedy
Tolerance
Shaft Hole
- +0.164 -
Lift cylinder 45
Clearance between +0.007
1 piston rod and
bushing
-0.080 +0.132 0.086 -
Tilt cylinder 40 0.574
-0.142 +0.006 0.274
Clearance between
2 piston rod supporting Lift cylinder
shaft and bushing
Clearance between
3 cylinder bottom Tilt cylinder 35 -0.200 +O. 142 0.280 - 1.0
supporting shaft -0.400 +0.080 0.542
and bushing
Clearance between
4 cylinder trunnion Lift cylinder
and bushing
5
Clearance between
piston rod and retainer
Tilt cylinder
I
60 - I - Replace
40-41
D31 E-20, D31 P-20A
D37E-5, D37P-5A
1) LIFT CYLINDER
* The diagram shows the D31A-18 lift cylinder.
w 617.8 * 61.8 Nm
m 676.7’* 67.7 Nm
(63 5 6.3 kgm) (Width across flats: 41 mm)
(69 * 6.9 kgm)
113F18319
2) ANGLE CYLINDER
w 617.8 it 61.8 Nm
Q 676.7 * 67.7 Nm
(63 * 6.3 kgm) (Width across flats: 41 mm)
(69 * 6.9 kgm)
F11318059-1
3) TILT CYLINDER
I Qa 617.8 Jo61.8 Nm
m 676.7 * 67.7 Nm (63 f 6.3 kgm) (Width across flats: 41 mm)
(69 + 6.9 kgm)
113F18322
40-42
Unit: mm
NOI. Check item Criteria Remedy

-
Clearance
limit
Lift cylinder 0.574
Clearance between
1 piston rod and Tilt cylinder -0.080 +0.132 0.086 - 0.574
40
-0.142 +0.006 0.274
bushing
-0.080 +0.132 0.086 -

Angie cylinder 40 0.574
-0.142 +0.006 0.274
Lift cylinder 40 -0.025 -:.012 0.013 -

1.0
-0.064 0.064
Replace
Clearance between bushing
40 -0.025 -:.012 0.013 -
2 piston rod supporting Tilt cylinder 1.0
-0.064 0.064
shaft and bushing
Angle cylinder 40 -0.025 -:.012 0.013 -

1.0
-0.064 0.064
Lift cylinder 1.0
Clearance between
cylinder bottom 1.0
3 Tilt cylinder
supporting shaft
and bushing
Angle cylinder 1.0
40-43
DOZER SHOVEL
D31 S, Q-20
1) BUCKET LIFT CYLINDER
? i
m 1078.7 * 107.8 Nm
w 588.4 * 58.8 Nm (110 f 11 kgm)
(60 + 6.0 kgm)
113F18328
2) BUCKET DUMP CYLINDER
m 588.4 f 58.8 Nm m 1078.7 k 107.8 Nm

(60 * 6.0 kgm) (110 * 11 kgm)
1:3F18329
Unit: mm
No. Check item

r Criteria Remedy
Tolerance
Standard _ Standard Clearance
Shaft Hole
Clearance between
1
piston rod and bushing
Lift cylinder 50 - - - -
Dump cylinder 45 - - -
Replace
bushing
50 -0.025 +0.039 0.025 -
Lift cylinder 1 .o
Clearance between -0.064 0 0.103
2 piston rod supporting
shaft and bushing
Dump cylinder 1 .o
-
Clearance between Lift cylinder 1 .o

cylinder bottom
3
supporting shaft
-0.025 +0.142 0.105 -
and bushing Dump cylinder 40 1 .o
I -0.064 I +0.080 I 0.206
40-44
WORK EQUIPMENT

D31 E-20, D31 P-20A, D37E-5, D37P-5A
B-B
D-D
1 F-F
k 102.9Nm
(94.5 + 10.5 kgm)
8
5 5
H-H
3
8
5
3
7
0 0 0 0 0 0 000
5
_-
\
-259.7534.3Nm -926.li102.9Nm 13 J-J
(26.5+3.5kgm) (94.5i10.5kgm)
114FO2055
40-46
Unit: mm
No.
I Check item
I
Criteria
Tolerance
, Clearance between pin and frame
Shaft Hole
support bracket
-0.050 +0.500 0.350 -

50 1.6
-0.100 +0.300 0.600
+0.500
2 Clearance between pin and frame 50 1 .o
-I-0.300
3 Clearance between pin and collar bushing -

40 -0.025 +0.050 0.025 0.5
-0.064 0 0.144
4 Clearance between pin and frame -

40 -0.025 +0.400 0.125 1 .o
-0.064 +0.100 0.464
5 Clearance between pin and blade bracket -

40 -0.025 +0.400 0.125 1 .o
-0.064 f0.100 0.464
Clearance between pin and lift cylinder I -0.025 0 0.013 -

0.5
bushing~~ 40 -0.064 -0.012 0.064
, Clearance between pin and angle cylinder -

40 -0.025 0 0.013 0.5
bushing -0.064 -0.012 0.064
8 I Clearance between pin and tilt cylinder I 40 -0.025 -

0 0.013 0.5
-0.064 -0.012 0.064
9 I Clearance between pin and loader frame I 40 -0.025 +0.200 0.025 - 1 .o

-0.064 0 0.264
1o Clearance between pin and pitching rod I 40 -0.025 +0.039 0.025 - 0.5
bushino -0.064 0 0.103
11 Spherical clearance between blade

0.5 Adjust
trunnion and trunnion cap

12 Height of cutting edge and end bit
*2 Reolace
13 0
I Width of end bit
-1
40-47
STRAIGHT TILTDOZER
D31 P, PL, PLL-20
A-A B-B
F-F
2,13
-
G-G H-H
Il3Fl8079
40-48
MAINTENANCE STANDARD WORK EQUIPMENT
Unit: mm

I
Spherical clearance between trunnion and

1 Stz?d t,,
1
%
6
2 Clearance between pin and frame I 50 -0.100
-0.050 +0.050
+0.400 0.100
0.500 - 1 .o
I
3 1 .o
blade
Clearance between pin and bracket of I 50 -0.100
-0.050 +0.300
+0.500 0.600 -
0.350 I
Clearance between pin and brace 35 -0.200 +0.200 0.200 - 1 .o
4
- 0.400 0 0.600
Replace
Clearance between pin and -0.200 +0.142 0.280 - 1 .o
5
tilt cylinder bushing 35 -0.400 +0.080 0.542
6 Clearance between pin and frame I 35 -0.400

-0.200 +0.300
+0.500 0.500
0.900 - 1 .o
I
7 1 .o
blade
Clearance between pin and bracket of I 30 -0.072
-0.020 0
+0.250 0.322 -
0.020 I
Clearance between pin and -0.020 +0.033 0.020 - 0.5
8
lift cylinder bushing 30 -0.072 0 0.105
9 Clearance between pin and arm

I 35 - 0.400
-0.200 +0.200
0 0.200
0.600 - 1 .o I
10 Clearance between pin and frame 35 -0.200 +0.500 0.500 - 1 .o

-0.400 +0.300 0.900
Spherical clearance between - 1 .ooo + 1.000 1 .ooo - -

11 61
arm and cap -1.100 0 2.100
- I
12 and
Spherical clearance between brace 61 -0.100
0 + 01 .ooo o- 1.100 - Adjust
cap
Spherical clearance between tilt - 0.200 + 1 .ooo 0.200 -

13 cylinder and cap 61 - 0.300 0 1.300

14 Height of cutting edge and end bit
*2 Replace
-
0
15 Width of end bit
-1
40-&49
DOZER SHOVEL
D31 S, Q-20
, II,,
A-A
-627.2*29.4Nm
(64F3kgm)
B-B
D-D
E-E
114FO2056
40-50
Unit: mm
90 OTHERS
Trimming dozer . .._...._.............................................. 90-3

TRIMMING DOZER
D31E-20 (DDM031-4M)
D31E-20 (DDM031-4K)
D31P-20 (DDM031-4J)
. This section contains only information related to the trimming dozer.

For other information, see the D31-20, D37-5 Shop Manual.
CONTENTS
GENERAL
Specification drawing.. ......................................................................................................................................... go- 5
Specifications ........................................................................................................................................................ 90- 6
Weight table ................... ....................................................................................................................................... 90-12
Table of fuel, coolant and lubricants. .................................................................................................................... 90-I 4
Power train hydraulic piping.. ............................................................................................................................. 90-16
Transmission control ............................................................................................................................................ 90-18
Steering control ..................................................................................................................................................... 90-22
PPC valve ............................................................................................................................................................... 90-24
Track frame ........................................................................................................................................................... 90-36
Hydraulic piping .................................................................................................................................................... 90-38
Work equipment hydraulic circuit diagram ....................................................................................................... 90-40
Work equipment hydraulic system diagram ..................................................................................................... go-41
Work equipment control ...................................................................................................................................... 90-42
Work equipment control valve. ........................................................................................................................... 90-44
Trimming dozer .................................................................................................................................................... 90-48
Electrical wiring diagram ..................................................................................................................................... 90-51
Engine control ....................................................................................................................................................... go-52
0
MAINTENANCE STANDARD Z
PPC valve. ... ........................................................................................................................................................... 90-54 Z
0
Track frame ........................................................................................................................................................... 90-56
Idler cushion .......................................................................................................................................................... 90-58
Idler ............. . .......................................................................................................................................................... 90-60
Track roller ....... ..................................................................................................................................................... 90-64
Carrier roller ._........................................................................................................................................................ 90-66
Track ................ ....................................................................................................................................................... 90-68
Work equipment control valve ............................................................................................................................ 90-74
Hydraulic cylinder ................................................................................................................................................. 90-78
Trimming dozer .................................................................................................................................................... 90-80
GENERAL
. D31 E-20 (DDM031-4H)

OUTSIDE MOUNT LIFT CYLINDER TYPE
Unit: mm
2310
Il4FO2183
. D31 E-20 (DDM031-4K)
INSIDE MOUNT LIFT CYLINDER TYPE
Unit: mm
2310
2735 830
114FO2201
l D31 P-20 (DDM031-4J)
Unit: mm
;
3
:
:
:
.
’
s
CD \ IL I2815 -
I
2915 1150
Il4FO2184
Note: The values with ( ) are the values for rubber shoe.
SPECIFICATIONS
7
D31 E-20 D31 E-20 D31 P-20
Machine Model
(%I) (%2) (%I)
Serial Numbers 42001 and up 42001 and up 45001 and up
Trimming dozer type DDM031-4H DDM031-4K DDMOBI -4J
Operating weight (bare tractor) (kg) 5,120 5,120 5,750
Operating weight (with dozer) (kg) 6,800 6,660 7,470
Min. turning radius (m) 2.2 2.2 2.5
Gradeability (deg) 30 30 30
Stability (deg) 35 35 35
Forward 1st (km/h) 2.2 2.2 2.2
g Forward 2nd (km/h) 3.9 3.9 3.9
?
I Forward 3rd (km/h) 6.5 6.5 6.5
u
8 Reverse 1st (km/h) 2.4 2.4 2.4
CI
U-J Reverse 2nd (km/h) 4.3 4.3 4.3
Reverse 3rd (km/h) 7.1 7.1 7.1
~g Bare tractor (MPa(kg/cm*) 0.040(0.41) 0.040(0.41) 0.022(0.22)

3: %
$g With dozer (MPa(kg/cm? 0.044(0.45) 0.043(0.44) 0.027(0.28) Z
%
5 Bare tractor (mm) 2,910 2,910 3,035
F
2 With dozer (mm) 4,510 4,510 4,690
5 Bare tractor (mm) 1,790 1,790 2,050

=
1 With dozer (mm) 2,310 2,310 2,780
g To tip of exhaust pipe (mm) 1,950 1,950 1,900 < 1,890>

=
m
% To top of operator’s seat (mm) 1,955 1,955 1,975 <I ,965>
0
Track gauge (mm) 1,450 1,450 1,450
Length of track on ground (mm) 1,880 1,880 2,185
Width of track shoe (standard) (mm) 400 400
Min. ground clearance (mm) 315 315 380 <370>

(To drain port of steering case)
Note. l The value with < > for rubber shoe.

l %I : Outside mount lift cylinder type.
l %2: Inside mount lift cylinder type.
D31 E-20 D31 E-20 D31 P-20
Machine Model
(%I) (%2) (%I)
Trimming dozer type DDM031-4H DDMOBI -4K DDMOBI-4J
Model Komatsu 6D95L-1
Type 4-cycle, water cooled, in-line vertical type, direct injection
No. of cylinder - bore x stroke (mm) 6-95x115
Piston displacement (cc) 4,890
Rated horsepower (kW(HP)/rpm) 52.2 (70)/2,350
Max. torque (Nm(kgm)/rpm) 264.8 (27)/l ,400
High idling (rpm) 2,580
Low idling (rpm) 700
Min. fuel consumption ratio (g/kW * h (g/HP * h)) (217)160
Alternator 24V, 13A
Battery 12V,70Ahx2
I
Damper Wet, spring friction type
Planetary gear type, hydraulically actuated,

Transmission
lubrication pump force feed type, forward 3 speed, reverse 3 speed
Wet type, multiple disc, spring boosted,

Steering clutch
hand operated, PPC actuated (interconnected with brake)
Wet type, band type, PPC actuated,

Steering brake
interconnected with clutch
Final drive Spur gear, l-stage planetary gear, splash type lubrication

D31 E-20 D31 E-20 D31 P-20
Machine Model
(%I) (%2) (%I)
Trimming dozer type DDM031-4H DDM031-4K DDM031-4J
Suspension Rigid
Carrier roller (each side) 1
Track roller (each side) 5

I
I
5
I 6
Lubricated, _
Lubricated, assembly type assembly type
Single grouser, with hole Swamp shoe Rubber shoe

Pitch: 154 mm Pitch: 154 mm Steel code

pitch: 160 mm
Width: 400 mm Width: 600 mm Width: 600 mm
Max. pressure (MPa(kg/cm*)) 17.2 (175)
Gear type (SAL (2)-036)
/
90.1
Type l- Double action, piston type
Cylinder bore (mm) 90 90 90
Outside diameter of (mm) 40 40 40

piston rod
Piston stroke (mm) 450 393 450
Max. distance between (mm) 1,175 1,109 1,175

pins
Min. distance between (mm) 725 716 725

pins
Cylinder bore (mm) 90 90 90
Outside diameter of (mm) 40 40 40

piston rod
Piston stroke (mm) 260 260 260
Max. distance between (mm) 845 845 845

pins
Min. distance between (mm) 585 585 585

pins
Hydraulic
Note. l
tank
The value with < > for rubber shoe.

J- Externally mounted control valve

D31 E-20 D31 E-20 D31 P-20
Machine Model
(%I) (%2) (%I)
Trimming dozer type DDMOSI -4H DDM031-4K DDM031-4J
Type Hydraulically actuated trimming dozer
Blade support method Hydraulic cylinder type
Max. lifting height (mm) 1,480 1,480 1,630 < 1,620>

(from ground)
Max. lowering depth (mm) 710 650 <660>

(from ground)
Tilt angle (Forward tilt) (deg) 38 38 38
Tilt angle (Reverse tilt) (deg) 26 26 26
Blade cutting angle (deg) 90 90 90
Blade width (mm) 2,310 2,310 2,780
Blade height (mm) 750 750 750

WEIGHT TABLE
A Thus weight table is a guide for use when transporting or handling components.
Unit: kg
D31 E-20 D31 E-20 D31 P-20

Machine Model
(%I) (%2) (%I)
Trimming dozer type DDM031-4H DDMOBI -4K DDMOBI -4J
Engine and damper assembly 469 469 469

* Engine assembly 439 439 439
* Damper assembly 27 27 27
Radiator assembly 40 40 40
Fuel tank assembly (with fuel) 195 195 195
HYDROSHIFT transmission assembly 232 232 232

. Modulating valve assembly 6 6 6
. Speed and inching valve assembly 8 8 8
Bevel gear shaft and steering clutch assembly 140 140 140
. Steering clutch assembly (each side) 48 48 48
. Brake band assembly (each side) 9 9 9

%
. Bevel gear shaft 9 9 9
Z
. Bevel gear 15 15 15
Steering control valve assembly %3: 6. %4: 4.5 %3: 6. %4: 4.5 %3: 6. %4: 4.5
Final drive case (each side) 45 45 45
Sprocket (each side) 41 41 41
Rear guard assembly 210 210 210
Main frame and steering case 840 795 825
Sprocket shaft (each side) 32 32 32
Track group assembly (without trunnion) 505 510 575 <605>

(each side)
. Track frame (each side) 125 130 165 <175>
. Idler assembly (each side) 95 95 95 <lOO>
. Track roller assembly (each) 27 27 27 <30>
* Carrier roller assembly (each) 20 20 20 <16>
Track shoe assembly (each side) 470 470 670 <680>
Cross bar 110 110 110

Unit: kg
Machine Model
I D31 E-20
(%I) I
D31 E-20
(%2) I
D31 P-20
(%I)
Trimming dozer type DDMOBI -4H DDM031-4K DDM031-4J
Hydraulic tank assembly 87 87 87
Hydraulic control valve assembly 20 20 20
Blade lift cylinder assembly (each side) 26 30 26
Trimming cylinder assembly (each side) 20 20 20
Trimming dozer assembly 1,200 1,160 1,280
* Blade 480 480 460
* H-frame 430 355 455
* Trunnion 95 x 2 15x2 95 x 2
Radiator guard 60 60 60
Engine underguard 45 45 45
Transmission underguard 40 40 40
Hood 28 28 28
Loader frame 110 110 110
Operator’s seat assembly 15 15 15

l %3: Applicable Serial No. D31 E 42001 - 42198
D31 P 45001 - 45784
l Z.4: Applicable Serial No. D31E 42199 and up
D31 P 45785 and up
TABLE OF FUEL, COOLANT AND LUBRICANTS
KIND OF
AMBIENT TEMPERATURE CAPACITY ( !2)
RESERVOIR -22 -4 14 32 50 68 86 104
FLUID
-30 -20 -10 0 10 20 30 40 Specified Refill
Engine oil pan
Damper case
Transmission case 16
Transfer case
Steering clutch case Engine oil
Hydraulic system
Idler (each)
Track roller (each)
Fuel tank t Diesel fue 118 -
Cooling system Coolant Add antifreeze 23.3
% ASTM D975 No. 1
NOTE:
(1) When fuel sulphur content is less than 0.5%, change (2) When starting the engine in an atmospheric tem-
oil in the oil pan every periodic maintenance hours perature of lower than 0°C. be sure to use engine oil
described in Operation & Maintenance Manual. of SAEIOW, SAEIOW-30 and SAEl5W-40 even
Change oil according to the following table if fuel though an atmospheric temperature goes up to 10°C
sulphur content is above 0.5%. more or less in the day time.
(3) Use API classification CD as engine oil and if API
Change interval of oil classification CC, reduce the engine oil change inter-
Fuel sulphur content val to half.
in engine oil pan
(4) There is no problem if single grade oil is mixed with
0.5 to 1 .O% l/2 of regular interval multigrade oil (SAEIOW-30, 15W-40), but be sure to
I
add single grade oil that matches the temperature in
Above 1 .O% l/4 of regular interval the table on the left.
(5) We recommend Komatsu genuine oil which has
been specifically formulated and approved for use in
engine and hydraulic work equipment appications.
ASTM: American Society of Testing and Material
SAE: Society of Automotive Engineers
API : American Petroleum Institute
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
90-J 4
POWER TRAIN HYDRAULIC PIPING
D31E-20 42001 -42198
D31P-20 45001-45784
A 114FO2202
7. R.H. steering cylinder

1. Oil cooler
Transmission 8. R.H. brake cyliner
2. pump
9. L.H. brake cylinder
3. Oil cooler bypass valve
10. L.H. steering cylinder
4. Transmission modulating valve
Check valve 11. PPC valve
5.
Transmission case 12. Oil filter
6.
90&l 6
D31E-20 42199 and up
D31P-20 45785 and up
114FO2203

2. Transmission pump 8. R.H. brake cyliner
6. Transmission case 12. Oil filter
OUTLINE
l Oil in transmission case (6) is sucked up by lubrication circuit when clogging of the oil
pump (2) installed to the transmission. It passes cooler circuit causes the pressure to go above
through modulating valve (4), pushes open specified pressure.
check valve (5), 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
cording to the operation of the left and right hydraulic circuit. It prevents the oil in the trans-
steering levers, and sends it to one of left or mission hydrauic ciruit from flowing back.
right cylinder (7) or (10) to disengage the steer- In other words, if the gear is shifted when the
ing clutch. steering clutch is disengaged, the modulating
l The modulating valve sets the pressure in the valve acts to make the pressure in the circuit
circuit to specified pressure. Oil relieved by the 0 MPa (0 kg/cm’), so it becomes impossible to
main relief valve passes through bypass valve disengage the clutch.
(3), and is then sent to oil cooler (I), where it When this happens, the check valve shuts off
is cooled before being sent to lubricate the the two circuits and keeps the pressure in the
transmission. steering circuit high, so it remains possible to
l The oil cooler bypass valve acts to protect the disengage the steering clutch.
oil cooler from damage. It sends the oil directly
from the modulating valve to the transmission
D31 E-20 42001 - 42086
D31 P-20 45001 - 45420

2. Steering and directional lever l Gear shift lever (1) and steering and directional
3. Lock lever lever (2) in the operator’s compartment are inter-
the steering case.
0: Neutral
0: 3rd valve spool is actuated at the same time. A set of
@: Lock the machine travels.
0: Inching When inching .pedal (5) is operated, the inching
SAFETY MECHANISM WHEN SHIFTING TRANSMISSION
I 14FO2006

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
1. When steering and directional lever is at N;
The gear shift lever will enter 1st or 2nd position, \
C’ B I 14FOPOO;
but will not enter 3rd position.
. When steering and directional lever (I) is at N,
points A, B, and C are in a straight line. 3rd
2nd \
l 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.)
l When gear shift lever (2) is moved from 2nd posi-
tion to 1st position, there is clearance “a” at faces DE
F and G, so the operation is possible without
3’ I I4FO2008
moving intermediate lever (3).
90,’ 9
2. When steering and directional lever is at F or R;
The gear shift lever can be moved to 1st. 2nd or
3rd positions.
. 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).
I 14FO2009
3rd
Il4FO201C ,
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
l-
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.
. 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 I4FO20 I I
ing portion of the boss pushes face E, and gear
shift lever (2) is returned to 2nd position.
2
i
D31E-20 42087 and up
D31P-20 45421 and up

2. Steering and directional lever l Gear shift lever (I) and steering and directional
3. Lock lever lever (2) in the operator’s compartment are in-
4. Speed, directional, inching valve assembly terconnected with each spool of the speed, di-
5. inching pedal rectional, and inching valve assembly (4) on top
of the steering case.
0: Neutral
0: 1st ated, the directional valve spool is actuated,
0: 2nd and when gear shift lever (1) is operated, the
0: 3rd speed valve spool is actuated at the same time.
0: Free A set of 2 clutches inside the transmission is
0: Lock engaged and the machine travels.
0: Inching When inching pedal (5) is operated, the inching
reverse clutch inside the transmission is par-
tially or fully disengaged to make fine adjust-
ment of the travel speed or to make the ma-
chine stop.
STEERING CONTROL
D31E-20 42001 -42198
D3lP-20 45001 -45784
114FO2019
1. Brake lock lever

2. Brake pedal
3. Right brake
4. Right brake cylinder
5. Right steering cylinder
7. PPC valve
8. Left brake
9. Left steering cylinder
TO. Left brake cylinder
Lever, pedal positions

0: Left steering clutch disengaged
0: Left steering brake applied
0: Right steering clutch disengaged
8: Brake locked
D31E-20 42199 and up
D31P-20 45785 and up
114FO2205
1. Brake lock lever

2. Brake pedal OUTLINE
3. Right brake l Steering and directional lever (6) on the left
4. Right brake cylinder side of the operator’s compartment is intercon-
5. Right steering cylinder nected with PPC valve (7), and uses hydraulic
6. Steering and directional lever pressure to actuate the steering and brakes.
7. PPC valve Brake pedal (2) is interconnected only with the
8. Left brake brake lever.
9. Left steering cylinder . If the steering and directional lever is moved
10. Left brake cylinder slightly to the left, the left steering clutch is
partially disengaged and the machine turns
Lever, pedal positions slowly to the left.
0: Left steering clutch disengaged l If the steering and directional lever is moved
0: Left steering brake applied fully to the left, the left steering clutch is com-
0: Right steering clutch disengaged pletely disengaged, and left steering brake (8) is
0: Right steering brake applied also applied to make the machine turn sharply
0: Steering brake applied to the left.
@: Brake locked
PPC VALVE
D31 E-20 42001 - 42198

D31 P-20 45001 - 45784
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)
A-A B-B
I 14FO2022
1. Lever 7. Retainer
2. Disc 8. Metering spring
3. Joint 9. Valve
4. Piston 10. Body
5. Plate 11. Centering spring
6. Collar
OPERATION
1) At neutral
Ports A and B of the steering clutch cylinder
nected to drain chamber D through fine control
hole f in spool (1). (Fig. 1)

retainer (9) is pushed; spool (I) is also pushed
114FO2023
by metering spring (2), and moves down. (Fig. 1)
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.
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
P3.
When this happens, spool (I) moves up or
down so that the force of metering spring (2) is
balanced with the pressure at port P3. The rela-
r-i-
tionship in the position of spool (1) and body
(10) (fine control hole f is at a point midway PP
between drain hole D and pump pressure
chamber PP) does not change until retainer (9)
contacts spool (1).
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
(where control lever is returned) w
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 (2), 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)
-Pp
(Fig. 3)
114FO2025
4) At full stroke
tainer (9) pushes down spool (l), 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)
PP
(Fig. 4) 114FO2026
* 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) R

d
(Fig. 1) 114Fd2027
retainer (9) is pushed; spool (1) is also pushed by E
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 (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
ship in the position of spool (1) and body (10)
(fine control hole f is at a point midway between
drain hole D and pump pressure chamber PP)
(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
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 6
to fill the chamber with oil (Fig. 3)
(Fig. 3) 114FO2029
4) At full stroke
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.
port P2 through fine control hole f’ and flows to
(Fig. 4) 114FO2030
PPC VALVE

D31P-20 Serial No. 45785 and up
c a d
f b e
Z
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. P1 port (brake valve: to R.H. brake cylinder)
f. P3 port (steering valve: to L.H. steering cylinder)
90630
A-A
D-D
SADOIISD
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
OPERATION
1) At neutral
Ports A and B of the steering clutch cylinder (1)
nected to drain chamber D. (Fig. 1)
‘-=T/i=$~,~~,
2) During fine control (neutral - fine control)
When piston (4) starts to be pushed by disc (5), (Fig. 1)
by metering spring (Z), and moves down.
from port P3 to port A.
spool (1) is pushed back and port P3 is shut off
chamber D to release the pressure at port P3.
When the happens, spool (1) moves up or down
anced with the pressure at port P3. The relation-
ship in the position of spool (1) and body (10)
(1).
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)
9022
When this happens, port P3 is connected to drain
chamber D and the pressure oil at port W is
released.
If the pressure at port P3 drops too far, spool (1)
P3 is shut off from drain chamber D. At almost
until the pressure at port p3 recovers to a pres-
sure that corresponds to the lever position. (Fig.
3)
R
d
:
0 (Fig. 3)
4) At full stroke
When disc (5) pushes down piston (41, and re-
tainer (9) pushes down spool (I), port p3 is shut
chamber A from port P3, and pushes the piston
of steering clutch cylinder (11). (Fig. 4)
(Fig. 4)
OPERATION
1) At neutral
Ports A and B of brake cylinder (11) and ports
Pi and Pz of the PPC valve are connected to
'ADOII65
2) During fine control (neutral -. fine control)
When this happens, port Pi is shut off from drain
from port Pi to port A.
When the pressure at port PI becomes higher,
spool (1) is pushed back and port PI is shut off
chamber D to release the pressure at port Pi.
(1).
the control lever, so the pressure at port PI
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 A6
balanced. (Fig. 2) (Fig. 2)

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)
PI is shut off from drain chamber D. At almost
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)
SAD01 187
(Fig. 3)
4) At full stroke
When disc (5) pushes down piston (41, and re-
tainer (9) pushes down spool (11, port PI is shut
chamber A from port PI, and pushes the piston
of brake cylinder (11).
port P2 and flows to drain chamber D. (Fig. 4)
SAD01 188
(Fig. 4)
TRACK FRAME
D31 E-20
D31P-20 (STEEL SHOE SPEC.)
* The diagram shows the D31 E-20.
114FO2208
1. Idler OUTLINE
6. Track roller
Number of Number of
Model carrier roller track roller
(each side) (each side)
D31 E-20
I 1 I 5
D31 P-20 1 6
D31P-20 (RUBBER SHOE SPEC.)
UJ Ll
7
114FO2209
1. Idler OUTLINE
3. Rubber crawler weight, and moves the machine by driving rub-
4. Carrier roller ber crawler (3) using the motive force of the
5. Sprocket power train transmitted from sprocket (5).
6. Track roller
HYDRAULIC PIPING
TRIMMING DOZER
(OUTSIDE MOUNT LIFT CYLINDER TYPE)
D31 E-20 (DDM031-4H)

D31 P-20 (DDMOSI -45)
-4
114FO2210
1. Hydraulic pump OUTLINE

2. Hydraulic control valve l The oil in hydraulic tank (4) is sucked up by hy-
3. Hydraulic filter draulic pump (1) installed to the engine, and is
4. Hydraulic tank sent to hydraulic control valve (2).
5. Blade lift cylinder The hydraulic control valve sets the pressure in
6. Trimming cylinder the circuit to specified pressure. It switches the
flow of oil to lift cylinder (5), or trimming cylin-
der (6) to operate the blade according to the
movement of the work equipment control lever.
hydraulic tank.
l The hydraulic filter is a cartridge type.
TRIMMING DOZER
(INSIDE MOUNT LIFT CYLINDER TYPE)
D31 E-20 (DDMOSl-4K)
114FO2211
1. Hydraulic pump OUTLINE

2. Hydraulic control valve l The oil in hydraulic tank (4) is sucked up by hy-
3. Hydraulic filter draulic pump (1) installed to the engine, and is
4. Hydraulic tank sent to hydraulic control valve (2).
5. Blade lift cylinder The hydraulic control valve sets the pressure in
6. Trimming cylinder the circuit to specified pressure. It switches the
flow of oil to lift cylinder (5), or trimming cylin-
der (6) to operate the blade according to the
movement of the work equipment control lever.
hydraulic tank.
l The hydraulic filter is a cartridge type.
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
19.1 MPat___J
--ki-.lL8 REVERSE
r
TILT FORWARD TILT
hII (195 kg/cm:

0
7
6
(178 kg/cm>)
L- 1
114FO2212
1. Hydraulic tank 8. Trimming cylinder

2. Hydraulic pump (SAL(2)-036) 9. Check valve
3. Main relief valve 10. Blade lift valve spool
4. Check valve 11. Suction valve (for blade lower)
5. Trimming valve spool 12. Suction valve (for blade raise)
6. Safety valve with suction (Reverse tilt end) 13. Blade lift cylinder
7. Safety valve with suction (Forward tilt end) 14. Hydraulic filter
15. Hydraulic tank breaker relief valve
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM
114FO2213
WORK EQUIPMENT CONTROL
114FO2214
Lever positions 1. Blade control lever

0: Blade HOLD 2. Lock lever
0: Blade RAISE 3. Main control valve
0: Blade LOWER
0: Blade FLOAT
0: Blade FORWARD TILT
@: Blade REVERSE TILT
0: FREE
0: LOCK
9022
WORK EQUIPMENT CONTROL VALVE
TRIMMING DOZER
ll3Fl8033
P. From hydraulic pump A,. To lift cylinder head (RAISE)

A,. To trimming cylinder bottom (REVERSE TILT) B,. To lift cylinder bottom (LOWER)
B,. To trimming cylinder head (FORWARD TILT) T. To hydraulic tank
OUTLINE
for blade lift, and trimming. tion, and relieve the circuit when external shock
l Suction valves (22) and (25) act to prevent ne- causes abnormally high pressure.
gative pressure from being formed at the lift
cylinder when the blade is operated.
9024
lh 15 16 i7
18 B-B 19
\ /
20 21 22 c-c 25 24 23
A-A '10
D--D
\
11
114FO2215

2. Main relief valve IO. Detent ball 18. Safety valve (REVERSE TILT)
3. Trimming spool 11. Plug 19. Safety valve (FORWARD TILT)
6. Return spring 14. Plug 22. Suction valve (LOWER)
8. Detent spring 16. Check valve spring 24. Suction valve spring
25. Suction valve (RAISE)
90-&e
TRIMMING DOZER + RIPPER
%
6
114FO2216
P. From hydraulic pump B,. To lift cylinder bottom (LOWER)

A,. To trimming cylinder bottom (REVERSE TILT) A,. To ripper cylinder
B To trimming cylinder head (FORWARD TILT) B,. To ripper cylinder
A;: To lift cylinder head (RAISE) T. To hydraulic tank
OUTLINE
for blade lift, trimming and ripper. tion, and relieve the circuit when external shock
l Suction valves (22) and (25) act to prevent ne- causes abnormally high pressure.
gative pressure from being formed at the lift
cylinder when the blade is operated.
9026
15 16 17 18
B-B
‘\
,6
8
21 22 23 26 25 24
9
10
11
13 A-A
\
12
D-D
114FO2217

2. Main relief valve 11. Detent ball 19. Safety valve (REVERSE TILT)
3. Trimming spool 12. Plug 20. Safety valve (FORWARD TILT)
5. Ripper spool 14. Return spring 22. Suction valve spring
6. Detent and spring case 15. Plug 23. Suction valve (LOWER)
7. Return spring 16. Check valve 24. Plug
8. Detent plug 17. Check valve spring 25. Suction valve spring
9. Detent spring 26. Suction valve (RAISE)
9027
D31 E-20 (DDM031-4H)
D31 P-20 (DDM031-45)
114FO2218
1. Blade
2. Trimming cylinder
3. H-frame
4. Lift cylinder
5. Bracket
6. Trunnion
7. Edge
PO-$8
D31 E-20 (DDM031-4K)
114FO2219
1. Blade
2. Trimming cylinder
3. H-frame
4. Lift cylinder
5. Trunnion
6. Trunnion
7. Arm
8. Rod
9. Edge
9029
MAINTENANCE STANDARD
PPC VALVE
D31 E-20 42001 - 42198
D31 P-20 45001 - 45784
-34.3+4.9Nm
(3.5+0.5kgm)
44.1+4.9Nm
(4.5*0.5kgm)
m
17.7+3.9Nm
(1.8+0.4kgm).
/m 31.4+2.9Nm
.l (3.2+0.3kgm)
114FO2052
Unit: mm
Free length Installed Installed Free Installed

1 Metering spring x O.D. length load length load
Replace spring
32.8 x 7.6 29.4 36.3 N 23.5 29.0 N if any
(3.7 kg) (2.96 kg) damages or
deformations
are found
Metering spring 35.7 x 7.4 29.4 44.8 N 23.5 35.9 N
2
(4.57 kg) (3.66 kg)
Return spring 28.3 x 11.5 17.5 14.7 N 14 11.8 N

(1.5 kg) (1.2 kg)
D31P-20 Serial No. 45785 and up
13.'23*
1.47Nm
(1.35*0.15kam)
A-A c-c
SAOOl191
Unit: mm
No. Check item Criteria
Centering spring (for P3 and P4 ports)
deformations
Metering spring (for P3 and P4 ports)
Centering spring (for PI and P2 ports)
Metering spring (for PI and P2 ports)

TRACK FRAME
D31 E-20
D31P-20 (STEEL SHOE SPEC.)
114FO2222
Unit: mm

- 7 (In length of 3,000 mm)
- Repair or
2 Torsion of track frame 3 (In length of level of 300 mm)
replace

-
Distance between right and left track Max. 6 (Difference of forward and
4 1,450
frame center rearward)
90-56
0
D31P-20 (RUBBER SHOE SPEC.)
114FO2223
Unit: mm

_ 7 (In length of 3,000 mm)
_ Repair or
2 Torsion of track frame 3 (In length bf level of 300 mm)
replace
Distance between right and left track Max. 6 (Difference of forward and
4 1,450
frame center rearward)
9og7
IDLER CUSHION
114FO2224
Unit: mm
-

I
1
Free Installation installation Free Installation
Recoil spring
68.6 kN 61.1 kN
465 379 454
I (7.000 kg) (6,230 kg)
I Tolerance I I Replace
-
50 -0.080 +0.164 0.087 0.5
-0.142 +0.007 0.306
-
-
3 Clearance between shaft and bushing 50 -0.080 +0.164 0.087 0.5
-0.142 +0.007 0.306
-
IDLER
STEEL SHOE SPEC.
D31 E-20
D31 P-20
-i=J
3 4
%
6
Gza 117.7 *
(12 * 2
90-60
0
Unit: mm
I

Outside diameter‘of protruding section
1
on idler
552 540
Outside diameter of idler tread face 520 508 Repair by

I I build-up
welding or
Width of protruded section on idler 52 40 replace
5 Overall width of idler 118 110
6 Width of collar on shaft I 10 I 9

- I
Tolerance
Standard Standard Clearanc
7 Clearance between shaft and bushing Shaft Hole
-0.250 +0.074 0.250 -

55 0.374
1.5
-0.300 0
Tolerance
Standard Standard Interfere”
8 Interference between idler and bushing Shaft Hole
+0.072 +0.054 -0.072 -

88
+0.037 0 0.017
-
0.40 - 0.85 1.5
Clearance between guide plate Repair or

10 1 .o 5.0
and support I I reolace

11 0.5 3.0
and side plate
Adjust
or replace
12 Thickness of shim for guide plate 5.0
90-6 1
0
RUBBER SHOE SPEC.
D31 P-20
. 5
1
t---d
3 4
m 117.7zt
c12*2
Il3F18334
90-62
0
Unit: mm

, Outside diameter of protruding section
on idler
566 544
2 Outside diameter of idler tread face 510 498 Repair by

build-up
% welding or
3 Width of protruded section on idler 56 50 replace
z
5 Overall width of idler 118 110
-
6 Width of collar on shaft 10
I 9
0.250 -
55 -0.250 +0.074 1.5
-0.300 0 0.374
Replace
i-O.072 +0.054 -0.072 -

88 -
-ho.037 0 I 0.017
-
I
0.40 - 0.85 1.5
I
Clearance between guide plate Repair or
10 1 .o 5.0
and support I replace

11 0.5 3.0
-
and side plate I
Adjust
12 or replace
Thickness of shim for guide plate 5.0
90-63
Cc
TRACK ROLLER
STEEL SHOE SPEC.

D31 E-20
D31 P-20
9
SBDO1192
Unit: mm
I

198.0 188.0
Outside diameter of track roller

2 170.0 I 160.0 I
tread face
3 Overall width of track roller

-
4 Width of track roller tread face

-
5 Width of flange
6 Width of collar on shaft 10.0 9.0

I I
-
55 -0.250 +0.074 0.250 1.5
-0.300 0 0.374
Standard
size
8 Interference between shaft and bushing
+0.072 +0.035 -0.072 -

88
fO.037 0 -0.002

0.40 - 0.85 1.5
RUBBER SHOE SPEC.
D31 P-20
m 117.7rt19.6Nm 1
(12+2kgm)
\i
z
d
Il3Fl8335
?
Unit: mm
6 -
- I
Outside diameter of track roller tread

face
2 Overall width of track roller
3 Width of track roller tread face 26
4 Width of collar on shaft
Clearance between shaft and bushing
Size
Standard 1 shaT’err Hole 1 i~g;;$e Interff;nce Replace
Interference between outer bushing
and roller
+0.072 +0.035 -0.072 - -

88.0
+0.037 0 -0.002

I I
Free play of shaft in the axial direction
0.40 - 0.85 1.5
I I
CARRIER ROLLER
STEEL SHOE SPEC.
D31 E-20
D31 P-20
Il3Fl6063
Unit: mm
No. Check item Criteria

170 160
Repair by
Outside diameter of carrier roller build-up
2 142 130
tread face I II welding or
I
replace
-
4 Width of carrier roller tread face 35 I 42
Clearance
limit
I I I
40 -0.080 +o.o3g 0.080 -

1 .o
-0.119 0 0.158
Standard
I Tolerance I
Interference
Interference between carrier size -1 in%Ze limit
6 Replace
roller and bushing
+0.062 +0.030 -0.062 -

52
+0.032 0 -0.002
-
Interference between shaft and +0.070 +0.039 -0.070 -
7 40
support +0.050 0 -0.011
1
8 Free play of roller in the axial direction
0.525 - 0.700 1.5
-
g %ting pressure of shaft 39.2 - 117.7 kN (4- 12 ton) Adjust
9026
RUBBER SHOE SPEC.
D31 P-20
m 117.7 i 19.6 Nm
(12 i 2 kgm) 6 5
\ 2 /’
0 \
Il3Fl6336
g 7
z Unit: mm
0 ‘-
Outside diameter of carrier roller trea

1
face
2 Width of carrier roller tread face
3 Clearance between shah and bushing
-
40.0 -0.080 +0.039 0.080 1.0
-0.119 0 0.158
Standard
nterference between bushing and size fii inEXZe Inte%nce Replace
4
*oiler
I I I I
+0.062 f0.030 -0.062 - -

52.0
+0.032 0 -0.002
5 nterference between shaft and bracket +0.070 +0.039 -0.070 -

40.0
+0.050 0 -0.011 I
Standard clearance I Clearance limit 1
‘ree play of carrier roller in the axial
6
iirection
0.525 - 0.700 1.5
7 ‘itting pressure of shaft 39.2-117.7kN(4-12ton) Adjust
90-67
0
TRACK SHOE
D31E, P-20
LUBRICATED TRACK LINK (l/2)
IO 2 7 17 18 I5
Xl
I I 1 I
P 3
rba

%2. Triple-grouser shoe
%3. Swamp shoe
Unit: mm

1 Link pitch
154.25 157.25
Reverse or
When turned replace
Standard size
47 42.2 44.2

Repair or
3 Link height
replace
a7 80

4 23.5
(bushing press-fitting portion)
%
5 112.4
z
0 Replace
6 Shoe bolt pitch 82.4
7 57
a Inside width 52.4
Repair or
IO Tread width 30.1

Adjust or
replace
16 Thickness of spacer a.4
17 19.6-49 kN {2-5ton)
ia Press-fitting force 76.4 - 117.6 kN I8 - 12 ton) -
x
19 -
X : Dry type track link

208 20a
.x 3
SEDO2141

~42. Triple-grouser shoe
%3. Swamp shoe
90&70
Unit: mm

(Nm {kgm)) I angle (deg.)
a. Regular link
147.1 + 19.6 I15 * 2) 60 5 IO

I
Shoe bolt Retighten
20
(Nm {kgml) angle (deg.) (Nm IkgmH
b. Master link
%
F 147.1 * 19.6 I15 2 2) 180 + IO 255 126)
0
D31 E-20: 37
No. of shoes (each side)
D31 P-20: 41
Standard
size b in%ZZe
nterference between
21
oushing and link
+0.287 +0.062
47 0.185 - 0.287
I +0.247 I 0
nterference between
22 vegular pin and link 28 I +O.lOO I -0.148 0.148 - 0.300
0 -0.200
Clearance between
23
,egular pin and bushing
+O.lOO +0.785 Adjust or
28 0 +0.285 0.185 - 0.785
I replace
Standard
% size -1 in?%~~e
24
master pin and link
% Clearance between
- - - -
x : Dry type track link
90&7’
D31E, P-20
DRY TYPE TRACK LINK (l/2)
0 2 21 22 5 14 24 16 13
12 17 23 18 7 25 19 15
I
x3
V v
SBDO2142

E-3. Swamp shoe
90-72
Unit: mm

I
-

1 Link pitch
154.25 157.25
Reverse or
When turned replace
Standard size
47 42.2 44.2

Repair or
3 Link height
replace
87 80

4 23.5
(bushing press-fitting portion) I
%
5 112.4
z
0 - Replace
6 Shoe bolt pitch 57
I
7 15
I I
8 Inside width 52.4
Repair or
10 Tread width 30.1

-

Adjust or
replace
16 Thickness of spacer -
17 Bushing 49 - 147 kN {5 - 15 ton}
18 Press-fitting force Regular pin 88.2 - 235.2 kN 19 - 24 ton) -

-
%
19 Master pim 49 - 137.2 kN 15 - 14 ton}
90&73
8 2 21 22 fi II 5 14 24 16 13
I I
IO I
I Id
I \ \
I7 23 I8 7 25
SBD02142
~1. Single-grouser shoe

x3. Swamp shoe
90-F’
Unit: mm
Check item Criteria Remedy

(Nm Ikgm}) angle (deg.)
a. Regular link
147.1 ? 19.6 {15 + 2} 60 = 10

Shoe bolt Retighten
(Nm Ikgm)) angle (deg.) (Nm {kgml)
b. Master link
- - -
D31 E-20: 37
No. of shoes (each side)
D31 P-20: 41
21
bushing and link
+0.287 +0.062
47 0.185 - 0.287
+0.247 0
Interference between +O.lOO -0.148

22 regular pin and link 28 0 -0.200 0.148 - 0.300
Tolerance
Standard Standard
size clearance
Clearance between Shaft Hole
23
regular pin and bushing
+0.830 -0.200 Adjust or

28 +0.330 -0.400 0.530 - 1.230
replace
%
24
master pin and link
I 28 I -0.070
-0.030 I -0.200
-0.148 0.078 - 0.170
x Clearance between
I 28
I
+0.630
+0.230 I
-0.200
-0.400 0.430 - 1.030
9oi3-2
SINGLE GROUSER SHOE
SED01627
Unit: mm
I
1 Height
47 20
Rebuild or
2 Thickness 8.5 replace
3 Length of base 19.6
4 Length at tip 7
90-G?3
TRIPLE GROUSER SHOE
SDD01629
Unit: mm

-

1 Iieight
20 10
2 rhickness 9
3 19
Rebuild or
Length of base replace
4
6 Length at tip 10
I
7 16
90;3-4
SWAMP SHOE
2
SED01630
Unit: mm

-
I Standard size I Repair limit

I
D31S, Q-20, D37E-5
1 Height 74.5 62.5
D37P-5A
D31E, P, PL, PLL-20 Rebuild or

74.5 67.5 replace
D31 P-20A
D31S, Q-20, D37E-5

17 5
D37P-5A
2 Thickness
D31E. P, PL, PLL-20
12 5
D31 P-20A
RUBBER CRAWLER
D31 P-20
i \ \_L i \ I
A-A SBD02143
Unit: mm

1 Wear of grouser height
70 35 (5)
2 Wear of roller guard 93.5 73.5 Replace
3 Wear of roller on tread face 32 27
4 Wear of sprocket mating face 36.5 41.5
Note. The value with ( ) for ground condition with no drop in drawbar pull.
WORK EQUIPMENT CONTROL VALVE
TRIMMING DOZER
&a 108f15Nm
(11 k 1.5 kgm)
B-B
c-c 6
7
\
Qa34*5N/m &x8*2Nm
(3.5 * 0.5 kgm) (1.5 + 0.5 kgm) (0.8 f 0.2 kgm) D-D
A-A 114FO2226
90-74
@
I
m 69ztlONm/
(7+ 1 kgm) w
m 83*15Nm w 6g*10NmW 39klONm 34f5Nm
(8.5 * 1.5 kgm) 1 (7 * ’ 7”) ,(4 + 1 kgm) (3.5 f- 0.5 kgm)
/
m 59klONm w 69* IONm

(6 * 1 kgm) W 88 + 10 Nm (7 * 1 kgm)
Qa 52*7Nm (9 * 1 kgm) Qa 52*7Nm
(5.3 f 0.7 kgm) (5.3 f 0.7 kgm)
\ \ /
Il3Fl8074
Unit: mm
Check item Criteria
Spool return spring

TRIMMING DOZER + RIPPER
m 108f15Nm
4 (11 i 1.5 kgm)
\ /
B-B
’ 15i5Nm c-c
(1.5 f 0.5 kgm)
A-A
/ \
m 34+5Nm
-8i2Nm
(3.5 i 0.5 kgm)
(0.8 f 0.2 kgm)
174FO2227
90-76
e
m 69klONm
(7 + 1 kgm)
,m 34+5Nm
(3.5 f 0.5 kgm)
LB A-i & 52+7Nm

w BB+lONm (5.3 i 0.7 kgm)
(9 ? 1 kgm)
\
m 59+10N’m
(6 f 1 kgm)
114FO2228
Unit: mm
Spool return spring
Spool return spring
31 N 25 N
6 Main relief valve spring 24.2 18.3 23.0
(3.2 kg) (2.6 kg)
1.57 N 1.27 N
7 Suction valve spring 15.5 8.0 13.9
(0.16 kg) (0.13 kg)
Height of main relief pressure 8.35 (One turn of the screw oil charge the pressure: 2.43 MPa (24.8 kg/cm? Adjust
8
adjustment screw
90-77
0
HYDRAULIC CYLINDER
. LIFT CYLINDER
1) OUTSIDE MOUNT TYPE
B 785 + 78.5 Nm
2 DS 677 + 67.5 Nm (80 + 8 kgm)
(69 i 6.9 kgm) (Width across flats: 46 mm) 3
I I '
114FO2229
2) INSIDE MOUNT TYPE
m 785 f 78.5 Nm
677 +
? m (69 f6.967.5kgm)
Nm 1 (Width
180 * 8 across
kgm) flats: 46 mm) 3
114FO2230
l TRIMMING CYLINDER
677 f 67.5 Nm m 785 * 78.5 Nm

2 m (69 k 6.9 kgm) (80 + 8 kgm)
1 (Width across flats: 46 mm) 3
F114DM017
90678
Unit: mm
-
Tolerance
Shaft Hole
Clearance between
Outside type -0.025 +0.132 0.031 -
1 piston rod and 40 0.519
lift cylinder -0.087 +0.006 0.219
bushing
Inside type -0.080 +0.132 0.086 -
40 0.572
lift cylinder -0.142 +0.006 0.272
Trimming -0.025 +0.132 0.031 -

40 0.519
cylinder -0.087 +0.006 0.219
-
Outside type -0.025 0 0.037 - Replace
40 0.5
lift cylinder -0.064 -0.012 0.064 bushing
Clearance between
inside type -0.025 0 0.037 -
2 piston rod supporting 40 0.5
lift cylinder -0.064 -0.012 0.064
shaft and bushing
Trimming -0.025 +0.142 0.105 -
40 1
cylinder -0.064 +0.080 0.206
Outside type -0.025 0 0.037 -

40 0.5
lift cylinder -0.064 -0.012 0.064
Clearance between
cylinder bottom Inside type -0.025 0 0.037 -
3 40 0.5
supporting shaft lift cylinder -0.064 -0.012 0.064
and bushing
Trimming -0.025 +0.142 0.105 -
40 1
cylinder -0.064 +0.080 0.206
TRIMMING DOZER
D31 E-20 (DDMOBI-4H)
D31 P-20 (DDM031-4J)
B-B
A-A
5 D-D
114FO2231
Unit: mm
Tolerance
Clearance between trimming cylinder
Shaft Hole
rod bushing and pin
0.105 -
40 -0.025 +0.142 1 .o
-0.064 +0.080 0.206
Clearance between frame bushing and -0.030 +0.300 0.230 -

1.o
pin 60 -0.104 +0.200 0.404
Replace
Clearance between trimming cylinder -0.025 +0.142 0.105 -
bottom bushing and pin 40 -0.064 +0.080 0.206
1.o
Clearance between lift cylinder rod -0.025 0 0.037 -

4 bushing and pin 40 -0.064 -0.012 6.064 0.5
Clearance between lift cylinder bottom -0.025 0 0.037 -

5 bushing and pin 40 -0.064 -0.012 0.064 0.5
-
Spherical clearance between trunnion -0.500 +1.500 0.500 -
6 and trunnion 90 -1 .ooo 0 2.500 3.5
cap
D31 E-20 (DDM031-4K)
A-A B-B
5
4
E-E
F-F
‘G-G
H-H
114FO2232
Unit: mm
-
No. I Check item Criteria Remedy
Clearance between trimming cylinder

1
rod bushing and pin
2 pin 60 -0.104 f0.200 0.404 1 .o

Clearance between frame bushing and I -0.030 +0.300 0.230 - I
3 bottom bushing and pin 40 -0.064 f0.080 0.206 1.0
Clearance between trimming cylinder -0.025 f0.142 0.105 - I
Clearance between rod bushing and -0.025 0 0.010 -
4 40 -0.087 -0.015 0.087 0.5 Replace
pin (H-frame end)
pin (Arm end) 40 -0.087 -0.015 0.087 0.5

Clearance between rod bushing and -0.025 0 0.010 - I
40 -0.064 -0.012 0.064 0.5
bushing
Clearanceand pin
between lift cylinder rod I -0.025 0 0.037 - I
7 40 -0.064 -0.012 0.064 0.5
bushing
Clearanceand pin
between lift cylinder bottom I -0.025 0 0.037 - I
Clearance between arm bushing and 0 f0.209 0.143 -
trunnion shaft 100 -0.054 f0.143 0.263 1 .o
Spherical clearance between trunnion -0.500 +1.500 0.500 -

and trunnion cap 90 -1 .ooo 0 2.500 3.5
9023
Komatsu America international Company
440 North Fairwav Drive I 1
Vernon Hills, IL 66061-8112 U.S.A.
Attn: Technical Publications PROPOSAL FOR MANUAL REVlslON
Fax No. (847) 970-4186
FOR INTERNAL USE ONLY -- No. PMR
2 NAME OF COMPANY: LOCATION:
: PHONE NO:
:
S DEPARTMENT: DATE:
E
R NAME:
MANUAL NAME:
MANUAL NO:
MACHINE MODEL:
S/N IF APPLICABLE:
PAGE NO:
PROBLEM:
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D31E 20 - Sn42001and Up PDF

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SEBMOOI 007

May 1997 Copyright 1997 Komatsu America International Company

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

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

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

The affected pages are indicated by the use of the

a Page to be replaced Replace

Page to be deleted Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGE

Time of Time 01 Time of Time of Time of

0 oo- 1 Ol- 5 01-33 10-5 @ 10-31

oo- 5 01-13 01-41 10-11-2 @ 10-37-2 @

00- 6 01-14 01-42 IO-12 10-37-3 @

00- 7 01-15 01-43 IO-14 10-37-4 @

00- 8 01-16 01-44 10-15 10-37-5 @

oo- 9 01-17 01-45 lo-16 10-37-6 @

00-10 01-18 01-46 lo-17 IO-38

00-11 01-19 01-47 IO-18 IO-39

00-12 01-20 01-48 IO-19 10-40

00-13 01-21 01-49 IO-20 IO-41

00-14 01-22 01-50 10-22 lo-42

00-15 01-23 01-51 lo-23 10-43

00-16 01-24 01-52 IO-24 10-44

00-l7 01-25 01-53 IO-25 10-45

00-18 01-26 01-54 lo-26 IO-46

00-19 01-27 lo-27 10-47 @

01-l 01-29 lo- 2 10-29-l @ IO-49 @

01-2 01-30 lo- 3 10-29-2 @ 10-49-l @

01-3 01-31 lo- 3-l 10-29-3 0 10-49-2 @

01-4 01-32 lo- 4 10-30 10-49-3 @

IO-50 @ 20- 7 @ 20-31 20-67 @ 20-90

10-51 20- 8 @ 20-31-I 20-68 @ 20-91

IO-53 @ 20-9-I @ 20-31-3 20-70 @ 20-93

10-53-2 @ 20-9-3 @ 20-32 20-72 @ 20-95

10-54 @ 20-9-4 @ 20-33 20-72-I @ 20-96

IO-55 20-10 @ 20-33-l 20-72-2 @ 20-97

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

10-56-I @ 20-12 @ 20-34 20-72-4 @ 20-99

10-56-2 @ 20-12-I @ 20-35 20-72-5 @

10-57 @ 20-12-2 @ 20-36 20-72-G @ l 30- 1

IO-58 @ 20-13 @ 20-37 20-72-7 @ 0 30- 2

IO-59 20-13-l @ 20-38 20-72-8 @ 0 30- 3

10-59-I @ 20-13-2 @ 20-39 20-72-g @ 0 30- 4

10-59-2 @ 20-14 @ 20-40 20-72-10 @ l 30- 5

IO-60 20-15 @ 20-41 20-72-11 @ 0 30- 5-1

lo-61 20-15-1 @ 20-42 20-72-12 @ 0 30- 5-2

IO-62 @ 20-15-2 @ 20-43 20-72-13 @ 0 30- 5-3

lo-63 20-16 @ 20-44 20-72-14 @ 0 30- 6

lo-64 20-17 @ 20-45 20-72-15 @ l 30- 7

lo-65 @ 20-17-I @ 20-46 20-72-16 @ 0 30- 7-l

IO-66 20-17-2 @ 20-47 20-72-17 0 30- 7-2

lo-67 20-18 @ 20-48 20-73 0 30- 7-3

10-68 20-19 @ 20-49 20-74 0 30- 8

IO-69 @ 20-19-l @ 20-50 20-75 0 30- 9

10-69-I @ 20-20 @ 20-51 20-76 0 30- 9-I

10-69-2 @ 20-21 @ 20-54 20-77 c 30- 9-2

10-70 @ l 20-22 (FJ 20-55 20-78 0 30- 9-3

10-71 @ 20-23 @ 20-56 20-79 0 30- 9-4

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

10-73 @ 20-23-2 @ 20-58 20-81 0 30-10

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

20-25 @ 20-60 20-83 0 30-10-2

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