SEBM033602

MACHINE MODEL SERIAL No.

D21A, P-8 83001 and up

• This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may
require. Materials and specifications are subject to change without notice.

• D21-8 mount the 4D94LE-2 engine.

For details of the engine, see the 94E, 98E Series Engine Shop Manual.

© 2003 1 00-1
All Rights Reserved
Printed in Japan 11-03 (01)
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 CONTENTS

No. of page

01 GENERAL ......................................................................... 01-1

10 STRUCTURE AND FUNCTION ....................................... 10-1

20 TESTING AND ADJUSTING ........................................... 20-1

30 DISASSEMBLY AND ASSEMBLY .................................. 30-1

40 MAINTENANCE STANDARD .......................................... 40-1

90 OTHERS............................................................................ 90-1

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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.
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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 ¤ is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.

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

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
• Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
• Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.

00-3
SAFETY SAFETY NOTICE

PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.

00-4
FOREWORD GENERAL

FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.

STRUCTURE AND FUNCTION

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

TESTING AND ADJUSTING

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

DISASSEMBLY AND ASSEMBLY

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.

MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.

OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.

NOTICE

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

00-5
FOREWORD HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

W h en a m an u a l is r e vis ed , a n e d itio n ma rk
VOLUMES
Shop manuals are issued as a guide to carrying out 123
( ....) is recorded on the bottom of the pages.
repairs. They are divided as follows:

Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
Revised pages are shown in the LIST OF REVISED

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

DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
¤ Safety
Special safety precautions
are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order.
2. Following examples show how to read the page s Caution
tions or other precautions
for preserving standards
are necessary when per-

4
number.
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3 tems. Caution necessary
Weight when selecting hoisting

3
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
Places that require special

2
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
Places to be coated with

5
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or

6
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
item. Places where oil or water
Drain m u s t b e d r a i n e d , a nd
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204

00-6
FOREWORD HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS

HOISTING

¤ Heavy parts (25 kg or more) must be lifted

Slinging near the edge of the hook may cause
the rope to slip off the hook during hoisting, and

4
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol

• If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing
3) Do not sling a heavy load with one rope alone,
interference with the part to be removed.

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

★ The allowable load value is estimated to be one-

sixth or one-seventh of the breaking strength of
the rope used.

2) Sling wire ropes from the middle portion of the

hook.

00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

¤ Before carrying out the following work, release

the residual pressure from the hydraulic tank.
Type 1

For details, see TESTING AND ADJUSTING,

Releasing residual pressure from hydraulic

¤
tank.

Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.

Disconnection
1) Release the residual pressure from the hydrau-
lic tan k. Fo r d e tails , se e TES TIN G AN D
ADJUSTING, Releasing residual pressure from
hydraulic tank.

2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
★ The adapter can be pushed in about 3.5
mm.
★ Do not hold rubber cap portion (4).

3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)

4) Hold hose adapter (1) or hose (5) and pull it out.

(See Fig. 3)
★ Since some hydraulic oil flows out, prepare
an oil receiving container.

Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
★ Do not hold rubber cap portion (4).

2) After inserting the hose in the mating adapter

perfectly, pull it back to check its connecting
condition. (See Fig. 5)
★ When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.

00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.

2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly

3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.

• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection

00-9
FOREWORD COATING MATERIALS

COATING MATERIALS

★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
★ For coating materials not listed below, use the equivalent of products shown in this list.

Category Komatsu code Part No. Q'ty Container Main applications, featuresr

• Used to prevent rubber gaskets,

LT-1A 790-129-9030 150 g Tube rubber cushions, and cock plug
from coming out.

• Used in places requiring an imme-

diately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyeth-
LT-1B 790-129-9050
(2 pcs.) container ylene, polyprophylene, tetrafluor-
oet hl ene and vi nyl chl oride),
rubber, metal and non-metal.

• Features: Resistance to heat and

LT-2 09940-00030 50 g Polyethylene chemicals
container • Used for anti-loosening and seal-
ant purpose for bolts and plugs.

Adhesive: • Used as adhesive or sealant for

790-129-9060 metal, glass and plastic.
(Set of 1 kg
Hardenin
LT-3 adhesive and Can
hardening g
agent:
agent)
500 g
Adhesives

Polyethylene • Used as sealant for machined

LT-4 790-129-9040 250 g holes.
container

Holtz • Used as heat-resisting sealant for

MH 705 790-126-9120 75 g Tube repairing engine.

• Quick hardening type adhesive

Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of met-
als, rubbers, plastics and woods.

• Quick hardening type adhesive

• Quick cure type (max. strength af-
Aron-alpha Polyethylene
201 790-129-9130 2g container ter 30 minutes)
• Used mainly for adhesion of rub-
bers, plastics and metals.

Loctite Polyethylene • Resistance to heat, chemicals

79A-129-9110 50 cc • Used at joint portions subject to
648-50 container
high temperatures.

• Used as adhesive or sealant for

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

• Used as sealant for various

threads, pipe joints, flanges.
LG-5 790-129-9070 1 kg Can • Used as sealant for tapered
Gasket plugs, elbows, nipples of hydrau-
sealant lic piping.

• Features: Silicon based, resist-

ance to heat, cold
• Used as sealant for flange sur-
LG-6 790-129-9020 200 g Tube
face, tread.
• mab Used as sealant for oil pan,
final drive case, etc.

00-10
FOREWORD COATING MATERIALS

Category Komatsu code Part No. Q'ty Container Main applications, featuresr

• Ftures: Silicon based, quick hard-

ening type
LG-7 790-129-9070 1g Tube • Used as sealant for flywheel
housing, intake manifold, oil an,
Adhesives thermostat housing, etc.

Three bond • Used as heat-resisting sealant for

790-129-9090 100 g Tube repairing engine.
1211

• Used as lubricant for sliding por-

LM-G 09940-00051 60 g Can
tion (to prevent from squeaking).
Molybdenum
disulphide • Used to prevent seizure or scuf-
lubricant fling of the thread when press fit-
LM-P 09940-00040 200 g Tube ting or shrink fitting.
• Used as lubricant for linkage,
bearings, etc.

SYG2-400LI • General purpose type

SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI

SYG2-400CA • Used for normal temperature,

Grease SYG2-350CA light load bearing at places in con-
G2-CA SYG2-400CA-A Various Various tact with water or steam.
SYG2-160CA
SYGA-160CNCA

Molybdenum 400 g • Used for places with heavy load

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

00-11
FOREWORD STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.

Thread diameter Width across

of bolt flats

mm mm Nm kgm

6 10 13.2 0 1.4 1.35 0 0.15

8 13 31 03 3.2 0 0.3
10 17 66 07 6.7 0 0.7
12 19 113 0 10 11.501
14 22 177 0 19 1802
16 24 279 0 30 28.5 0 3
18 27 382 0 39 39 0 4
20 30 549 0 59 56 0 6
22 32 745 0 83 76 0 8.5
24 36 927 0 103 94.5 0 10.5

27 41 1320 0 140 135 0 15

30 46 1720 0 190 175 0 20
33 50 2210 0 240 225 0 25
36 55 2750 0 290 280 0 30
39 60 3290 0 340 335 0 35

Thread diameter Width across

of bolt flats

mm mm Nm kgm

6 10 0
7.85 1.95 0.8 0 0.2
8 13 0
18.6 4.9 1.9 0 0.5
10 14 0
40.2 5.9 4.1 0 0.6
12 27 0
82.35 7.85 8.4 0 0.8

Sealing surface

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

★ In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
SAD00483
the table below.
Thread diameter Width across flat Tightening torque

mm mm Nm kgm

14 19 0
24.5 4.9 0
2.5 0.5
18 24 0
49 19.6 5 2 0
22 27 0
78.5 19.6 8 2 0
24 32 0
137.3 29.4 14 3 0
30 36 0
176.5 29.4 18 3 0
33 41 0
196.1 49 20 5 0
36 46 0
245.2 49 25 5 0
42 55 0
294.2 49 30 5 0

00-12
FOREWORD STANDARD TIGHTENING TORQUE

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.

Thread diameter Width across flat Tightening torque

mm mm Nm kgm

10 14 0
65.7 6.8 0
6.7 0.7
12 17 112 9.80 11.5 1 0
16 22 279 290 28.5 3 0

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Thread diameter Width across flat Tightening torque

Norminal No.
mm mm Nm kgm

02 14 0
34.3 4.9 3.5 0 0.5
03, 04 20 Varies depending 0
93.1 9.8 9.5 01
05, 06 24 on type of 0
142.1 19.6 14.5 02
10, 12 33 connector. 0
421.4 58.8 43 06
14 42 0
877.1 132.3 89.5 0 13.5

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Thread diameter Width across flat Tightening torque

Norminal No.
mm mm Nm kgm

08 08 14 0
7.35 1.47 0.75 0.15 0
10 10 17 0
11.27 1.47 1.15 0.15 0
12 12 19 0
17.64 1.96 1.8 0.2 0
14 14 22 0
22.54 1.96 2.3 0.2 0
16 16 24 0
29.4 4.9 3 0.5 0
18 18 27 0
39.2 4.9 4 0.5 0
20 20 30 0
49 4.9 5 0.5 0
24 24 32 0
68.6 9.8 7 1 0
30 30 32 0
107.8 14.7 11 1.5 0
33 33 n 0
127.4 19.6 13 2 0
36 36 36 0
151.9 24.5 15.5 2.5 0
42 42 n 0
210.7 29.4 21.5 3 0
52 52 n 0
323.4 44.1 33 4.5 0

00-13
FOREWORD STANDARD TIGHTENING TORQUE

TIGHTENING TORQUE FOR 102 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 0
10 2 1.02 0 0.20
8 0
24 4 2.45 0 0.41
10 0
43 6 4.38 0 0.61
12 0
77 12 7.85 0 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 8 20 0.81 0 0.20
8 0
10 2 1.02 0 0.20
10 0
12 2 1.22 0 0.20
12 0
24 4 2.45 0 0.41
14 0
36 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
Thread diameter Tightening torque
inch Nm kgm
1 / 16 3 10 0.31 0 0.10
1/8 8 20 0.81 0 0.20
1/4 0
12 2 1.22 0 0.20
3/8 0
15 2 1.53 0 0.41
1/2 0
24 4 2.45 0 0.41
3/4 0
36 5 3.67 0 0.51
1 0
60 9 6.12 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) type Face seal type
Nominal size Width across
of hose flats Nominal thread
Range Target Thread size size - Threads per Root diameter
(mm) (mm) (Reference)
inch, Thread series
9
02 19 35 - 63 {3.5 - 6.5} 44 {4.5} 14 – - 18UNF 14.3
16
11
22 54 - 93 {5.5 - 9.5} 74 {4.5} – – - 16UN 17.5
03 16
24 59 - 98 {6.0 - 10.0} 78 {8.0} 18 – –
13
04 27 84 - 132 {8.5 - 13.5} 103 {10.5} 22 – - 16UN 20.7
16
05 32 128 - 186 {13.0 - 19.0} 157 {16.0} 24 1 - 14UNS 25.4
3
06 36 177 - 245 {18.0 - 25.0} 216 {22.0} 30 1 – - 12UNF 30.3
16
(10) 41 177 - 245 {18.0 - 25.0} 216 {22.0} 33 – –
(12) 46 197 - 294 {20.0 - 30.0} 245 {25.0} 36 – –
(14) 55 246 - 343 {25.0 - 35.0} 294 {30.0} 42 – –

00-14
FOREWORD ELECTRIC WIRE CODE

ELECTRIC WIRE CODE

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

CLASSIFICATION BY THICKNESS

Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands
(mm2) (mm 2)

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal

15 84 0.45 13.36 7.0 59 Starting (Glow plug)

40 85 0.80 42.73 11.4 135 Starting

60 127 0.80 63.84 13.6 178 Starting

100 217 0.80 109.1 17.6 230 Starting

CLASSIFICATION BY COLOR AND CODE

Circuits
Priori-
ty Classi- Charging Ground Starting Lighting Instrument Signal Other
fication

Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue

Code WR n BW RW YR GW LW
2
Color White & Red n White & Black Red & White Rellow & Red Green & White Blue & White

Code WB n BY RB YB GR LR
3
Color White & Black n Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow

Code WL n BR RY YG GY LY
4 Auxi-
liary
Color White & Blue n Black & Red Red & Yellow
Yellow &
Green
Green &
Yellow
Blue & Yellow

Code WG n n RG YL GB LB
5
Color White & Green n n Red & Green Yellow & Blue Green & Black Blue & Black

Code n n n RL YW GL n
6
Color n n n Red & Blue Yellow & White Green & Blue n
00-15
FOREWORD CONVERSION TABLE

CONVERSION TABLE

METHOD OF USING THE CONVERSION TABLE

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

EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
A
(1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line
A
from .
B
(2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down
B
from .
C
(3) Take the point where the two lines cross as . This point C gives the value when converting from mil-
limeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

B
Millimeters to inches

1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9

0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536

C
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

A 50
60
1.969
2.362
2.008
2.402
2.047
2.441
2.087
2.480
2.126
2.520
2.165
2.559
2.205
2.598
2.244
2.638
2.283
2.677
2.323
2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

00-16
FOREWORD CONVERSION TABLE

Millimeters to Inches
1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9

0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

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

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

Kilogram to Pound
1 kg = 2.2046 lb

0 1 2 3 4 5 6 7 8 9

0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03

50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

00-17
FOREWORD CONVERSION TABLE

Liter to U.S. Gallon

1l = 0.2642 U.S. Gal

0 1 2 3 4 5 6 7 8 9

0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944

50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153

Liter to U.K. Gallon

1l = 0.21997 U.K. Gal

0 1 2 3 4 5 6 7 8 9

0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778

50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777

00-18
FOREWORD CONVERSION TABLE

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

0 1 2 3 4 5 6 7 8 9

0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4

50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1

100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

00-19
FOREWORD CONVERSION TABLE

kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2

0 1 2 3 4 5 6 7 8 9

0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9

50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408

100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119

150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830

200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542

00-20
FOREWORD CONVERSION TABLE

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

°C °F °C °F °C °F °C °F

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

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

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

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

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

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 0 140.0 35.0 95 203.0

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

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

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

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

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

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

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

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

00-21
FOREWORD UNITS

UNITS

In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.

Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}

00-22
 20 TESTING AND ADJUSTING

Standard value table for engine .......................................................................................................... 20-2

Standard value table for chassis .......................................................................................................... 20-3
TESTING AND ADJUSTING .................................................................................................................. 20-101
TROUBLESHOOTING ............................................................................................................................. 20-201

D21A, P-8 20-1

(2)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE

STANDARD VALUE TABLE FOR ENGINE

Applicable machine model D21-8

Engine model 4D94LE-2

Item Condition Unit Standard value Permissible value

High idling speed 2,580 ± 50 2,580 ± 50

Engine speed Low idling speed rpm 895 ± 25 895 ± 25
Rated speed 2,450 2,450

Quick acceleration Bosch 2–4 5.3

Exhaust gas color
At high idling scale 0.2 – 1.0 3

(at cold) –
Valve clearance Intake valve mm 0.2 ± 0.05
Exhaust valve 0.2 ± 0.05 –

Oil temperature:
40 – 60°C
MPa
Compression pressure Engine speed: 3.4 ± 0.1 {35 ± 1} 2.7 ± 0.1 {28 ± 1}
{kg/cm2}
320 – 360 rpm
(SAE30 oil)

Water temperature
Inside operating range kPa
Blow-by pressure – –
At rated speed {mmH2O}
(SAE30 oil)

(Water temperature:
Inside operating range) MPa
Oil pressure
At high idling {kg/cm2} 0.29 – 0.39 {3.0 - 4.0} –
At low idling Min. 0.06 {Min. 0.6} –

Oil temperature All speed (inside oil pan) °C 80 – 110 120

Fuel injection timing B.T.D.C. degree 11 ± 1 11 ± 1

Deflection when pushed 7 – 9 (New)

Fan belt tension mm 10 – 15
with a force of 98 N {10 kg} 10 – 15 (Used)

20-2 D21A, P-8

(2)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

STANDARD VALUE TABLE FOR CHASSIS

Classi-
Item Measurement conditions Unit Standard value Permissible value
fication
• Center of lever
Fuel control lever Slow ➞ Full 74 – 120
knob
• Engine stop N➞ 35 – 43
Forward 1st *1 30 – 40
N➞ 35 – 43
Forward 2nd *1 30 – 40

N➞ *1
30 – 40
Forward 3rd
Gear shift lever
N➞ 35 – 43
Reverse 1st *1 30 – 40
N➞ 35 – 43
Reverse 2nd *1 30 – 40

N➞ *1
30 – 40
Reverse 3rd
Lever, pedal travel

• Center of lever knob N ➞ Forward,

35 – 45
Steering, directional • Max. value to reverse
lever end of stroke N ➞ Left,
62 – 70
• Engine stopped right turn
mm
• Center of pedal
Inching pedal End of stroke 103 – 113
• Engine stopped
To operating
force of 147.1
N {15 kg}
(when
Brake pedal 93 – 103 134
clearance
between lining
and drum is
0.3 mm)
HOLD ➞
50 – 65
RAISE, LOWER
• Center of lever LOWER ➞
35 – 50
Work equipment knob Float
control lever • Engine stopped HOLD ➞ Left,
50 – 60
right tilt
(PAT machine) HOLD ➞ Left,
50 – 65
right angle

Note:
*1: These values are for the F3, R3 transmission.
PAT: Power angle, power tilt machine

D21A, P-8 20-3

(2)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Classi-
Item Measurement conditions Unit Standard value Permissible value
fication
• Center of lever 39.2 – 78.5
Fuel control lever Slow ➞ Full
knob {4.0 – 8.0}
• Engine stopped N Each
–
speed range
29 – 39
Gear shift lever 1st 2nd
{3.0 – 4.0}
Operating force of control levers and pedals

*1 29 – 39
2nd 3rd
{3.0 – 4.0}
N ➞ Forward, 32 – 44
reverse {3.3 – 4.5}
Steering, directional N➞ 25 – 39
lever Right turn {2.5 – 4.0}
N➞ 20 – 34
Left turn N {kg} {2.0 – 3.5}
• Center of pedal 83 – 113
Inching pedal End of stroke
• Engine stopped {8.5 – 11.5}
64 – 83
Brake pedal End of stroke
{6.5 – 8.5}
• Center of lever HOLD ➞ 14 – 34
knob RAISE, LOWER {1.5 – 3.5}
• Engine stopped LOWER ➞ 39 – 59
FLOAT {4.0 – 6.0}
Work equipment FLOAT ➞ 15 – 59
control lever HOLD {1.5 – 6.0}
HOLD ➞ Left, 20 – 39
right tilt {2.0 – 4.0}
(PAT machine) HOLD ➞ Left, 20 – 39
right angle {2.0 – 4.0}
• Oil temperature: 2.3 – 2.6
40 – 60°C Engine: {23.5 – 26.5}
• Gear shift lever Low idling *1 1.8 – 2.1
Transmission at neutral {18.0 – 21.0}
modulating pressure 2.6 – 2.8
Engine: {26.5 – 28.5}
Full throttle *1 2.0 – 2.3
Hydraulic pressure

{20.0 – 23.0}
• Oil temperature: 2.3 – 2.6
40 – 60°C Engine: MPa {23.5 – 26.5}
• Steering lever Low idling {kg/cm2} *1 1.8 – 2.1
Steering main relief operated {18.0 – 21.0}
pressure 2.6 – 2.8
Engine: {26.5 – 28.5}
Full throttle *1 2.0 – 2.3
{20.0 – 23.0}
• Oil temperature: Engine: 13.2
Work equipment main 40 – 60°C Low idling {135}
relief pressure • Work equipment Engine: 15.2 – 15.9
cylinder at end of stroke Full throttle {155 – 162}

Note:
*1: These values are for the F3, R3 transmission.
PAT: Power angle, power tilt machine

20-4 D21A, P-8

(2)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Classi-
Item Measurement conditions Unit Standard value Permissible value
fication
• On level ground 2.6
Forward 1st *1
• Engine at full 2.2
throttle 4.4
• Engine water Forward 2nd *1 4.1
Transmission

temperature: *
Within operating Forward 3rd 1 6.8
Travel speed range km/h
• Run–up distance: 3.3
Reverse 1st *1
10 – 30 m 2.5
• Distance for 5.6
measurement: Reverse 2nd *1 4.4
20 m *
Reverse 3rd 1 7.4

Blade 100 100

fl Raise blade from ground to 300 mm.

Hydraulic drift

mm

fl Put the corner of the blade on a block,

and operate the tilt to raise the chassis
fully.
Blade tilt • From this position, measure hydraulic
(Downward move- drift “h” of the blade.
50 50
ment of chassis • Start to measure immediately after
when blade is titled) setting in position.
• Measure the amount of hydraulic drift
for the next 15 minutes.
• Machine on level ground
• Control lever in NEUTRAL position
• Engine stopped
• Hydraulic oil temperature: 40 – 60°C

Note:
*1: These values are for the F3, R3 transmission.

D21A, P-8 20-5

(2)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Check item Conditions Unit Standard value Permissible value

Ground raise fully

RAISE 1.8 1.8

LOWER 1.4 1.4

L.H.
TILT 1.7 1.7

Blade L.H. tilt fully R.H. tilt fully

(PAT) R.H.
• Ground TILT 2.0 2.0
Work equipment speed

Raise fully
• L.H. tilt fully
R.H. tilt fully L.H.
ANGLE 1.5 1.5
• L.H. angle fully sec.
R.H. angle fully

R.H.
fl Raise blade from ground to ANGLE 1.5 1.5
300 mm
L.H. angle fully R.H. angle fully
RAISE 1.4 1.4

LOWER 1.2 1.2

Blade
(straight tiltdozer)
L.H.
fl Raise blade from ground to TILT 1.2 1.2
300 mm
• Machine on level ground
• Engine: full throttle R.H.
• Hydraulic oil temperature: TILE 1.3 1.3
40 – 60°C

Note:
PAT: Power angle, power tiltdozer

20-6 D21A, P-8

(2)
 TESTING AND ADJUSTING

List of testing, adjusting, and troubleshooting tools ........................................................................................... 20-102

Measuring engine speed ......................................................................................................................................... 20-103
Measurement of exhaust gas color ....................................................................................................................... 20-104
Adjusting valve clearance ....................................................................................................................................... 20-105
Measuring compression pressure .......................................................................................................................... 20-107
Testing and adjusting fuel injection timing .......................................................................................................... 20-108
Bleeding air from fuel circuit.................................................................................................................................. 20-110
Measuring engine oil pressure .............................................................................................................................. 20-111
Testing and adjusting fan belt tension ................................................................................................................. 20-112
Adjusting fuel control linkage ................................................................................................................................ 20-113
Measuring power train oil pressure ...................................................................................................................... 20-115
Adjusting PPC valve ................................................................................................................................................ 20-116
Bleeding air from steering circuit .......................................................................................................................... 20-116
Measuring and adjusting work equipment main relief pressure ....................................................................... 20-117
Bleeding air from hydraulic cylinders ................................................................................................................... 20-118
Bleeding air from angle cylinder circuit ................................................................................................................ 20-119
Adjusting fuel control lever .................................................................................................................................... 20-120
Adjusting travel of inching pedal ........................................................................................................................... 20-121
Adjusting brake pedal, brake cylinder ................................................................................................................... 20-122
Adjustng brake lining clearance ............................................................................................................................. 20-123

D21A, P-8 20-101

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TESTING AND ADJUSTING LIST OF TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS

LIST OF TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS

Symbol

Q’ty
Testing/Adjusting item Part No. Part Name Remarks

L: 60 – 2,000 rpm
Measuring engine speed A 799–203–9000 Multitachometer 1
H: 60 – 19,999 rpm
Measuring coolant tempera-
ture, oil temperature, and B 799–101–1502 Digital thermometer 1 –99.9 – 1,299 °C
exhaust temperature

1 799–201–9000 Handy smoke checker 1 Pollution level: 0 – 70% (With standard color)
Measuring exhaust gas
C
color Commercially
2 Smoke meter 1 (Pollution level x 1/10 = Bosch index)
available
Commercially
Adjusting valve clearance D Feeler gauge 1 –
available
0 – 6.9 MPa {0 – 70 kg/cm2}
1 795–502–1590 Compression gauge 1
Measuring compression KIT No.: 795–502–1205
pressure E
2 795–111–1110 Adapter 1 –
3 795–101–1571 Joint 1 –
Oil pressure gauge Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799–101–5002 1
kit (Analog) {25, 60, 400, 600 kg/cm2}
Measuring engine oil 1
F Oil pressure gauge
pressure 790–261–1203 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
kit (Digital)
2 799–401–2320 Oil pressure gauge 1 Pressure gauge: 0.98 MPa {10 kg/cm2}
Oil pressure gauge Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799–101–5002 1
Measuring and adjusting oil kit (Analog) {25, 60, 400, 600 kg/cm2}
1
pressures in work equip- Oil pressure gauge
G 790–261–1203 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
ment, and power train kit (Digital)
circuits 799–101–5220 Nipple 1 10 x 1.25 mm
2
07002–11023 O–ring 1 –
Measuring leakage from Commercially
N Measuring cylinder 1 –
work equipment cylinder available

– 79A–264–0021 1 0 – 294 N {0 – 30 kg}

Measuring operating effort Push–pull scale
and pressing force
– 79A–264–0091 1 0 – 490 N {0 – 50 kg}

Measuring stroke and Commercially

– Rule 1 –
hydraulic drift available
Measuring work equipment Commercially
– Stopwatch 1 –
speed available
Measuring voltage and Commercially
– Multimeter 1 –
resistance available

fl For the model names and part Nos. of the T–boxes and T–adapters used for troubleshooting for the sensors,
actuators, and wiring harnesses, see TROUBLESHOOTING, List of T–boxes and T–adapters.

20-102 D21A, P-8

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TESTING AND ADJUSTING MEASURING ENGINE SPEED

MEASURING ENGINE SPEED

fl Tools for measuring engine speed.

Symbol Part No. Part name

A 799–203–9000 Multi–tachometer

 Be careful not to touch any hot parts when installing

or removing the measurement equipment.

fl Measure the engine speed under the following condi-

tions.
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 (2) of tachometer A to fuel injec-

tion pipe (1).

fl Remove clamp (2) of each fuel injection pipe so that

the pulsation of other cylinders will not affect the
measured cylinder.

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

 Be careful not to touch any rotating parts or hot

parts when measuring the engine speed.

3. Start the engine and measure the engine speed at

high idling and low idling

D21A, P-8 20-103

(2)
TESTING AND ADJUSTING MEASUREMENT OF EXHAUST GAS COLOR

MEASUREMENT OF EXHAUST GAS COLOR

fl Exhaust gas color measurement tool

Symbol Part No. Part name

1 799–201–9000 Handy Smoke Checker

C Commercially
2 available Smoke Meter

 Be careful to touch the highly heated parts, while

fitting and detaching a measurement tool.

fl If no compressed air or power is not available in the

field, use Handy Smoke Checker C1. For recording
official data, use Smoke Meter C2.

1. Measurement with Handy Smoke Checker C1.

1) Fit a filtering paper to Handy Smoke Checker C1.
2) Insert the exhaust gas intake pipe into the ex-
haust pipe.
3) Accelerate the engine sharply and operate the
handle of smoke checker C1 simultaneously to
let the exhaust gas stay on the filtering paper.
4) Take out the filtering paper and compare it with
the attached scale for judgment.

2. Measurement with Smoke Meter C2

1) Insert probe [1] of the Smoke Meter C2 into the
exhaust gas pipe outlet, and fasten it to the out-
let with a clip.
2) Connect the probe hose [2], accelerator switch [3]
outlet and air hose [4] to the Smoke Meter C2.
fl Keep the pressure of the supplied compressed
air below 1.47 MPa {15 kg/cm2}.
3) Connect the power cable to AC socket.
fl Confirm that the Smoke Meter power switch
is in the OFF position, before connecting the
power cable to an outlet.
4) Fit a filtering paper by loosening the suction pump
cap nut (5).
fl Fit the filtering paper securely so that air may
not leak.
5) Move the Smoke Meter C2 power switch to the
ON position.
6) Accelerate the engine sharply and depress accel-
erator pedal [3] of smoke meter C2 simultane-
ously to let the exhaust gas stay on the filtering
paper.
7) Put the polluted filtering paper on non–polluted
filtering paper (more than 10 sheets) in the filter-
ing paper holder, and read the indicated value.

20-104 D21A, P-8

(2)
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE

ADJUSTING VALVE CLEARANCE

fl Tools for adjusting valve clearance

Symbol Part No. Part name

Commercially
D available Feeler gauge

1. Disconnect at 4 fuel injection pipes (1), then remove

the cylinder head cover (2).

2. Rotate the crankshaft in the normal direction to align

the 1 – 4 TOP mark on crankshaft pulley (3) with 0°
line (4) on the gear case.
fl When rotating, check the movement of the intake
and exhaust valves and set the No. 1 cylinder to
the compression top dead center.
fl The No. 1 cylinder is at the flywheel end (rear of
the chassis).
fl To check the top dead center, check that there is
a clearance at the rocker arms on both the intake
and exhaust sides.

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

center, adjust the valves marked
•in the table.

fl It is also possible to turn the crankshaft 180° each

time and adjust the valve clearance of each cylinder
according to the firing order.
fl Firing order: 1 – 3 – 4 – 2

4. To adjust the valve clearance, loosen locknut (6) of

adjustment screw (5), then insert feeler gauge D of
the specified thickness in clearance a between valve
cap (7) and rocker arm (8) and turn the adjustment
screw until the clearance is a sliding fit.

D21A, P-8 20-105

(2)
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE

fl Check that valve cap (7) is not worn or at an

angle.

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

direction and adjust the valve clearance of the re-
maining valves marked . fi
6. After adjusting the valve clearance, tighten locknut
(6) to hold adjustment screw (5) in position.
3 Locknut: 17.2 + 2.5 Nm {1.75 + 0.25 kgm}

fl After adjusting No. 1 cylinder at compression top dead

center, it is also possible to turn the crankshaft 180°
each time and adjust the valve clearance of each cyl-
inder according to the firing order.
• Firing order: 1 – 3 – 4 – 2
(The No. 1 cylinder is at the flywheel end.)

fl After tightening the locknut, check the valve clear-

ance again.

20-106 D21A, P-8

(2)
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE

MEASURING COMPRESSION PRESSURE

fl Tools for measuring compression pressure

Symbol Part No. Part name

1 795–502–1590 Compression gauge

E 795–111–1110 Adapter
2
795–101–1570 Joint

 When measuring the compression pressure, be ex-

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

1. Adjust valve clearance.

fl For details, see ADJUSTING VALVE CLEARANCE.

2. Warm up engine so that the oil temperature is 40 –

60°C.

3. Disconnect 4 fuel injection pipes (1), then remove

cylinder head cover (2).

4. Remove 4 nozzle holder assembly.

5. Install adapter E2 in the nozzle holder mount and

connect compression gauge E1.

6. Disconnect connector (1) (S01) of the engine stop

solenoid, then crank the engine with the starting mo-
tor and measure the compression pressure.

 If the connector of the engine stop solenoid is not

disconnected, fuel will spurt out.

fl Measure the compression pressure at the point where

the pressure gauge indicator remains steady.
fl If the cranking feels slow, check the battery voltage
and the starting motor, then measure again.
fl After measuring the compression pressure, install the
nozzle holder assembly again.

D21A, P-8 20-107

(2)
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING

TESTING AND ADJUSTING FUEL INJECTION TIMING

TESTING
Check mounting nut (1) of the fuel injection pump for
looseness.

fl The fuel injection timing does not change as long as

the mounting nut is not loosened. Accordingly, when
removing and installing or replacing the fuel injection
pump, refer to the following adjusting procedure.

ADJUSTING
fl The injection timing of the MP-type fuel injection pump
used engine cannot be measured like the former mod-
els. Accordingly, adjust the injection angle instead of
measuring the injection timing.
1. Before removing fuel injection pump (2), remove the
cover in front of the timing gear case and make match
marks on the meshing parts of pump drive gear (3)
and idle gear (4).

2. Accurately record the relative positions of stamped

line (5) of the fuel injection pump body and stamped
line (6) of the gear case with mark-off lines (7), etc.

3. Stick injection angle adjustment seal (8) to the gear

case, matching its center line to stamped line (5) of
the fuel injection pump body.

4. Remove the fuel injection pump and read the “injec-

tion angle” recorded on it.
fl See Removal, installation of fuel injection pump.

20-108 D21A, P-8

(2)
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING

5. Read the “injection angle” recorded on the fuel injec-

tion pump to be installed and calculate the difference
between it and the “injection angle” of the removed
fuel injection pump.
fl When the same fuel injection pump is installed
again, the angle difference is 0.
fl Injection angle difference (Cam angle) = (Injec-
tion angle of fuel injection pump to be installed)
– (Injection angle of removed fuel injection pump)

CAUTION
If the injection angle of the fuel injection pump is difficult
to read, notify YAMMAR of the fuel injection pump No.
and ask the injection angle.

6. Install the fuel injection pump temporarily and tighten

the nut at the shaft end.
fl See Removal, installation of fuel injection pump.

7. Read the injection angle difference calculated in step

5 above by the scale of the adjustment seal (Mini-
mum division: 0.5° of cam angle) and adjust the in-
stalled angle of the fuel injection pump.
fl If the injection angle difference is +1°, lean the fuel
injection pump away from the cylinder block by 1°.
If the injection angle difference is –1°, lean the fuel
injection pump toward the cylinder block by 1°.

8. Tighten the fuel injection pump mounting nut.

REFERENCE
Standard installed angle θ of fuel injection pump: 12°

REMARK
Injection angle θ i (cam angle) is the difference be-
tween the angle at which injection is started and the
angle at which the plunger lift of the fuel injection
pump is 2.5 mm while the fuel injection pump unit is
driven with a motor.
Actual injection angle θ i is measured for each fuel
injection pump and recorded on the pump body.

D21A, P-8 20-109

(2)
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT

BLEEDING AIR FROM FUEL CIRCUIT

1. Bleeding air automatically
Keep the starting switch key in the ON position for 20
– 30 seconds, and the electric fuel pump bleeds air
automatically.

20-110 D21A, P-8

(2)
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE

MEASURING ENGINE OIL PRESSURE

fl Measuring instruments for engine oil pressure

Symbol Part No. Part name

1 799–101–5002 Oil pressure gauge kit (Analog)

F 790–261–1203 Oil pressure gauge kit (Digital)

2
799–401–2320 Oil pressure gauge

fl Measure the engine oil pressure under the following

condition.
• Coolant temperature: Within operating range

1. Remove engine oil pressure switch (1).

2. Install nipple [1] of oil pressure gauge kit F1 and

connect oil pressure gauge F2 (9.8 MPa {10 kg/cm2})
by hose [2].

3. Start the engine and measure the oil pressure at low

idling and high idling.

D21A, P-8 20-111

(2)
TESTING AND ADJUSTING TESTING AND ADJUSTING FAN BELT TENSION

TESTING AND ADJUSTING FAN BELT TENSION

(When standard alternator is installed)

TESTING FAN BELT TENSION

1. Check the amount of the fan belt deflection a when

pushed with a force of F at a point midway between
the fan pulley and the alternator pulley.
a: 10 – 15 mm
F: 98.1 N{10 kg}

ADJUSTING FAN BELT TENSION

1. Loosen the mounting bolt of he alternator assembly

and belt tension adjustment bolt (1).

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

adjust the fan belt tension.

3. Tighten adjustment bolt (1), the tighten the alternator

mounting bolt.

20-112 D21A, P-8

(2)
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL LINKAGE

ADJUSTING FUEL CONTROL LINKAGE

1. Place fuel control lever (3) at the low idling position

(A), then adjust distance “a”, “b” of cable (4) to the
dimensions below, and secure in position.
fl Standard dimension of “a”: 192 mm
Standard dimension of “b”: 243 mm
fl “b”: left side of frame

2. In the above position, adjust distance “c” of cable (5)

to the dimension below.
fl Standard dimension of “c”: 191 mm

3. Place fuel control lever (3) at the high idling position

(B), then adjust distance “d”, “e”, “f” to the dimen-
sions below.
fl Standard dimension of “d”: 302.6 mm
Standard dimension of “e”: 300 mm
Standard dimension of “f”: 286 mm
fl “d”: left side of frame
“e”, “f”: right side of frame
fl Connect so that the loose spring is not com-
pressed.

D21A, P-8 20-113

(2)
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL LINKAGE

4. Place fuel control lever (3) at the low idling position

(A), and adjust rod (7) so that governor lever (6) of
the injection pump contacts the low idling stopper.
fl Push rod (7) to low idling direction so that play of
cable becomes 0.

5. Pull fuel control lever so that governor lever (6) con-

tacts the high idling stopper.
In the above position, screw in stopper bolt (8) until
the clearance “g” becomes 0, then turn back 2 turns
(“g”=2 mm) and secure in position.

6. Same as above, place fuel control lever (3) to low

idling position, adjust stopper bolt (9) so that the
clearance “g” becomes 0, then secure in position.

20-114 D21A, P-8

(2)
 TROUBLESHOOTING

Points to remember when troubleshooting ........................................................................................ 20-202

Sequence of events in troubleshooting .............................................................................................. 20-203
Points to remember when carrying out maintenance ....................................................................... 20-204
Checks before troubleshooting ............................................................................................................ 20-212
Classification and steps for troubleshooting ...................................................................................... 20-215
Types and locations of connectors ...................................................................................................... 20-216
Connection table for connector pin numbers .................................................................................... 20-218
TROUBLESHOOTING OF MECHANICAL SYSTEM ............................................................................. 20-301
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM ...................................................... 20-401
TROUBLESHOOTING OF ENGINE ........................................................................................................ 20-501

D21A, P-8 20-201

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TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING

CHECKS BEFORE TROUBLESHOOTING

Judgement
Item Remedy
standard

1. Check fuel level – Add fuel

2. Check for dirt or water in fuel – Clean, drain
Lubricating oil, coolant

3. Check hydraulic oil level – Add oil

4. Check hydraulic oil strainer – Clean, drain
5. Check power train oil level – Add oil
Checks before starting

6. Check engine oil level (level of oil in oil pan) – Add oil
7. Check coolant level – Add water
8. Check condition of dust indicator – Clean or
replace
9. Check brake pedal travel – Adjust
mechanical Electrical equipment

10. Check for loose or corroded battery terminals or wires – Tighten or

replace
11. Check for loose or corroded alternator terminals or wires – Tighten or
replace
12. Check for loose or corroded starting motor terminals or wires – Tighten or
replace
components

13. Check for abnormal noise or smell – Repair

Hydraulic,

14. Check for oil leakage – Repair

15. Bleed air from system – Bleed air

16. Check battery voltage (engine stopped) 20 – 30 V Replace

Add or
Other check items

17. Check level of battery electroyte –

replace
Electrical components

18. Check for discolored, burnt, or bare wiring – Replace

19. Check for missing wiring clamps, hanging wires – Repair
20. Checks for water leaking onto wiring (Check carefully for – Dry area
water leakage at connectors and terminals) around
connector
21. Check for broken or corroded fuses – Replace
22. Check alternator voltage (engine running at over half throttle) After running Replace
engine for
several miniutes
13.75 – 14.75 V

20-212 D21A, P-8

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TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING

Phenomena considered to be failures and troubleshooting No.

Troubleshooting
No. Phenomenon considered to be failure
E-mode H-mode S-mode

Phenomena related to engine

1 The engine does not start easily (It always takes time to start) S-1

2 The engine does not crank E-1 S-2a)

3 The engine does not start The engine cranks but exhaust smoke does not come out S-2b)

4 Exhaust smoke comes out but the engine does not start S-2c)

5 The engine speed does not rise sharply (Follow-up performance is low) S-3

6 The engine stops during operation S-4

7 Engine rotation is abnormal (The engine hunts) S-5

8 Output is insufficient or power is low S-6

9 Exhaust gas color is bad (Incomplete combustion) S-7

10 Oil is consumed much or exhaust gas color is blue S-8

11 Oil becomes dirty quickly S-9

12 Fuel is consumed much S-10

13 Coolant contains oil, or it blows back or reduces S-11

14 Engine oil pressure lowers S-12

15 Oil level rises S-13

16 Coolant temperature rises too high (Overheating) S-14

17 Abnormal sound comes out S-15

18 Vibration is excessive S-16

19 The preheater does not operate E-3

Phenomena related to power train

20 Machine does not start H-1 S-6

21 Drawbar pull or travel speed is low H-2

22 Time lag is large in starting and shifting gear H-3

23 Machine cannot be steered at all or easily H-4

24 When engine is started, machine moves H-5

25 Large shocks are made when machine starts or gear is shifted H-6

26 Oil level in transmission case and bevel gear case rises or lowers H-7

Phenomena related to work equipment

27 Rising power and speed of blade are insufficient H-8

28 Blade cannot be raised and machine body cannot be pushed up H-9

29 Hydraulic drift of blade is large H-10

30 Blade sways up and down during finish grading (While control lever is in HOLD position) H-11

D21A, P-8 20-213

(2)
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING

Troubleshooting
No. Phenomenon considered to be failure
E-mode H-mode S-mode

31 Blade lowers H-12

Tilting power and speed are insufficient and machine body cannot be
32 pushed up by tilting H-13

33 Blade cannot be tilted H-14

34 Hydraulic drift of blade tilt is large H-15

35 Angling power and speed of blade are insufficient

(Applied to power angle and power tiltdozer) H-16

36 Blade cannot be angled H-17

37 Blade returns or sways while it is operated in angling position

(While control lever is in HOLD position) H-18

38 Operating effort of work equipment control lever is heavy H-19

Other phenomena

39 Battery is not charged normally (Caution lamp lights up) E-4

40 Horn does not sound E-5

41 Headlamp (Rear lamp) does not light up E-6

42 Coolant temperature gauge is abnormal E-7

43 Fuel level gauge is abnormal E-8

44 Backup buzzer does not sound E-9

45 Service meter does not operate while engine is running E-10

20-214 D21A, P-8

(2)
TROUBLESHOOTING CLASSIFICATION AND STEPS FOR TROUBLESHOOTING

CLASSIFICATION AND STEPS FOR TROUBLESHOOTING

Classification of troubleshooting

Mode Content

E mode Troubleshooting of electrical system

H mode Troubleshooting of hydraulic and mechanical system

S mode Troubleshooting of engine

D21A, P-8 20-215

(2)
TROUBLESHOOTING TYPES AND LOCATIONS OF CONNECTORS

TYPES AND LOCATIONS OF CONNECTORS

Connector No. Type Number of pins Location

CN8 DT 2 Coolant temperature sensor

CN9 X 4 Safety relay

CN11 S 10 Intermediate connector

CN12 M 6 Intermediate connector

CN16 M 2 Intermediate connector

CN17 X 2 Service power supply

CN18 Terminal 1 Ground

CN20 KES 2 Horn

AC PT 2 Intermediate connector (Air cleaner clogging sensor)

AC1 Terminal 1 Starting switch ACC

AC3 Terminal 1 Starting switch ACC

AC4 Terminal 1 Starting switch ACC

AL M 2 Alternator terminals L and IG

ALB Terminal 1 Alternator terminals B

ALP M 1 Alternator terminals P

BO Terminal 1 Ground

BB X 2 Backup buzzer

BR Terminal 1 Battery terminal (+)

BR1 Terminal 1 Starting switch terminal BR

BS S 2 Backup buzzer

DY1 SWP 2 Diode

DY2 SWP 2 Diode

EN DT 4 Intermediate connector (Engine stop solenoid, etc.)

FB – – Fuse box

FS DT 2 Fuel tank level sensor

FMW YAZAKI 2 Night lighting (Fuel level gauge)

HE1 Terminal 1 Air heater relay (Contact outlet)

HE2 Connector 1 Air heater relay (Coil inlet)

HL DT 2 Intermediate connector (Headlamp)

HL2 DT 2 Intermediate connector (Headlamp)

HLL DT 3 Headlamp (Left)

HLR DT 3 Headlamp (Right)

FMB Terminal 1 Fuel level gauge terminal B

FME Terminal 1 Fuel level gauge terminal E

FMT Terminal 1 Fuel level gauge terminal T

20-216 D21A, P-8

(2)
TROUBLESHOOTING TYPES AND LOCATIONS OF CONNECTORS

Connector No. Type Number of pins Location

HO1 M 2 Horn switch

HS YAZAKI 2 Heater signal

HU M 2 Fusible link

LM DT 3 Limit switch

LS M 4 Headlamp switch

M6 Terminal 1 Intake air heater

OPS Terminal 1 Engine oil pressure switch

PL SWP 6 Pilot lamp

PM X 2 Fuel pump

RL DT 3 Rear lamp

SC Terminal 1 Starting switch terminal C

SFB Terminal 1 Safety relay (Terminal B)

SFS Terminal 1 Safety relay (Terminal B)

SM1 YAZAKI 1 Service meter

SM2 YAZAKI 1 Service meter

SO1 X 3 Engine stop solenoid

SO2 X 2 Intermediate connector

SBA Terminal 1 Starting switch terminal B

SBB Terminal 1 Starting switch terminal B

SR1 YAZAKI 2 Engine stop solenoid relay

SR1 Terminal 1 Starting switch terminal R1

SR2 YAZAKI 1 Engine stop solenoid relay

SR3 YAZAKI 1 Engine stop solenoid relay

STB Terminal 1 Starting motor (Terminal B)

STS Terminal 1 Starting motor (Terminal S)

TMR YAZAKI 4 Timer (Engine stop solenoid)

WTB Terminal 1 Coolant temperature gauge terminal B

WTE Terminal 1 Coolant temperature gauge terminal E

WTT Terminal 1 Coolant temperature gauge terminal T

WTW YAZAKI 2 Night lighting (Coolant temperature gauge)

D21A, P-8 20-217

(2)
 TROUBLESHOOTING OF
ELECTRICAL SYSTEM
(E MODE)

Before carrying out troubleshooting in E-MODE ................................................................................................. 20-302

Information contained in troubleshooting table .................................................................................................. 20-303
E-1 The engine does not start ............................................................................................................................. 20-304
E-2 The engine does not stop ............................................................................................................................. 20-310
E-3 The heater signal is not heated red, or the heater does not become hot even
if the heater signal is heated red ................................................................................................................. 20-312
E-4 The battery is not charged normally (Caution lamp lights up) ................................................................ 20-314
E-5 The horn does not sound .............................................................................................................................. 20-315
E-6 The headlamp (rear lamp) does not light up ............................................................................................. 20-316
E-7 The coolant temperature gauge is abnormal ............................................................................................. 20-318
E-8 The fuel level gauge is abnormal ................................................................................................................ 20-319
E-9 The backup buzzer does not sound ............................................................................................................. 20-320
E-10 The service meter does not operate while engine is running .................................................................. 20-321

D21A, P-8 20-301

(2)
TROUBLESHOOTING BEFORE CARRYING OUT TROUBLESHOOTING IN E-MODE

BEFORE CARRYING OUT TROUBLESHOOTING IN E-MODE

Connection table of fuse box

fl This connection table shows the devices to which each power supply of the fuse box supplies power directly
(A switch power supply is a device which supplies power while the starting switch is at the ON position and
a constant power supply is a device which supplies power while the starting switch is at the OFF position).
fl When carrying out troubleshooting related to the electrical system, you should check the fuse box and fusible
link to see if the power is supplied normally.

Type of power supply Fuse No. Fuse capacity Destination of power

1 20A

2 10A Horn

Back-up buzzer
3 10A
Power supply for safety inspection
Switch power supply
Caution lamp
4 10A
Coolant temperature gauge and fuel level gauge

Air bleeding pump

5 30A
Engine stop solenoid

20-302 D21A, P-8

(2)
TROUBLESHOOTING E-1

E-1 The engine does not start

1) The engine does not start (The starting motor does not rotate)

Trouble • The engine does not start (The starting motor does not rotate)

Related • The engine starting circuit has the locking function. If the safety lock lever is not in the
information LOCK position, the engine does not start.

Cause Standard value in normal state/Remarks on troubleshooting

Insufficient battery Battery voltage Electrolyte specific gravity

1
capacity Min. 12 V Min. 1.26
Defective fusible link If the fusible link or fuse is broken, the circuit probably has a grounding
2
45A or fuse (5) fault.
1) Turn starting switch OFF.
2) Disconnect (–) battery terminal.
Starting switch Position Resistance
Defective starting
3 switch (Internal defec- OFF Min. 1 MΩ
Possible causes and standard value in normal state

tive contact) Between terminals B and C

START Max. 1 Ω
OFF Min. 1 MΩ
Between terminals B and ACC
ON Max. 1 Ω
1) Turn starting switch OFF.
2) Disconnect connector LM.
Defective safety lock
3) Connect T-adapter to LM (male).
switch (limit switch)
4
(Internal defective LM (male) Position of lock lever Resistance
contact)
FREE Max. 1 Ω
Between (A) and (C)
LOCK Min. 1 MΩ
1) Check by turning starting switch from OFF to START.
(If power supply and starting input/output are normal and starting motor
does not rotate, starting motor is defective.)
Starting motor Starting switch Voltage
5 Defective starting motor
Power supply: Between terminal B and
ON 10 – 15 V
chassis ground
Starting input: Terminal S and
START 10 – 15 V
chassis ground

Defective safety relay 1) Check by turning starting switch from OFF to START.
6 (Internal defective Between SFS (Safety relay terminal outlet) Voltage
contact or disconnection) and chassis ground
10 – 15 V

Defective alternator 1) Check by turning starting switch from OFF to ON or START.

7 (including regulator) Alternator Voltage
(Internal short circuit)
Between terminal P and chassis ground Max. 1 V

20-304 D21A, P-8

(2)
TROUBLESHOOTING E1

Cause Standard value in normal state/Remarks on troubleshooting

1) Turn starting switch OFF.
2) Disconnect related connector or terminal.
3) Set safety lock switch (limit switch) in LOCK position.
Wiring harness between battery (+) – HU (1) or (2)
Resistance Max.1 Ω
– CN16 (1) – starting switch terminal B
Wiring harness between starting switch terminal BR
Disconnection in wiring – fuse (10) or (5) – CN12 (3) – EN (1) – S01 (female) Resistance Max.1 Ω
Possible causes and standard value in normal state

harness (Disconnection (1) or TMR (female) (4) or SR2 (female) (1)

8 in wiring harness or Wiring harness between starting switch terminal C
defective contact in Resistance Max.1 Ω
– CN11 (6) – LM (A) or (C) – CN9 (female) (2)
connector)
Wiring harness between CN9 (female) (1) – AL
Resistance Max.1 Ω
(female) (1)
Wiring harness between CN9 (female) (3) – ALP (male)
Resistance Max.1 Ω
(1)
Wiring harness between CN9 (female) (4) – chassis
Resistance Max.1 Ω
ground
1) Turn starting switch OFF.
2) Disconnect related connector or terminal.
3) Set safety lock switch (limit switch) in LOCK position.
Between HU (female) (2) – CN16 (1) – starting switch
Resistance Min.1 MΩ
terminal B wiring harness and chassis ground

Short circuit with Between fuse (5) – CN12 (3) – EN (1) – S01 (female)
chassis ground in (1) or TMR (female) (4) or SR2 (female) (1) wiring Resistance Min.1 MΩ
9 harness and chassis ground
wiring harness (Contact
with ground circuit) Between starting siwtch terminal C – CN11 (6) – LM
(A) or (C) – CN9 (female) (2) wiring harness and Resistance Min.1 MΩ
chassis ground
Between CN9 (female) (1) – AL (female) (1) wiring
Resistance Min.1 MΩ
harness and chassis ground
Between CN9 (female) (3) – ALP (male) (1) wiring
Resistance Min.1 MΩ
harness and chassis ground

D21A, P-8 20-305

(2)
TROUBLESHOOTING E1

Related circuit diagram

20-306 D21A, P-8

(2)
D21A, P-8 20-307
(2)
TROUBLESHOOTING E1

2) The engine does not start (Engine stop solenoid system)

fl For the related circuit diagram, see 1).

Trouble • The engine does not start (Engine stop solenoid system)

Related • Carry out the following troubleshooting in the following case: When the starting motor is
information turned on, the engine does not start.

Cause Standard value in normal state/Remarks on troubleshooting

1 Defective fuse (11) If the fuse is broken, the circuit probably has a grounding fault.

1) Turn starting switch OFF.

Defective starting 2) Disconnect (–) battery terminal.
2 switch (Internal defec- Starting switch Position Resistance
tive contact)
Between terminals B and BR OFF Min. 1 MΩ
Possible causes and standard value in normal state

ON Max. 1 Ω
1) Turn starting switch OFF.
2) Disconnect connector S01.
Defective engine stop 3) Connect T-adapter to S01 (male).
solenoid (Internal S01 (male) Resistance
3
disconnection or short
Between (1) and (3) 22 – 28 Ω
circuit)
Between (2) and (3) 0.63 – 0.77 Ω
Between (1), (2) and body Min. 1 MΩ
1) Check by turning starting switch from OFF to ON.
Defective timer (Inter-
TMR Measurement conditions Voltage
4 nal disconnection or
short circuit) Between For 1 second after starting switch is turned ON 10 – 15 V
(1) and (2) After 1 second has passed Max. 1 V
1) Turn starting switch OFF.
2) Disconnect connector SR1.
SR1 (male) Resistance
Defective engine stop Between (1) and (2) 33 – 41 Ω
solenoid relay (Internal 1) Check by turning starting switch from OFF to ON.
5
disconnection or short
SR3 Measurement conditions Voltage
circuit)
Between (1) For 1 second after starting switch is turned ON 10 – 15 V
and chassis ground After 1 second has passed Max. 1 V

20-308 D21A, P-8

(2)
TROUBLESHOOTING E1

Cause Standard value in normal state/Remarks on troubleshooting

1) Turn starting switch OFF.
2) Disconnect related connector or terminal.
3) Set safety lock switch (limit switch) in LOCK position.
Wiring harness between starting switch terminal BR
– fuse (10) or (5) – CN12 (3) – EN (1) – S01 (female) Resistance Max. 1 Ω
Possible causes and standard value in normal state

Disconnection in wiring (1) or TMR (female) (4) or SR2 (female) (1)

harness (Disconnection Wiring harness between S01 (female) (2) – S02 – SR3
6 in wiring harness or Resistance Max. 1 Ω
(female) (1)
defective contact in
connector) Wiring harness between TMR (female) (1) – SR1
Resistance Max. 1 Ω
(female) (1)
Wiring harness between TMR (female) (2) – SR1
Resistance Max. 1 Ω
(female) (2)
Wiring harness between S01 (female) (3) or TMR
Resistance Max. 1 Ω
(female) (3) – chassis ground
1) Turn starting switch OFF.
2) Disconnect related connector or terminal.
3) Set safety lock switch (limit switch) in LOCK position.
Between fuse (5) – CN12 (3) – EN (1) – S01 (female)
Short circuit with (2) or TMR (female) (4) or TMR (female) (4) or SR2 Resistance Min. 1 MΩ
chassis ground in (female) (1) wiring harness and chassis ground
7
wiring harness (Contact
with ground circuit) Between S01 (female) (2) – S02 (1) – SR3 (female)
Resistance Min. 1 MΩ
(1) wiring harness and chassis ground
Between wiring harness between TMR (female) (1) –
Resistance Min. 1 MΩ
SR1 (female) (1) wiring harness and chassis ground
Between wiring harness between TMR (female) (2) –
Resistance Min. 1 MΩ
SR1 (female) (2) wiring harness and chassis ground

D21A, P-8 20-309

(2)
TROUBLESHOOTING E2

E-2 The engine does not stop

Trouble • The engine does not stop

Related
information

Cause Standard value in normal state/Remarks on troubleshooting

1) Turn starting switch OFF.
2) Disconnect connector S01.
standard value in normal state

Defective engine stop 3) Connect T-adapter to S01 (male).

1 solenoid (Internal
S01 (male) Resistance
Possible causes and

defect)
Between (1) and (3) 22 – 28 Ω
Between (2) and (3) 0.63 – 0.77

Defective starting 1) Check by turning starting switch from START to OFF.

2 switch (Internal short Starting switch Position Voltage
circuit)
Between terminal BR and chassis ground OFF Max. 1 V
1) Prepare with starting switch OFF, then carry out troubleshooting without
Short circuit with power
turning starting switch ON.
3 source in wiring har-
ness (Contact with 12-V Between starting switch terminal BR – S01
circuit) (female) (1) wiring harness and chassis Voltage Max. 1 V
ground

20-310 D21A, P-8

(2)
TROUBLESHOOTING E2

Related circuit diagram

D21A, P-8 20-311

(2)
TROUBLESHOOTING E3

E-3 The heater signal is not heated red, or the heater does not become hot even if the
heater signal is heated red

• When the starting switch is turned to the HEAT position, the heater signal is not heated
Trouble
red, or the heater does not become hot even if the heater signal is heated red.
• Check that the fusible link is normal.
Related • Refer to troubleshooting M-1, too.
information • When the starting switch is turned to the HEAT position, the heater signal is heated red
in 20 - 30 seconds.

Cause Standard value in normal state/Remarks on troubleshooting

1 Defective fusible link If the fusible link is broken, the circuit probably has a grounding fault.

1) Prepare with starting switch OFF.

Defective air heater 2) Set starting switch in HEAT position and carry out troubleshooting.
2
(Internal disconnection) Between starting switch terminal R1 and
Voltage 10 – 15 V
chassis ground
1) Turn starting switch OFF.
Defective starting
2) Disconnect (–) battery terminal.
3 switch (Internal defec-
tive contact) Between starting switch terminal B and
Resistance Max. 1 Ω
Possible causes and standard value in normal state

terminal R1
1) Prepare with starting switch OFF.
2) Set starting switch in ON position and carry out troubleshooting.
Between power supply side terminal of
Voltage 10 – 15 V
heater relay and chassis ground
1) Prepare with starting switch OFF.
Defective heater relay 2) Set starting switch in HEAT position and carry out troubleshooting.
4 (Internal disconnection Between power supply outlet side (HE1) of
or defective contact) Voltage 10 – 15 V
heater relay and chassis ground
Between HE2 (1) and chassis ground Voltage 10 – 15 V
1) Prepare with starting switch OFF.
2) Carry out troubleshooting with starting switch OFF.
Between ground terminal of heater relay
Resistance Max. 1 Ω
and chassis ground
1) Turn starting switch OFF.
2) Disconnect related connector or terminal.
Wiring harness between starting switch
Disconnection in wiring Resistance Max. 1 Ω
terminal R1 – CN12 (2) – HE2 (female) (1)
harness (Disconnection
Wiring harness between heater relay power
5 in wiring harness or Resistance Max. 1 Ω
supply outlet (HE1) – CN12 (1) – HS (female) (1)
defective contact in
connector) Wiring harness between heater relay power
Resistance Max. 1 Ω
supply outlet (HE1) – air heater inlet
Wiring harness between heater relay power
Resistance Max. 1 Ω
supply inlet – starting motor terminal B

20-312 D21A, P-8

(2)
TROUBLESHOOTING E3

Related circuit diagram

D21A, P-8 20-313

(2)
TROUBLESHOOTING E4

E-4 The battery is not charged normally (caution lamp lights up)
• The charge caution lamp lights up to indicate abnormal charge level while the engine is
Trouble
running.
• Check that the fan belt tension is normal.
Related • When the starting switch is turned from the OFF position to the ON position, the engine
information oil pressure caution lamp and charge caution lamp light up. This phenomenon does not
indicate abnormality.

Cause Standard value in normal state/Remarks on troubleshooting

1) Prepare with starting switch OFF.

2) Start engine and carry out troubleshooting.
1 Defective alternator
standard value in normal state

(Internal disconnection) Between AL (1) and chassis ground

Voltage 13.5 – 14.5 V
(Just after starting)
Possible causes and

1) Turn starting switch OFF.

Disconnection in wiring 2) Disconnect connectors AL and PL.
harness (Disconnection Wiring harness between (+) battery
2 in wiring harness or Resistance Max. 1 Ω
defective contact in terminal – alternator terminal B
connector) Wiring harness between AL (female) (2) –
Resistance Max. 1 Ω
CN11 (8) – PL (female) (1)
1) Turn starting switch OFF.
Short circuit with
chassis ground in 2) Disconnect connectors AL and PL.
3 wiring harness (Contact Between PL (female) (1) – CN11 (8) – AL
with chassis ground or (female) (2) wiring harness and chassis Resistance Min. 1 MΩ
ground circuit)
ground

Related circuit diagram

20-314 D21A, P-8

(2)
TROUBLESHOOTING E5

E-5 The horn does not sound

Trouble • The horn does not sound.

Related
information

Cause Standard value in normal state/Remarks on troubleshooting

If the fuse is broken, the circuit probably has a grounding fault.
1 Defective fuse (1)

1) Turn starting switch OFF.

2) Disconnect connector H01.
Defective horn switch
Possible causes and standard value in normal state

2 (Internal defective H01 (male) Resistance

contact) Switch OFF Min. 1 MΩ
Between (1) and (2)
Switch ON Max. 1 Ω
1) Prepare with starting switch OFF.
2) Carry out troubleshooting with starting switch ON.
Between CN20 (1) and chassis ground Voltage 10 – 15 V
3 Defective horn
1) Turn starting switch OFF.
2) Disconnect connector CN20.
Between CN20 (female) (2) and chassis ground Resistance Max. 1 Ω
1) Turn starting switch OFF.
Disconnection in wiring 2) Disconnect connectors CN20 and H01.
harness (Disconnection
Wiring harness between CN20 (female) (1)
4 in wiring harness or Resistance Max. 1 Ω
– H01 (female) (2)
defective contact in
connector) Wiring harness between fuse (2) – H01
Resistance Max. 1 Ω
(female) (1)
1) Turn starting switch OFF.
Short circuit with
2) Disconnect connectors CN20 and H01.
chassis ground in
Between CN20 (female) (1) – H01 (female)
5 wiring harness (Contact Resistance Min. 1 MΩ
with chassis ground or (2) wiring harness and chassis ground
ground circuit) Between fuse (2) – H01 (female) (1) wiring
Resistance Min. 1 MΩ
harness and chassis ground

Related circuit diagram

D21A, P-8 20-315

(2)
TROUBLESHOOTING E-6

E-6 The headlamp (rear lamp) does not light up

Trouble • The headlamp (rear lamp) does not light up.

Related
information

Cause Standard value in normal state/Remarks on troubleshooting

If the fuse is broken, the circuit probably has a grounding fault.
1 Defective fuse (1)

1) Turn starting switch OFF.

2) Disconnect connectors HLR, HLL, and RL.
3) Connect T-adapters to female side of HLR, HLL, and RL.
4) Turn starting switch ON.
5) Turn lamp switch ON.
Between HLR, HLL, and RL (female) (A)
2 Defective lamp Voltage 10 – 15 V
and chassis ground
1) Turn starting switch OFF.
2) Disconnect connectors HLR, HLL, and RL.
3) Connect T-adapters to female side of HLR, HLL, and RL.
4) Carry out troubleshooting with starting switch OFF.
Between HLR, HLL, and RL (female) (B)
Possible causes and standard value in normal state

Resistance Max. 1 Ω
and chassis ground
1) Turn starting switch OFF.
2) Disconnect connector LS.
Operation of switch LS (male) Resistance
Defective lamp switch Between (4) and (3) Min. 1 MΩ
Turn lamp switch OFF
3 (Internal defective Between (4) and (2) Min. 1 MΩ
contact)
Between (4) and (3) Max. 1 Ω
Set lamp switch in 1st position
Between (4) and (2) Min. 1 MΩ
Between (4) and (3) Max. 1 Ω
Set lamp switch in 2nd position
Between (4) and (2) Max. 1 Ω
1) Turn starting switch OFF.
2) Disconnect connectors HLR, HLL, RL, and LS.
3) Connect T-adapters to female side of HLR, HLL, and RL.
Disconnection in wiring
harness (Disconnection Wiring harness between LS (female) (3) –
4 in wiring harness or CN12 (5) – HL2 (1) – HL1 (1) – HLR (female) (A) Resistance Max. 1 Ω
defective contact in or HLL (female) (A)
connector) Wiring harness between LS (female) (2) –
Resistance Max. 1 Ω
CN12 (4) – and RL (female) (A)
Wiring harness between LS (female) (4) –
Resistance Max. 1 Ω
fuse (1)
1) Turn starting switch OFF.
2) Disconnect connectors HLR, HLL, RL, and LS.
3) Connect T-adapter to HLR, HLL, and RL (female).
Short circuit with
chassis ground in Between LS (female) (3) – CN12 (5) – HL (1) –
HL2 (1) – HLR (female) (A) or HLL (female) (A) Resistance Min. 1 MΩ
5 wiring harness (Contact
with chassis ground or wiring harness and chassis ground
ground circuit) Between LS (female) (2) – CN12 (4) – RL (female)
Resistance Min. 1 MΩ
(A) wiring harness and chassis ground
Between LS (female) (4) – fuse (1) wiring harness
Resistance Min. 1 MΩ
and chassis ground

20-316 D21A, P-8

(2)
TROUBLESHOOTING E-6

Related circuit diagram

D21A, P-8 20-317

(2)
TROUBLESHOOTING E-7

E-7 The coolant temperature gauge is abnormal

1) The point of the gauge does not move from “C” on the panel

• When the starting switch is turned ON, the pointer of the gauge does not move from the
Trouble “C” or “H” position on the panel or its indication is largely deviated from the actual
temperature.
• Check that the coolant temperature is normal.
Related • When the starting switch is turned OFF, the pointer of the gauge does not move from
information the “C” position. This does not indicate abnormality.
• Refer to troubleshooting M-1, too.

Cause Standard value in normal state/Remarks on troubleshooting

1) Turn starting switch OFF.
2) Disconnect connectors CN8 and CN11.
Disconnection in wiring
3) Connect T-adapters to female side of CN8 and CN11.
standard value in normal state

harness (Disconnection
1 in wiring harness or Wiring harness between CN8 (female) (1)
Resistance Max. 1 Ω
– CN11 (male) (2)
Possible causes and

defective contact in
connector) Wiring harness between CN8 (female) (2)
Resistance Max. 1 Ω
– chassis ground
1) Turn starting switch OFF.
2) Disconnect connector CN8.
3) Connect T-adapter to male aside of CN8.
CN8 (male) Temperature Resistance
Defective coolant
2
temperature sensor 60°C 51.3 – 61.3 Ω
80°C 27.0 – 32.0 Ω
Between (1) and (2)
100°C 15.6 – 17.4 Ω
106°C 13.8 – 14.8 Ω

Related circuit diagram

20-318 D21A, P-8

(2)
TROUBLESHOOTING E-8

E-8 The fuel level gauge is abnormal

1) The pointer of the gauge does not move from “E” on the panel

• When the starting switch is turned ON, the pointer of the gauge does not move from the
Trouble “E” or “F” position on the panel or its indication is largely deviated from the actual fuel
level.
• Check that the fuel level is normal.
Related • When the starting switch is turned OFF, the pointer of the gauge does not move from
information the “E” position. This does not indicate abnormality.
• Refer to troubleshooting M-1, too.

Cause Standard value in normal state/Remarks on troubleshooting

1) Turn starting switch OFF.
2) Disconnect connectors FS and CN11.
Disconnection in wiring
3) Connect T-adapters to female side of FS and CN11.
harness (Disconnection
1 in wiring harness or Wiring harness between FS (female) (1)
standard value in normal state

Resistance Max. 1 Ω
defective contact in – CN11 (male) (9)
Possible causes and

connector) Wiring harness between FS (female) (2)

Resistance Max. 1 Ω
– chassis ground
1) Turn starting switch OFF.
2) Disconnect connector FS.
3) Connect T-adapter to male aside of FS.
Values in ( ) are
FS (male) Position of float
for reference
Defective fuel level
2 FULL 10
+1.0
Ω
sensor –1.5
3/4 (19 Ω)
Between (1) and (2) 1/2 32 ± 3 Ω
1/4 (49.5 Ω)
EMPTY 80 +12
– 2 Ω

Related circuit diagram

D21A, P-8 20-319

(2)
TROUBLESHOOTING E-9

E-9 The backup buzzer does not sound

Trouble • The backup buzzer does not sound.

Related
information

Cause Standard value in normal state/Remarks on troubleshooting

1 Defective fuse 3 If the fuse is broken, the circuit probably has a grounding fault.

1) Turn starting switch OFF.

2) Disconnect connector BS.
Defective backup buzzer
2 BS (male) Operation of switch Resistance
switch
Switch OFF Min. 1 MΩ
Between (1) and (2)
Switch ON Max. 1 Ω
1) Turn starting switch OFF.
2) Disconnect connector BB
standard value in normal state

3) Turn starting switch ON.

4) Set gearshift lever in REVERSE (Turn switch ON).
Possible causes and

3 Defective backup buzzer Between BB (female) (1) and chassis ground Voltage 10 – 15 V
1) Turn starting switch OFF.
2) Disconnect connector BB
Wiring harness between BB (female) (2)
Resistance Max. 1 Ω
and chassis ground
1) Turn starting switch OFF.
Disconnection in wiring 2) Disconnect connectors BS and BB.
harness (Disconnection
Wiring harness between BS (female) (2)
4 in wiring harness or Resistance Max. 1 Ω
defective contact in – BB (female) (1)
connector) Wiring harness between BS (female) (1) –
Resistance Max. 1 Ω
CN12 (6) – fuse (3)
1) Turn starting switch OFF.
Short circuit with 2) Disconnect connectors BS and BB.
chassis ground in
5 wiring harness (Contact Between BS (female) (2) – BB (female) (1)
Resistance Min. 1 MΩ
with chassis ground or wiring harness and chassis ground
ground circuit) Between BS (female) (1) – CN12 (6) – fuse (3)
Resistance Min. 1 MΩ
wiring harness and chassis ground

Related circuit diagram

20-320 D21A, P-8

(2)
TROUBLESHOOTING E-10

E-10 The service meter does not operate while engine is running
• The service meter (integration of the operating hours) does not operate while the engine
Trouble
is running.
• The service meter keeps operating while the engine is running, even if the machine is
Related not moving at all.
information • The service meter does not operate while the engine is stopped.
• Refer to troubleshooting M-1, too.

Cause Standard value in normal state/Remarks on troubleshooting

1) Turn starting switch OFF.
standard value in normal state

2) Disconnect connector SM1.

3) Start engine.
Possible causes and

Between SM1 and chassis ground Voltage 10 – 15 V

1 Defective service meter
1) Turn starting switch OFF.
2) Disconnect connector SM2.
Wiring harness between SM2 – chassis
Resistance Max. 1 Ω
ground
Disconnection in wiring 1) Turn starting switch OFF.
harness (Disconnection in 2) Disconnect connectors AL and SM1.
2
wiring harness or defec- Wiring harness between AL (female) (1) –
tive contact in connector) Resistance Max. 1 Ω
CN11 (7) – SM1

Related circuit diagram

D21A, P-8 20-321

(2)
 TROUBLESHOOTING OF HYDRAULIC,
MECHANICAL SYSTEM
(H MODE)

Method of using troubleshooting chart .............................................................................................. 20-402

H-1 Machine does not start ................................................................................................................. 20-404
H-2 Drawbar pull is weak, travel speed is slow................................................................................ 20-405
H-3 Excessive time lag when starting or shifting gear checks before troubleshooting .............. 20-406
H-4 Steering does not work property ................................................................................................ 20-407
H-5 Machine moves when engne is started ..................................................................................... 20-408
H-6 Excessive shock when starting or shifting gear ........................................................................ 20-408
H-7 Level of oil in transmission case or bevel gear case changes ................................................ 20-408
H-8 Lack of blade lifting force, speed ................................................................................................ 20-409
H-9 Impossible to raise blade or push up chassis ........................................................................... 20-410
H-10 Excessive hydraulic drift of blade ............................................................................................... 20-411
H-11 Blade moves up and down during leveling operations (control lever at HOLD) .................. 20-411
H-12 Blade goes down........................................................................................................................... 20-411
H-13 Blade tilt lacks power, speed, impossible to push up chassis with tilt .................................. 20-412
H-14 Blade cannot be tilted ................................................................................................................... 20-413
H-15 Excessive hydraulic drift of blade tilt ......................................................................................... 20-414
H-16 Blade angle lacks power, speed (applicable to power angle, power tilt dozer) .................... 20-415
H-17 Blade cannot be angled (applicable to power angle tiltdozer) ............................................... 20-416
H-18 When blade is angled, blade returns to straight position or
shakes during operations (control lever at HOLD) .................................................................... 20-417
H-19 Work equipment control levers are heavy ................................................................................. 20-418

D21A, P-8 20-401

(2)
 TROUBLESHOOTING OF ENGINE
(S MODE)

Method of using matrix troubleshooting chart .................................................................................. 20-502

S-1 Starting performance is poor (Starting always takes time) ..................................................... 20-506
S-2 Engine does not start ................................................................................................................... 20-507
S-3 Engine does not pick up smoothly (Follow-up is poor) ........................................................... 20-510
S-4 Engine stops during operations .................................................................................................. 20-511
S-5 Engine does not rotate smoothly ................................................................................................ 20-512
S-6 Engine lacks output (no power) .................................................................................................. 20-513
S-7 Exhaust gas is black (incomplete combustion) ......................................................................... 20-514
S-8 Oil consumption is excessive (or exhaust gas is blue) ............................................................ 20-515
S-9 Oil becomes contaminated quickly ............................................................................................. 20-516
S-10 Fuel consumption is excessive .................................................................................................... 20-517
S-11 Oil is in cooling water, or water spurts back, or water level goes down .............................. 20-518
S-12 Oil pressure lamp lights up (drop in oil pressure).................................................................... 20-519
S-13 Oil level rises ................................................................................................................................. 20-520
S-14 Water tempreture becomes too high (overheating).................................................................. 20-521
S-15 Abnormal noise is made .............................................................................................................. 20-522
S-16 Vibration is excessive ................................................................................................................... 20-523

D21A, P-8 20-501

(2)
 30 DISASSEMBLY AND ASSEMBLY

METHOD OF USING MANUAL .................... 30- 2 BEVEL GEAR SHAFT AND BEVEL GEAR
PRECAUTIONS WHEN CARRYING Removal ................................................... 30-58
OUT OPERATION .................................... 30- 4 Installation ............................................... 30-62
FUEL INJECTION PUMP FINAL DRIVE
Removal ................................................... 30- 6 Removal and Installation ....................... 30-68
Installation ............................................... 30- 7 FINAL DRIVE FIRST PINION
RADIATOR GUARD Removal ................................................... 30-69
Removal ................................................... 30- 8 Installation ............................................... 30-70
Installation ............................................... 30- 9 FINAL DRIVE
ENGINE Disassembly ............................................ 30-72
Removal ................................................... 30-10 Assembly ................................................. 30-75
Installation ............................................... 30-12 POWER TRAIN OIL COOLER
HYDROSHIFT TRANSMISSION Removal and Installation ....................... 30-79
Disassembly ............................................ 30-13 RECOIL SPRING
Assembly ................................................. 30-28 Removal and Installation ....................... 30-80
MODULATING VALVE Disassembly and Assembly .................. 30-81
Assembly ................................................. 30-45 TRACK SHOE
SELECTOR AND INCHING VALVE Removal and Installation ....................... 30-82
Assembly ................................................. 30-47 HYDRAULIC CONTROL VALVE
STEERING PPC VALVE Assembly ................................................. 30-83
Assembly ................................................. 30-49 HYDRAULIC CYLINDER
STEERING CLUTCH Assembly ................................................. 30-85
Removal ................................................... 30-50 BLADE
Installation ............................................... 30-52 Removal and Installation ....................... 30-87
Disassembly ............................................ 30-53
Assembly ................................................. 30-55

D21A, P-8 30-1

(1)
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL

METHOD OF USING MANUAL

1. When removing or installing unit assemblies

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

(Example)
REMOVAL OF


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


ASSEMBLY .... Title of operation
‡ Carry out installation in the reverse
order to removal.
1 ................................................ Technique used during installation
fl ................................................ Technique or important point to remember when
installing    (2).
‡ Adding water, oil ............................. Step in operation
fl ................................................ Point to remember when adding water or oil
5 ................................................ Quantity of filling oil and water

2. General precautions when carrying out installation or removal (disassembly or assembly) of units
are given together as PRECAUTION WHEN CARRYING OUT OPERATION, so be sure to follow
these precautions when carrying out the operation.

3. Listing of special tools

(1) For details of the description, part number, and quantity of any tools (A1, etc.) that appear in
the operation procedure, see the SPECIAL TOOLS LIST given in this manual.

30-2 D21A, P-8

(1)
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.
‡ 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 alternately.
‡ Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt
from entering after removal.

fl Precautions when handling piping during disassembling

Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Hoses and tubes using sleeve nuts
Nominal Plug (nut end) Sleeve nut (elbow end)
number Use the two items below as a set
02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
03 07376-50315 07221-20315 (Nut), 07222-00312 (Plug)
04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)
10 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)

2) Split flange type hoses and tubes

Nominal Flange (hose end) Sleeve head Split flange
number (tube end)
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500

3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12 Taper 1/8
øD

ød

12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
L
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30 DEW00401

27 07049-02734 27 22.5 34

D21A, P-8 30-3

(1)
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION

2. Precautions for installation operations

‡ Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
‡ Install the hoses without twisting or interference.
‡ Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
‡ Bend the cotter pin or lock plate securely.
‡ When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded
portion with 2 – 3 drops of adhesive.
‡ When coating with gasket sealant, clean the surface and remove all oil and grease, check that there
is no dirt or damage, then coat uniformly with gasket sealant.
‡ Clean all parts, and correct any damage, dents, burrs, or rust.
‡ Coat rotating parts and sliding parts with engine oil.
‡ When press fitting parts, coat the surface with antifriction 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 fully, and
align the direction of the hook.
‡ When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one
side.

3. Precautions when completing the operations

‡ 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, such as hydraulic cylinders, pumps, or motors, have been
removed for repair, always bleed the air from the system after reassembling the parts.
fl For details, see TESTING AND ADJUSTING, Bleeding air.
‡ Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
related parts.

4. Other precautions

‡ To maintain the performance of the machine and to prevent failures, it is particularly important to
pay attention to the degree of cleanliness of the oil in the hydraulic circuits. When adding oil or
changing the oil, or when replacing the filters, check that the oil container and area around the
filler of the hydraulic tank are clean.
‡ To keep the hydraulic circuits clean and to protect the hydraulic equipment, be careful of the
following points when disassembling or assembling.
• Before disassembling, wash the machine. Be particularly careful to completely clean the area
that is to be disassembled.
• Do not let dirt or dust get into the hydraulic circuits when disassembling or assembling.
• Carry out thorough flushing of the parts, and be particularly careful to do this thoroughly for
the circuits or parts that have failed.
• When disassembling or after flushing, always mask the openings of the piping or hydraulic
equipment completely.
• Do not use seal tape for the thread of the plug mounts or connections.
‡ If any internal part of the hydraulic equipment breaks, disassemble and clean all the hydraulic
equipment and circuits to remove any dirt or pieces from the circuit. If any parts of the hydraulic
circuits are disassembled and assembled, also carry out thorough flushing of the hydraulic circuits.
‡ When changing the oil in the hydraulic tank, or when removing the piston pump or piston pump
piping, always bleed the air before starting the engine to prevent seizure of the pump.
For details, see TESTING AND ADJUSTING, Bleeding air from piston pump.

30-4 D21A, P-8

(1)
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION

fl After replacing or flushing the hydraulic tank oil, filter element, or strainer, or when removing and
installing any hydraulic cylinder, hydraulic pump or any other hydraulic equipment or work equip-
ment piping, always bleed the air as follows after completion of installation.

1. Run the engine at low idling, and extend and retract the steering, bucket, and lift arm cylinders
4 – 5 times without going to the end of this stroke. (Stop approx. 100 mm before the end of the
stroke.)
2. Operate the steering, bucket, and lift arm cylinders 3 – 4 times to the end of the stroke, then
stop the engine and bleed the air from the plugs at the top of the hydraulic tank filter.
3. Raise the engine speed and repeat Step 2. to bleed the air. Repeat this procedure until no more
air comes out from the plugs.
4. After completing bleeding the air, tighten the plugs.
3 Plug: 11.3 ± 1.5 Nm {1.15 ± 0.15 kgm}
fl If the engine is run at high speed from the start, or the cylinders are operated to the end of
this stroke, the air inside the cylinder will cause damage to the piston packing.
fl After repair or long storage, follow the same procedure.

D21A, P-8 30-5

(1)
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP

REMOVAL OF FUEL
INJECTION PUMP ASSEMBLY
1. Loosen the fan belt and remove fan (1).

2. Before removing fuel injection pump (2), remove

the cover in front of the timing gear case. Using
paint, make match marks on the meshing parts
of pump drive gear (3) and idle gear (4).

3. Accurately record the relative positions of stamped

line (5) of the fuel injection pump body and stamped
line (6) of the gear case with mark-off lines (7), etc.

4. Remove fuel high pressure injection pipe (8).

1

5. Disconnect fuel hoses (9) and (10) and engine

stop solenoid connector (SO1).

30-6 D21A, P-8

(1)
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP

6. Remove lubrication tube (11) and 3 fuel injection

pump mounting nuts (12).

7. Remove nut (13) from the fuel injection pump drive

shaft end. 2

fl Take care not to drop the nut in the case.

fl Never loosen mounting bolt (14) of pump

drive gear (3) and flange.
(If the relative positions of the flange and
fuel injection pump drive gear change, it be-
comes very difficult to adjust the fuel injec-
tion timing.)

8. Using a puller, push the fuel injection pump drive

shaft out of the gear and remove fuel injection
pump assembly (2). 3

INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY
fl Carry out installation in the reverse order to re-
moval.

1
fl For installation of the fuel high-pressure injection
pipe, see the illustration at right.

3 Nut at shaft end: 113 – 123 Nm

{11.5 – 12.5 kgm}

3
fl Install the fuel injection pump temporarily and
tighten the nut at the shaft end first.

fl Adjust the fuel injection angle. For details, see

TESTING AND ADJUSTING, Testing and adjust-
ing fuel injection timing.

D21A, P-8 30-7

(1)
DISASSEMBLY AND ASSEMBLY RADIATOR GUARD

REMOVAL OF RADIATOR
GUARD ASSEMBLY
1. Drain coolant.

2. Remove left and right engine side covers (3), en-

gine hood (4), and radiator grill (5).

3. Disconnect oil cooler hoses (7) from power train

oil cooler (6).
fl After disconnecting, install blind plugs to pre-
vent the oil from leaking.

4. Disconnect radiator hoses (8) and (9), and front

lamp wiring harness (10).

5. Remove fan guard (11) and fan (12).

6. Disconnect the clamp of fuel hose (14) from the

radiator guard.

7. Disconnect headlamp wiring harness (10).

30-8 D21A, P-8

(1)
DISASSEMBLY AND ASSEMBLY RADIATOR GUARD

8. Install wires to the radiator upper bracket and lift

off radiator guard assembly (13).

4 Radiator guard assembly: 65 kg

INSTALLATION OF RADIATOR
GUARD ASSEMBLY
• Carry out installation in the reverse order to re-
moval.

• Refilling with coolant

fl Add coolant through coolant filler to the speci-
fied level.
fl Run the engine to circulate the coolant through
the system. Then check the coolant level again.

• Refilling with oil (transmission case)

fl Add engine oil through oil filler to the speci-
fied level.
fl Run the engine to circulate the oil through the
system. Then check the oil level again.

D21A, P-8 30-9

(1)
DISASSEMBLY AND ASSEMBLY ENGINE

REMOVAL OF ENGINE
ASSEMBLY
 Disconnect the cable from the negative (–) termi-
nal of the battery.

1. Remove the radiator guard assembly. For details,

see REMOVAL OF RADIATOR GUARD ASSEMBLY.

2. Remove the cover and drain the hydraulic oil.

6 Hydraulic tank: Approx. 21 ¬

3. Disconnect alternator wiring harness (1) and start-

ing motor wiring harness (2).

4. Disconnect air heater relay wiring harnesses (3)

(HE1) and (4) (HE2).

5. Disconnect ground wiring harness (5).

6. Disconnect fuel hoses (6) and (7). 1

fl Plug the hoses to stop the fuel from leaking
out.

7. Disconnect fuel control rod (8). 2

30-10 D21A, P-8

(1)
DISASSEMBLY AND ASSEMBLY ENGINE

8. Disconnect engine oil pressure sensor connector

(9), engine stop solenoid connector (10), and dust
indicator connector (11).

9. Disconnect work equipment pump suction hose

(12) from the rear of the fuel injection pump.

10. Remove the floor plate and disconnect work

equipment pump outlet hose (13) from the top of
the right rear engine mount.

11. Disconnect universal joint (14) from the damper

end. 3

12. Remove the engine mounting bolts and lift off

engine assembly (15). 4

4 Engine assembly: 300 kg

fl When removing the engine assembly, take

care of the center of gravity and check that
all the pipes and wires are disconnected.

fl When storing the engine mount rubbers,

make marks of the front and rear sides on
them.

D21A, P-8 30-11

(1)
DISASSEMBLY AND ASSEMBLY ENGINE

INSTALLATION OF ENGINE
ASSEMBLY
• Carry out installation in the reverse order to re-
moval.

1
fl Bleed the air from fuel circuit.
fl For details, see TESTING AND ADJUSTING,
Bleeding air from fuel circuit.

2
fl Adjust the cable.
For details, see TESTING AND ADJUSTING,
Adjusting fuel control cable.

3
3 Universal joint mounting bolt:
30.1 ± 3.4 Nm (3.15 ± 0.35 kgm)
4
fl Check the distinguishing marks on the front
and rear engine mount rubbers when install-
ing.
• Front: [ZZ] embossed mark
• Rear: Round blue paint mark

2 Thread of engine mount mounting bolt:

Thread tightener (LT-2)
3 Engine mount mounting bolt:
277 ± 31.9 Nm (28.25 ± 3.25 kgm)

• Refilling with coolant

fl Add coolant through coolant filler to the speci-
fied level.
fl Run the engine to circulate the coolant through
the system. Then check the coolant level again.

• Refilling with oil (transmission case, hydraulic

tank)
Add engine oil through oil filler to the specified
level.
fl Run the engine to circulate the oil through
the system. Then check the oil level again.

30-12 D21A, P-8

(1)
 ELECTRICAL WIRING DIAGRAM

D21A, P-8 90-11

 CAB AND AIR CONDITIONER ELECTRICAL CIRCUIT

D21A, P-8 90-13