WHEEL DOZER
SERIAL
NUMBERS
55001 and up
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The contents of this shop manual are shown together with Form No. in a list.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs.....................................................................SEN04979-13
00 Index and foreword....................................................................................................................SEN04980-13
100Index..................................................................................................................................SEN04981-13
200Foreword and general information.....................................................................................SEN04982-02
01 Specification...............................................................................................................................SEN04983-01 100Specification and technical data.........................................................................................SEN04984-01
10 Structure, function and maintenance standard...........................................................................SEN04985-04
100Engine and cooling system................................................................................................SEN04986-00
201Power train, Part 1.............................................................................................................SEN04987-00
202Power train, Part 2.............................................................................................................SEN04988-00
300Steering system.................................................................................................................SEN04989-01
400Brake system.....................................................................................................................SEN04990-00
500Undercarriage and frame...................................................................................................SEN04991-00
601Hydraulic system, Part 1.................................................................................................... SEN04992-00
602Hydraulic system, Part 2.................................................................................................... SEN04993-00
700Work equipment.................................................................................................................SEN04994-00
800Cab and its attachments....................................................................................................SEN04995-00
901Electrical system, Part 1....................................................................................................SEN04996-02
902Electrical system, Part 2....................................................................................................SEN04997-00
903Electrical system, Part 3....................................................................................................SEN04998-02
20 Standard value table...................................................................................................................SEN04999-02
100Standard service value table..............................................................................................SEN05044-02
30 Testing and adjusting.................................................................................................................SEN05000-08
101Testing and adjusting, Part 1..............................................................................................SEN05045-04
102Testing and adjusting, Part 2..............................................................................................SEN05046-01
103Testing and adjusting, Part 3..............................................................................................SEN05047-02
104Testing and adjusting, Part 4..............................................................................................SEN05048-06
40 Troubleshooting..........................................................................................................................SEN05001-03
100Failure code table and fuse locations................................................................................SEN05049-01
200General information on troubleshooting.............................................................................SEN05050-01
301Troubleshooting by failure code (Display of code), Part 1.................................................SEN05051-01
302Troubleshooting by failure code (Display of code), Part 2.................................................SEN05052-02
303Troubleshooting by failure code (Display of code), Part 3.................................................SEN05053-02
304Troubleshooting by failure code (Display of code), Part 4.................................................SEN05054-02
305Troubleshooting by failure code (Display of code), Part 5.................................................SEN05055-02
306Troubleshooting by failure code (Display of code), Part 6.................................................SEN05056-03
307Troubleshooting by failure code (Display of code), Part 7.................................................SEN05057-01
308Troubleshooting by failure code (Display of code), Part 8.................................................SEN05058-01
309Troubleshooting by failure code (Display of code), Part 9.................................................SEN05059-01
310Troubleshooting by failure code (Display of code), Part 10...............................................SEN05060-01
400Troubleshooting of electrical system (E-mode)..................................................................SEN05061-01
500Troubleshooting of hydraulic and mechanical system (H-mode)........................................SEN05062-01
600Troubleshooting of engine (S-mode)..................................................................................SEN05063-00
50 Disassembly and assembly........................................................................................................SEN05002-05
100General information on disassembly and assembly...........................................................SEN05141-00
201Engine and cooling system, Part 1.....................................................................................SEN05142-01
202Engine and cooling system, Part 2.....................................................................................SEN05143-02
301Power train, Part 1..............................................................................................................SEN05144-01
302Power train, Part 2..............................................................................................................SEN05145-02
303Power train, Part 3..............................................................................................................SEN05146-01
304Power train, Part 4..............................................................................................................SEN05147-00
400Brake system......................................................................................................................SEN05148-01
500Undercarriage and frame...................................................................................................SEN05149-01
600Hydraulic system................................................................................................................SEN05150-01
700Work equipment.................................................................................................................SEN05151-00
800Cab and its attachments.....................................................................................................SEN05152-02
900Electrical system................................................................................................................SEN05153-00
90 Diagrams and drawings..............................................................................................................SEN05003-04
100Hydraulic diagrams and drawings......................................................................................SEN05004-01
200Electrical diagrams and drawings.......................................................................................SEN05005-03
Failure code [15SAL1] ECMV F clutch: When command current is
Failure code [15SALH] ECMV F
Failure code [15SBL1] ECMV R clutch:
Failure code [15SBLH] ECMV R clutch: When command current is ON, fill signal is
Failure code [15SEL1] ECMV (1): When command current is OFF, fill signal is
Failure code [15SELH] ECMV (1): When command current
Failure code [15SFL1] ECMV (2): When command current is
Failure code [15SFLH] ECMV (2): When command
Failure
Failure code [15SGLH] ECMV (3):
Failure code [AB00MA] Alternator: Malfunction............................................................................................12
Failure code [B@BAZG] Engine oil pressure: Low error...............................................................................14
Failure code [B@BAZK] Eng Oil Level Low..................................................................................................15
Failure code [B@BCNS] Engine coolant temperature: Overheating.............................................................16
Failure code [B@BCZK] Engine coolant level low........................................................................................18
Failure code [B@C7NS] Brake oil overheating.............................................................................................20
Failure code [b@CENS] Torque converter oil overheating...........................................................................21
Failure code [B@CENS] Torque converter oil overheating...........................................................................22
Failure code [B@GAZK] Low Battery Fluid Level.........................................................................................23
Failure code [B@HANS] Hyd Oil Overheat...................................................................................................24
Failure code [CA111] Abnormality in engine controller..................................................................................26
Failure code [CA115] Engine Ne or Bkup speed sensor error......................................................................
Failure code [CA122] Charge (boost) pressure sensor high error................................................................30
Failure code [CA123] Charge (boost) pressure sensor low
Failure code [CA131] Throttle sensor high error...........................................................................................34
Failure code [CA132] Throttle sensor low error............................................................................................37
Failure code [CA135] Engine oil pressure sensor high error........................................................................40
Failure code [CA141] Engine oil pressure sensor low
Failure code [CA144] Coolant temperature sensor high error......................................................................44
Failure code [CA145] Coolant temperature sensor low
Failure code [CA153] Charge (boost) temperature sensor high
Failure code [CA154] Charge (boost) temperature sensor low
Failure code [CA187] Sensor power supply 2 low error................................................................................52
Failure code [CA212] Engine oil temperature sensor
Failure code [CA213] Engine oil temperature sensor
Failure
Failure code [CA222] Atmospheric pressure sensor
Failure code [CA227] Sensor power supply 2 high
303Troubleshooting by failure code (Display of code), Part
Failure code [CA234] Engine overspeed......................................................................................................3
Failure code [CA238] Ne speed sensor power supply error.........................................................................4
Failure code [CA263] Fuel Temp Sensor High Error.....................................................................................6
Failure code [CA265] Fuel Temp Sensor Low Error......................................................................................8
Failure code [CA271] PCV1 Short circuit......................................................................................................10
Failure code [CA272] PCV1 Disconnection..................................................................................................11
Failure code [CA273] PCV2 Short circuit......................................................................................................12
Failure code [CA274] PCV2 Disconnection..................................................................................................13
Failure code [CA322] Injector #1 open/short error........................................................................................14
Failure code [CA323] Injector #5 open/short error........................................................................................16
Failure code [CA324] Injector #3 open/short error........................................................................................18
Failure code [CA325] Injector #6 open/short error........................................................................................20
Failure code [CA331] Injector #2 open/short error........................................................................................22
Failure code [CA332] Injector #4 open/short error........................................................................................24
Failure code [CA342] Calibration code
Failure code [CA351] Injectors drive circuit
[CA352] Sens Supply 1 Volt
code [CA386] Sensor power supply 1 high
code [CA431]
[CA432]
[CA441]
[CA442]
[CA449]
[CA451]
[CA452]
Failure code [CA553] Common rail pressure high error 1.............................................................................44
Failure code [CA554] Common rail pressure sensor in range error..............................................................45
Failure code [CA559] Supply pump pressure very low error 1......................................................................46
Failure code [CA689] Engine Ne speed sensor error...................................................................................50
Failure code [CA731] Engine Bkup speed sensor phase error.....................................................................52
Failure code [CA757] All continuous data lost error......................................................................................53
Failure code [CA778] Engine Bkup speed sensor error................................................................................54
Failure code [CA1228] EGR valve servo error 1...........................................................................................56
Failure code [CA1625] EGR valve servo error
Failure code [CA1626] (Bypass valve solenoid
Failure code [CA1627] (Bypass valve solenoid current low
Failure code [CA1628] Bypass Valve Servo Error
Failure code [CA1629] Bypass Valve Servo Error 2......................................................................................63
Failure code [CA1631] (Bypass valve lift sensor high error)..........................................................................64
Failure code [CA1632] (Bypass valve lift sensor low error)...........................................................................66
Failure code [CA1633] KOMNET datalink timeout error................................................................................68
304Troubleshooting by failure code (Display of code), Part
Failure code [CA2185] Throttle sensor supply voltage high error.................................................................4 Failure code [CA2186]
Failure code [DAFRKR] CAN communication with machine monitor: Communication error (Abnormality in target component system)...........................................................................................................................44
Failure code [DAQ0KK] Transmission controller: Source voltage low...........................................................45
Failure code [DAQ0KT] Transmission controller: Defect in controller...........................................................48
Failure code [DAQ2KK] Transmission controller load power supply line: Source voltage low (Input)...........50
Failure code [DAQ9KQ] Transmission controller model selection: Model selection signal disagreement.....53
Failure code [DAQRKR] CAN communication with transmission controller: Communication error (Abnormality in target component system)...................................................................................................................54
Failure code [DAQRMA] Transmission controller (Option setting): Malfunction............................................59 305Troubleshooting by failure code (Display of code), Part 5 SEN05055-02
Failure code [DB2RKR] CAN communication from engine controller: Communication error (Abnormality in target component system)...........................................................................................................................4
Failure code [DB90KK] Work equipment controller: Source voltage low (input)............................................7
Failure code [DB90KT] Work equipment controller: Defect in controller.......................................................10
Failure code [DB92KK] Work equipment controller load power supply line: Source voltage low (input).......11
Failure code [DB95KX] Work equipment controller power supply output: Out of range................................14
Failure code [DB99KQ] Work equipment controller model selection: Model selection signal disagreement.16
Failure code [DB9RKR] CAN communication with work equipment controller: Communication error (Abnormality in target component system)...............................................................................................................17
Failure code [DB9RMA] Work equipment controller (Option setting): Malfunction........................................18
Failure code [DB9RMC] CAN communication with transmission controller: Malfunction..............................19
Failure code [DBB0KK] or change of VHMS_LED display from "n9" to "01" (VHMS controller: Source voltage low (input))...............................................................................................................................................20
Failure code [DBB0KQ] or change of VHMS_LED display from "nF" to "11" (VHMS controller: Disagreement of model selection signals)..........................................................................................................................22
Failure code [DBB3KK] or change of VHMS_LED display from "n9" to "05" (VHMS controller battery power supply: Source voltage low (input)).........................................................................................................24
Failure code [DBB5KP] or change of VHMS_LED display from "n9" to "04" (VHMS controller 5 V power supply output: Output voltage low).....................................................................................................................26
Failure code [DBB6KP] or change of VHMS_LED display from "n9" to "02" (VHMS controller 24V power supply output: Output voltage low).....................................................................................................................28
Failure code [DBB7KP] or change of VHMS_LED display from "n9" to "03" (VHMS controller 12V power supply output: Output voltage low).....................................................................................................................30
Failure code [DBBQKR] or change of VHMS_LED display from "n8" to "02" (CAN communication of VHMS controller: Communication error (Abnormality in target component system)).........................................32
Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed for long time.............................34
Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time.............................36
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time..............................38
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time..............................40
306Troubleshooting by failure code (Display of code), Part 6SEN05056-03
Failure code [DDA7L4] RPM set ON/OFF switch: ON-OFF signals disagree...............................................4
Failure code [DDA8KB] RPM set idle-up/down selector switch (idle-up): Short circuit.................................6
Failure code [DDA9KB] RPM set idle-up/down selector switch (idle-down): Short circuit............................9
Failure code [DDB6L4] Parking brake switch (Neutralizer): ON/OFF signals disagree................................12
Failure code [DDD1LD] Pitch operation switch: Switch is kept pressed for long time..................................16
Failure code [DDDBKA] Traction adjustment dial: Disconnection.................................................................18
Failure code [DDDBKB] Traction adjustment dial: Short circuit....................................................................20
Failure code [DDE5MA] Emergency steering drive switch: Malfunction.......................................................22
Failure code [DDK4KA] AJSS FNR switch: Disconnection........................................................................... 24
Failure code [DDK4KB] AJSS FNR switch: Short circuit...............................................................................26
Failure code [DDK5L4] AJSS shift-up/down switch: ON/OFF signals disagree............................................28
Failure code [DDK6KA] FNR lever switch: Disconnection............................................................................31
Failure code [DDK6KB] FNR lever switch: Short circuit................................................................................34
Failure code [DDP5KA] Lock detection pressure switch of steering lock lever: Disconnection....................36
Failure code [DDT0L4] Shift mode selector switch: ON/OFF signals disagree.............................................38
Failure code [DDW9LD] Kick-down switch: Switch is kept pressed for long time.........................................40
Failure code [DDWLLD] Hold switch: Switch is kept pressed for long time..................................................42
Failure code [DF10KA] Transmission shift lever switch: Disconnection........................................................44
Failure code [DF10KB] Transmission shift lever switch: Short circuit........................................................... 48
Failure code [DGE5KX] (or VHMS_LED display: “n4” o “01”) (Atmospheric temperature sensor: Out of input signal range)................................................................50
Failure code [DGF1KA] Transmission oil temperature sensor: Disconnection.............................................52
Failure code [DGF1KB] Transmission oil temperature sensor: Short circuit.................................................54
307Troubleshooting by failure code (Display of code), Part 7SEN05057-01
Failure code [DGH2KX] Hydraulic oil temperature sensor: Out of input signal range...................................4
Failure code [DGR2KA] Rear brake oil temperature sensor: Disconnection................................................6
Failure code [DGR2KX] Rear brake oil temperature sensor: Out of input signal range................................8
Failure code [DGT1KA] Torque converter oil temperature sensor: Disconnection........................................10
Failure code [DGT1KB] Torque converter oil temperature sensor: Short circuit...........................................12
Failure code [DGT1KX] Torque converter oil temperature sensor: Out of input signal range)......................14
Failure code [DGT4KA] (or VHMS_LED display: "n3" → "12") Exhaust gas temperature sensor (F): Disconnection..........................................................................................................................................................16
Failure code [DGT4KB] (or VHMS_LED display: "n3" → "11") Exhaust gas temperature sensor (F): Short circuit...........................................................................................................................................................19
Failure code [DGT5KA] (or VHMS_LED display: "n3" → "22") Exhaust gas temperature sensor (R): Disconnection.....................................................................................................................................................22
Failure code [DGT5KB] (or VHMS_LED display: "n3" → "21") Exhaust gas temperature sensor (R): Short circuit...........................................................................................................................................................25
Failure code [DH21KA] Work equipment pump oil pressure sensor: Disconnection....................................28
Failure code [DH21KB] Work equipment pump oil pressure sensor: Short circuit........................................30
Failure code [DHE5KB] (or VHMS_LED display: “n3” → “32”) Blow-by pressure sensor: Short circuit........32
Failure code [DHE5KY] (or VHMS_LED display: “n3” → “31”) Blow-by pressure sensor: Short circuit with power supply line.....................................................................................................................................34
Failure code [DHT2L6] Transmission filter clogging sensor: Signal disagrees with operating state of engine36
Failure code [DHT8KX] (or VHMS_LED display: “n5” → “33”) Steering oil pressure sensor: Out of input signal range.......................................................................................................................................................38
Failure code [DHTBKA] Modulation clutch oil pressure sensor: Disconnection............................................42
Failure code [DHTBKB] Modulation clutch oil pressure sensor: Short circuit................................................44
Failure code [DHU2KX] (or VHMS_LED display: “n7” → “11”) Front brake oil pressure sensor (F): Out of input signal range.............................................................................................................................................46
Failure code [DHU3KX] (or VHMS_LED display: “n7” → “12”) Rear brake oil pressure sensor (R): Out of input signal range.............................................................................................................................................48
Failure code [DK30KA] AJSS lever angle sensor: Disconnection.................................................................50
Failure code [DK30KY] AJSS lever angle sensor: Short circuit with power supply line................................52
308Troubleshooting by failure code (Display of code), Part 8SEN05058-01
Failure code [DK59KA] Lift EPC lever potentiometer (Main): Disconnection................................................3
Failure code [DK59KY] Lift EPC lever potentiometer (Main): Short circuit with power supply line................6
Failure code [DK59L8] Lift EPC lever potentiometer (Main): Analog signals disagree.................................8
Failure code [DK5AKA] Lift EPC lever potentiometer (Sub): Disconnection.................................................11
Failure code [DK5AKY] Lift EPC lever potentiometer (Sub): Short circuit with power supply line.................14
Failure code [DK5BKA] Tilt & pitch EPC lever potentiometer (Main): Disconnection....................................16
Failure code [DK5BKY] Tilt & pitch EPC lever potentiometer (Main): Short circuit with power supply line...20
Failure code [DK5BL8] Tilt & pitch EPC lever potentiometer (Main): Analog signals disagree.....................22
Failure code [DK5CKA] Tilt & pitch EPC lever potentiometer (Sub): Disconnection.....................................25
Failure code [DK5CKY] Tilt & pitch EPC lever potentiometer (Sub): Short circuit with power supply line.....28 Failure code [DKD0KA]
Failure
Failure code [DLT3LC] Transmission output shaft speed sensor (2): Speed signals disagree.....................44
Failure code [DLT4KB] Transmission output shaft speed sensor (1): Short circuit.......................................46
Failure code [DLT4KX] Transmission output shaft speed sensor (1): Out of input signal range...................48
Failure code [DV00KB] Alarm buzzer: Short circuit.......................................................................................50
Failure code [DW4PKA] Blade raise EPC solenoid: Disconnection..............................................................52
Failure code [DW4PKB] Blade raise EPC solenoid: Short circuit.................................................................. 54
Failure code [DW4PKY] Blade raise EPC solenoid: Short circuit with power supply line..............................55
Failure code [DW4QKA] Blade lower EPC solenoid: Disconnection.............................................................56
Failure code [DW4QKB] Blade lower EPC solenoid: Short circuit.................................................................57
Failure code [DW4QKY] Blade lower EPC solenoid: Short circuit with power supply line............................58
Failure code [DW4RKA] Tilt & pitch EPC solenoid: Disconnection...............................................................59
Failure code [DW4RKB] Tilt & pitch EPC solenoid: Short circuit...................................................................60
Failure code [DW4RKY] Tilt & pitch EPC solenoid: Short circuit with power supply line...............................61
Failure code [DW4SKA] Tilt & pitch EPC solenoid: Disconnection................................................................62
Failure code [DW4SKB] Tilt & pitch EPC solenoid: Short circuit...................................................................63
Failure code [DW4SKY] Tilt & pitch EPC solenoid: Short circuit with power supply line...............................64
Failure code [DW7BKA] Fan reverse solenoid: Disconnection.....................................................................66
Failure code [DW7BKB] Fan reverse solenoid: Short
Failure code [DW7BKY] Fan reverse solenoid: Short circuit with power supply line.....................................70
309Troubleshooting by failure code (Display of code), Part 9 SEN05059-01
Failure code [DWM1KA] Work equipment neutral lock solenoid: Disconnection..........................................4
Failure code [DWM1KB] Work equipment neutral lock solenoid: Short circuit..............................................6
Failure code [DWM1KY] Work equipment neutral lock solenoid: Short circuit with power supply line..........8
Failure code [DWN7KA] Blade float magnet detent solenoid: Disconnection...............................................10
Failure code [DWN7KB] Blade float magnet detent solenoid: Short circuit...................................................12
Failure code [DWN7KY] Blade float magnet detent solenoid: Short circuit with power supply line...............14
Failure code [DWNFKA] Modulation clutch cut-off release solenoid: Disconnection....................................16
Failure code [DWNFKB] Modulation clutch cut-off release solenoid: Short circuit........................................18
Failure code [DWNFKY] Modulation clutch cut-off release solenoid: Short circuit with power source line....20
Failure code [DX16KA] Fan pump EPC solenoid: Disconnection.................................................................22
Failure code [DX16KB] Fan pump EPC solenoid: Short circuit..................................................................... 23
Failure code [DX16KY] Fan pump EPC solenoid: Short circuit with power supply line................................24
Failure code [DXA1KA] Pump PC-EPC solenoid: Disconnection.................................................................25
Failure code [DXA1KB] Pump PC-EPC solenoid: Short circuit.....................................................................26
Failure code [DXF0KA] AJSS EPC solenoid: Disconnection........................................................................27
Failure code [DXF0KB] AJSS EPC solenoid: Short circuit............................................................................28
Failure code [DXH1KA] Lockup ECMV solenoid: Disconnection..................................................................30
Failure code [DXH1KB] Lockup ECMV solenoid: Short circuit...................................................................... 32
Failure code [DXH1KY] Lockup ECMV solenoid: Short circuit with power supply line.................................34
Failure code [DXH4KA] 1st clutch ECMV solenoid: Disconnection..............................................................36
Failure code [DXH4KB] 1st clutch ECMV solenoid: Short circuit.................................................................. 38
Failure code [DXH4KY] 1st clutch ECMV solenoid: Short circuit with power supply line..............................40
310Troubleshooting by failure code (Display of code), Part 10SEN05060-01
Failure code [DXH5KA] 2nd clutch ECMV solenoid: Disconnection.............................................................4
Failure code [DXH5KB] 2nd clutch ECMV solenoid: Short circuit.................................................................6
Failure code [DXH5KY] 2nd clutch ECMV solenoid: Short circuit
Failure code [DXH6KA] 3rd clutch ECMV solenoid: Disconnection..............................................................10
Failure code [DXH6KB] 3rd clutch ECMV solenoid: Short circuit..................................................................
Failure code [DXH6KY] 3rd clutch ECMV solenoid: Short circuit with power supply
Failure code [DXH7KA] R clutch ECMV solenoid: Disconnection.................................................................16
Failure code [DXH7KB] R clutch ECMV solenoid: Short
Failure code [DXH7KY] R clutch ECMV solenoid: Short circuit with power supply line................................20
Failure code [DXH8KA] F clutch ECMV solenoid: Disconnection.................................................................22
Failure code [DXH8KB] F clutch ECMV solenoid: Short circuit.....................................................................24
Failure code [DXH8KY] F clutch ECMV solenoid: Short circuit with power supply line................................26
Failure code [DXHHKA] 4th clutch ECMV solenoid: Disconnection..............................................................28
Failure code [DXHHKB] 4th clutch ECMV solenoid: Short circuit.................................................................30
Failure code [DXHHKY] 4th clutch ECMV solenoid: Short circuit with power supply line.............................32
Failure code [DXHJKA] RH pitch REAR EPC solenoid: Disconnection........................................................34
Failure code [DXHJKB] RH pitch REAR EPC solenoid: Short circuit............................................................35
Failure code [DXHJKY] RH pitch REAR EPC solenoid: Short circuit with power supply line.......................36
Failure code [DXHKKA] RH pitch FORWARD EPC solenoid: Disconnection...............................................37
Failure code [DXHKKB] RH pitch FORWARD EPC solenoid: Short circuit...................................................38
Failure code [DXHKKY] RH pitch FORWARD EPC solenoid: Short circuit with power supply line..............39
Failure code [DXHPKA] Modulation clutch solenoid: Disconnection.............................................................40
Failure code [DXHPKB] Modulation clutch solenoid: Short circuit................................................................ 42
Failure code [DXHPKY] Modulation clutch solenoid: Short circuit with power source line............................44
Failure code [DXHPMA] Modulation clutch solenoid: Malfunction................................................................46
Failure code [F@BBZL] (or VHMS_LED display: “n3” → “38”) Blow-by pressure: High error......................48
Failure code [F@BYNR] (or VHMS_LED display: “n3” o “62”) (Exhaust gas temperature (F): Abnormal heat).......................................................................................50
Failure code [F@BYNS] (or VHMS_LED display: “n3” → “61”) Exhaust gas temperature (F): Overheat.....52
Failure code [F@BZNR] (or VHMS_LED display: “n3” o “72”)
(Exhaust gas temperature (R): abnormal heat).......................................................................................54
Failure code [F@BZNS] (or VHMS_LED display “n3” → “71”) Exhaust gas temperature (R): Overheat.....56
400Troubleshooting of electrical system (E-mode)SEN05061-01 Before carrying out troubleshooting of electrical system...............................................................................2
E-1 Engine does not start..............................................................................................................................6
E-2 Wiper does not operate..........................................................................................................................16
E-3 Windshield washer does not operate.....................................................................................................24
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off...................................30
E-5 Working lamp does not light up or go off................................................................................................46
E-6 Step lamp does not light up or go off......................................................................................................54
E-7 Turn signal lamp and hazard lamp do not light up or go off....................................................................56
E-8 Brake lamp does not light or it keeps lighting up....................................................................................66
E-9 Backup lamp does not light or it keeps lighting up..................................................................................70
E-10 Backup buzzer does not sound or it keeps sounding...........................................................................74
E-11 Horn does not sound or it keeps sounding............................................................................................78
E-12 Alarm buzzer does not sound or it keeps sounding..............................................................................82
E-13 Air conditioner does not operate or stop...............................................................................................84
E-14 Electric priming pump does not operate or does not stop automatically...............................................86
E-15 When starting switch is turned to ON position, machine monitor displays nothing...............................88 500Troubleshooting of hydraulic and mechanical system (H-mode)SEN05062-01 Method of using troubleshooting chart..........................................................................................................4 Table of failure modes and causes................................................................................................................6
H-1 Machine does not start...........................................................................................................................10
H-2 Torque converter lockup is not switched (engine stalls).........................................................................12
H-3 Torque converter lockup is not turned on................................................................................................13
H-4 Travel speed is slow, thrusting force is weak, uphill traveling power is weak, and gear is not
H-5 Shocks are large at the times of starting and shifting gear.....................................................................16
H-6 Time lag is large at the times of starting and shifting gear......................................................................18
H-7 Torque converter oil temperature is high................................................................................................20
H-8 Steering does not turn [machine with steering wheel]............................................................................21
H-9 Steering does not turn [machine with AJSS]...........................................................................................22
H-10 Turning, response of steering is poor [machine
H-11
H-12
H-13 When machine turns, it shakes or makes large shocks [machine with steering
H-14 When machine turns, it shakes or makes large
H-15
H-18
S-11
S-12
Form No. SEN04981-13
KOMATSU All Rights Reserved Printed in Japan 02-23 (01)
WD600-6 Wheel dozer
©2023
Safety notice 1
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
1.General precautions
k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work.
1)Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual.
2)Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
3)When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
q Always wear safety glasses when hitting parts with a hammer.
q Always wear safety glasses when grinding parts with a grinder, etc.
4)When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator's compartment.
5)Only qualified workers must carry out work and operation which require license or qualification.
6)Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.
7)If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work.
8)Before starting work, warm up your body thoroughly to start work under good condition.
9)Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places.
Safety points
1Good arrangement
2Correct work clothes
3Following work standard
4Making and checking signs
5 Prohibition of operation and handling by unlicensed workers
6Safety check before starting work
7 Wearing protective goggles (for cleaning or grinding work)
8 Wearing shielding goggles and protectors (for welding work)
9Good physical condition and preparation
10 Precautions against work which you are not used to or you are used to too much
2.Preparations for work
1)Before adding oil or making any repairs, park the machine on a hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving.
2)Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.
3)When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work.
4)Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
3.Precautions during work
1)Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out.
2)The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool befo re carrying out any work on the oil or water circuits.
3)Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts.
4) For the machine equipped with a battery disconnct switch, turn the battery disconnect switch to the OFF (O) position, before starting the work. For machines without a battery disconnct switch, remove the cable from the battery, before starting the work. Always remove the cable from the negative (-) terminal first.
5)When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.
6)When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover.
7)When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires.
8)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 and can even start fires.
9)As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular.
10)Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is operated.
11)When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. In addition, check that connecting parts are correctly installed.
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12)When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly.
13)When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.
14)When measuring hydraulic pressure, check that the measuring tools are correctly assembled.
15)Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.
16)If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.
4.Precautions for sling work and making signs
1)Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily. The sign maker must always stan d in front of the load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2)Check the slings before starting sling work.
3)Keep putting on gloves during sling work. (Put on leather gloves, if available.)
4)Measure the weight of the load by the eye and check its center of gravity.
5)Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall.
6)Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically.
k Slinging with 1 rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.
7)Limit the hanging angle to 60°, as a rule. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120°. If the 2 ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150°, each of them is subjected to a force as large as 39.2 kN {4,000 kg}.
8)When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping.
9)Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc.
10)Apply wire ropes to the middle portion of the hook.
q Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.
11)Do not use twisted or kinked wire ropes.
12)When lifting up a load, observe the following.
q Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught.
q After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.
q If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again.
q Do not lift up the load slantingly.
13)When lifting down a load, observe the following.
q When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly.
q Check that the load is stable, and then remove the sling.
q Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.
5.Precautions for using mobile crane
a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely.
6.Precautions for using overhead hoist crane
k When raising a heavy part (heavier than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a part heavier than 25 kg is indicated after the mark of 4.
1)Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, electric shock prevention earth leakage breaker, crane collision prevention device, and power application warning lamp, and check safety.
2)Be sure not to touch the lifting tool and lifted load directly. Use push-pull sticks or tagline ropes.
3)Observe the signs for sling work.
4)Operate the hoist at a safe place.
5)Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail.
6)Do not sling a load slantingly. Do not move the crane while the slung load is swinging.
7)Do not raise or lower a load while the crane is moving longitudinally or laterally.
8)Do not drag a sling.
9)When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up.
10)Consider the travel route in advance and lift up a load to a safe height.
11)Place the control switch on a position where it will not be an obstacle to work and passage.
12)After operating the hoist, do not swing the control switch.
13)Remember the position of the main switch so that you can turn off the power immediately in an emergency.
14)If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the electric shock prevention earth leakage breaker, check that the devices related to that switch are not in operation state.
15)If you find an obstacle around the hoist, stop the operation.
16)After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook.
7.Selecting wire ropes
1)Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below.
Wire ropes (Standard “Z” twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal diameter of rope Allowable load
a The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).
8.Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit
1)Disconnection
k For the environment, the air conditioner of this machine uses the refrigerant (air conditioner gas: R134a) which has fewer factors of the depletion of the ozone layer. However, it does not mean that you may discharge the refrigerant into the atmosphere as it is. Be sure to recover the refrigerant when disconnecting the refrigerant gas circuit and then reuse it.
a Ask professional traders for collecting and filling operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the atmosphere.
k If the refrigerant gas gets in your eyes or contacts your skin, you may lose your sight and your skin may be frozen. Accordingly, put on safety glasses, safety gloves and safety clothes when recovering or adding the refrigerant. Refrigerant gas must be recovered and added by a qualified person.
2)Connection
1]When installing the air conditioner circuit hoses and tubes, take care that dirt, dust, water, etc. will not enter them.
2]When connecting the air conditioner hoses and tubes, check that O-rings (1) are fitted to their joints.
3]Check that each O-ring is not damaged or deteriorated.
4]When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8, VALEO THERMAL SYSTEMS: ZXL100PG (equivalent to PAG46)) to its O-rings.
a Example of O-ring (Fitted to every joint of hoses and tubes)
a For tightening torque, see the precautions for installation in each section of "Disassembly and assembly".
How to read the shop manual 1
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the engine volume of the engine model mounted on the machine.
1.Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00.Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01.Specification
This section explains the specifications of the machine.
10.Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20.Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30.Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
40.Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50.Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90.Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2.Revision and distribution
Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work.
200 Foreword and general information How to read the shop manual
3.Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition table.
q Revised edition mark
When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1. (Example: 00, 01, 02 …)
q Revisions
Revised brochures are shown in the shop manual composition table.
4.Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically.
SymbolItemRemarks
k SafetySpecial safety precautions are necessary when performing work.
a Caution Special technical precautions or other precautions for preserving standards are necessary when performing work.
4 Weight Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
3 Tightening torque Places that require special attention for tightening torque during assembly.
2 CoatPlaces to be coated with adhesives, etc. during assembly.
5 Oil, coolantPlaces where oil, etc. must be added, and capacity.
6 DrainPlaces where oil, etc. must be drained, and quantity to be drained.
5.Units
In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
Explanation of terms for maintenance standard 1
The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the machine maintenance work. The following terms are used to explain the criteria.
1.Standard size and tolerance
q To be accurate, the finishing size of parts is a little different from one to another.
q To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated.
q The above size set temporarily is called the “standard size” and the range of difference from the standard size is called the “tolerance”.
q The tolerance with the symbols of + or – is indicated on the right side of the standard size.
a The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)]. Example) 120 (–0.022/–0.126)
q Usually, the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance.
q Indication of size of rotating shaft and hole and relationship drawing of them
2.Standard clearance and standard value
q The clearance made when new parts are assembled is called the “standard clearance“, which is indicated by the range from the minimum clearance to the maximum clearance.
q When some parts are repaired, the clearance is generally adjusted to the standard clearance.
q A value of performance and function of new products or equivalent is called the “standard value“, which is indicated by a range or a target value.
q When some parts are repaired, the value of performance/function is set to the standard value.
3.Standard interference
q When the diameter of a hole of a part shown in the given standard size and tolerance table is smaller than that of the mating shaft, the difference between those diameters is called the “interference”.
q The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the hole to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the “standard interference”.
q After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range.
4.Repair limit and allowable value or allowable dimension
q The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the “repair limit”.
q If a part is worn to the repair limit, it must be replaced or repaired.
q The performance and function of a product lowers while it is used. A value which the product can be used without causing a problem is called the “allowable value” or “allowable dimension”.
q If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated from various tests or experiences in most cases, however, it must be judged after considering the operating condition and customer's requirement.
200 Foreword and general information Explanation of terms for maintenance standard
5.Clearance limit
q Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the “clearance limit”.
q If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired.
6.Interference limit
q The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the “interference limit”.
q The interference limit shows the repair limit of the part of smaller tolerance.
q If the interference between the parts exceeds the interference limit, they must be replaced or repaired.
Handling of electric equipment and hydraulic component 1
To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handlin g electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
Points to remember when handling electric equipment
1.Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses.
2.Main failures occurring in wiring harness
1)Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connector about 10 times.
2)Defective crimping or soldering of connectors
The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.
3)Disconnections in wiring
If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.
4)High-pressure water entering connector
The connector is designed to make it difficult for water to en ter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. Accordingly, take care not to splash water over the connector. The connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be shortcircuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it.
5)Oil or dirt stuck to connector
If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer.
a When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. a If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.
3.Removing, installing, and drying connectors and wiring harnesses
1)Disconnecting connectors
1]Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart.
a Never pull with one hand.
2]When removing from clips
q Both of the connector and clip have stoppers, which are engaged with each other when the connector is installed.
q When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing stoppers.
a If the connector is twisted up and down or to the left or right, the housing may break.
3]Action to take after removing connectors
After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion.
a If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
2)Connecting connectors
1]Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion).
Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. Check that there is no damage or breakage to the outside of the connector.
a If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits.
a If there is any damage or breakage, replace the connector.
2]Fix the connector securely. Align the position of the connector correctly, and then insert it securely. For connectors with the lock stopper, push in the connector until the stopper clicks into position.
3]Correct any protrusion of the boot and any misalignment of the wiring harness.
For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position.
a If the connector cannot be corrected easily, remove the clamp and adjust the position.
q If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.
3)Heavy duty wire connector (DT 8-pole, 12pole)
Disconnection (Left of figure)
While pressing both sides of locks (a) and (b), pull out female connector (2).
Connection (Right of figure)
1]Push in female connector (2) horizontally until the lock clicks.
Arrow: 1)
2]Since locks (a) and (b) may not be set completely, push in female connector (2) while moving it up and down until the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled down (not set completely) and lock (b) is set completely.
(1):Male connector
(2):Female connector (a), (b): Locks
q Disconnection q Connection (Example of incomplete setting of (a))
4)Drying wiring harness
If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows.
1]Disconnect the connector and wipe off the water with a dry cloth.
a If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oil and water from the compressed air before blowing with air.
2]Dry the inside of the connector with a dryer.
If water gets inside the connector, use a dryer to dry the connector.
a Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.
3]Carry out a continuity test on the connector.
After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water.
a After completely drying the connector, blow it with contact restorer and reassemble.
4.Handling controller
1)The controller contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the controller.
2)Do not place objects on top of the controller.
3)Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand.
4)During rainy weather, do not leave the controller in a place where it is exposed to rain.
5)Do not place the controller on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand).
6)Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point.
5.Points to remember when troubleshooting electric circuits
1)Always turn the power OFF before disconnecting or connecting connectors.
2)Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Disconnect and connect the related connectors several times to check.
3)Always connect any disconnected connectors before going on to the next step.
a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated.
4)When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester.
a If there is any change, there is probably defective contact in that circuit.
Points to remember when handling hydraulic equipment
With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful.
1.Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust.
2.Disassembly and maintenance work in the field
If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to check the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be checked with special test equipment.
3.Sealing openings
After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out onto the ground, but collect it and ask the customer to dispose of it, or take it back with you for disposal.
4.Do not let any dirt or dust get in during refilling operations
Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.
5.Change hydraulic oil when the temperature is high
When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil.
6.Flushing operations
After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.
7.Cleaning operations
After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultra fine (about 3 m) particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device.
Handling of connectors newly used for engines 1
a Mainly, following engines are object for following connectors.
q 95E-5
q 107E-1
q 114E-3
q 125E-5
q 140E-5
q 170E-5
q 12V140E-3
1.Slide lock type
(FRAMATOME-3, FRAMATOME-2)
q 95 – 170, 12V140 engines
q Various pressure sensors and NE speed sensor Examples)
Intake air pressure sensor in intake manifold: PIM
(125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(95, 107, 114 engines)
Ne speed sensor of flywheel housing: NE(95 – 170, 12V140 engines)
Ambient pressure sensor: PAMB (125, 170, 12V140 engines)
Disconnect connector (1) according to the following procedure.
1)Slide lock (L1) to the right.
2)While pressing lock (L2), pull out connector (1) toward you.
a Even if lock (L2) is pressed, connector (1) cannot be pulled out toward you, if part A does not float. In this case, float part A with a small screwdriver while press lock (L2), and then pull out connector (1) toward you.
2.Pull lock type (PACKARD-2)
q 95 – 170, 12V140 engines
q Various temperature sensors Example)
Intake air temperature sensor in intake manifold: TIM
Fuel temperature sensor: TFUEL
Oil temperature sensor: TOIL
Coolant temperature sensor: TWTR, etc.
Disconnect the connector by pulling lock (B) (on the wiring harness side) of connector (2) outward.
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200 Foreword and general information Handling
3.Push lock type
q 95, 107, 114 engines
Example)
Fuel pressure sensor in common rail (BOSCH-03)
Disconnect connector (3) according to the following procedure.
1)While pressing lock (C), pull out connector (3) in the direction of the arrow.
q 114 engine
q 107 engine
a If the lock is on the underside, use flat-head screwdriver [1] since you cannot insert your fingers.
2)While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.
q 107, 114 engines
Example)
Intake air pressure/temperature sensor in intake manifold (SUMITOMO-04)
3)While pressing lock (D), pull out connector (4) in the direction of the arrow.
q 95, 125 – 170, 12V140 engines
4)While pressing lock (E) of the connector, pull out connector (5) in the direction of the arrow.
Example)
Fuel pressure sensor in common rail: PFUEL etc. (AMP-3)
200 Foreword and general information Handling of connectors newly used for engines
4.Turn-housing type (Round green connector) q 140 engine
Example)
Intake air pressure sensor in intake manifold (CANNON-04): PIM etc.
1)Disconnect connector (6) according to the following procedure.
1]Turn housing (H1) in the direction of the arrow.
a When connector is unlocked, housing (H1) becomes heavy to turn.
2]Pull out housing (H1) in the direction of the arrow.
a Housing (H1) is left on the wiring harness side.
Example)
Injection pressure control valve of fuel supply pump: PCV (SUMITOMO-2)
2)Connect the connector according to the following procedure.
1]Insert the connector to the end, while setting its groove.
2]Turn housing (H1) in the direction of the arrow until it “clicks”.
Example)
Speed sensor of fuel supply pump: G (SUMITOMO-3)
a Pull the connector straight up.
How to read electric wire code 1
a The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram.
Example:AEX0.85L- - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85
Indicates color of wire by color code. Color codes are shown in Table 3.
Indicates size of wire by nominal No. Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol. Type, symbol, and material of wire are shown in Table 1. (Since AV and AVS are classified by size (nominal No.), they are not indicated.)
1.Type, symbol, and material
AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Type Symbol
Low-voltage wire for automobile AV
Thin-cover low-voltage wire for automobile AVS
Heat-resistant low-voltage wire for automobile AEX
Conductor
Material
Annealed copper for electric appliance
InsulatorSoft polyvinyl chloride
Conductor
Using temperature range (°C)
Example of use
General wiring (Nominal No. 5 and above)
–30 to +60
Annealed copper for electric applianceGeneral wiring (Nominal No. 3 and below)
InsulatorSoft polyvinyl chloride
Conductor
Annealed copper for electric appliance
Insulator Heat-resistant crosslinked polyethylene
–50 to +110
General wiring in extremely cold district, wiring at high-temperature place
(Table 2)
Nominal No.0.5f(0.5)0.75f(0.85)1.25f(1.25)2f23f35
Conductor
Cover D
2.Dimensions “f” of nominal No. denotes flexible”.
Number of strands/Diameter of strand 20/0.187/0.3230/0.1811/0.3250/0.1816/0.3237/0.2626/0.3258/0.2641/0.3265/0.32
Sectional area (mm2) 0.510.560.760.881.271.291.962.093.083.305.23 d (approx.)1.01.21.51.91.92.32.43.0
AVSStandard2.02.22.52.92.93.53.6–AVStandard––– ––––4.6
AEXStandard2.02.22.73.03.1–3.84.6
Nominal No.815203040506085100
Number of strands/Diameter of strand 50/0.4584/0.4541/0.8070/0.8085/0.80108/0.80127/0.80169/0.80217/0.80
Conductor
Cover D
Sectional area (mm2) 7.9513.3620.6135.1942.7354.2963.8484.96109.1 d (approx.)3.74.86.08.08.69.810.412.013.6
AVSStandard AVStandard5.57.08.210.811.413.013.616.017.6 AEXStandard5.37.08.210.811.413.013.616.017.6
3.Color codes table
(Table 3)
Color CodeColor of wireColor CodeColor of wire
BBlackLgWLight green & White
BrBrownLgYLight green & Yellow
BrBBrown & BlackLRBlue & Red
BrRBrown & RedLWBlue & White
BrWBrown & WhiteLYBlue & Yellow
BrYBrown & YellowOOrange
ChCharcoalPPink
DgDark greenRRed
GGreenRBRed & Black
GBGreen & BlackRGRed & Green
GLGreen & BlueRLRed & Blue
GrGrayRWRed & White
GRGreen & RedRYRed & Yellow
GWGreen & WhiteSbSky Blue
GYGreen & YellowYYellow
LBlue YBYellow & Black
LBBlue & BlackYGYellow & Green
LgLight greenYLYellow & Blue
LgBLight green & BlackYRYellow & Red
LgRLight green & RedYWYellow & White
Remarks:In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
4.Types of circuits and color codes
(Table 4)
Type of wireAVS or AVAEX
Type of circuit
BrBrWBrRBrYBrB LgLgRLgYLgBLgW
Precautions when carrying out operation 1
[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
q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising components, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal.
a Precautions when handling piping during disassembly Fit the following plugs into the piping after disconnecting it during disassembly operations.
1)Face seal type hoses and tubes
Nominal number
Plug (nut end)Sleeve nut (elbow end) 0207376-7021002789-20210 0307376-7031502789-20315 0407376-7042202789-20422 0507376-7052202789-20522 0607376-7062802789-20628 1007376-7103407221-21034 1207376-7123407221-21234
2)Split flange type hoses and tubes
Nominal number Flange (hose end)Sleeve head (tube end)Split flange 0407379-0040007378-1040007371-30400 0507379-0050007378-1050007371-30500
3)If the part is not under hydraulic pressure, the following corks can be used.
Nominal number Part Number
Dimensions DdL
0607049-00608658 0807049-0081186.511
1007049-01012108.512
1207049-01215121015
1407049-014181411.518
1607049-016201613.520
1807049-01822181522
2007049-02025201725
2207049-022282218.528
2407049-02430242030
2707049-027342722.534
2.Precautions when carrying out installation work
q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 – 3 drops of adhesive.
q 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.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows:
1)Start the engine and run at low idle.
2)Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cylinder 100 mm from the end of its stroke.
3)Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4)After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3.Precautions when completing the operation
1)Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate t he coolant through the system. Then check the coolant level again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the en gine to circulate the oil through the system. Then check the oil level again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the parts.
a For details, see Testing and adjusting, “Bleeding air”.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
2)Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness. If any part is loosened, retighten it.
q For the tightening torque, see “Disassembly and assembly”.
3)Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leakage.
If any part is loosened or damaged, retighten or repair it.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage.
If any part is loosened or damaged, retighten or repair it.
200 Foreword and general information Precautions when carrying out operation
4)Checking muffler and exhaust pipe for damage and looseness
1]Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage. If any part is damaged, replace it.
2]Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for looseness.
If any bolt or nut is loosened, retighten it.
5)Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly and assembly”.
Method of disassembling and connecting push-pull type coupler
Method of disassembling and connecting push-pull type coupler 1
k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1.Disconnection
1)Hold adapter (1) and push hose joint (2) into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about 3.5 mm.
a Do not hold rubber cap portion (4).
2)After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against adapter (3) until it clicks. (Fig. 2)
3)Hold hose adapter (1) or hose (5) and pull it out. (Fig. 3)
a Since some hydraulic oil flows out, prepare an oil receiving container.
2.Connection
1)Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (Fig. 4)
a 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. (Fig. 5)
a When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.
200 Foreword and general information Method of disassembling and connecting push-pull type coupler
Type 2
1.Disconnection
1)Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6)
2)While holding the condition of Step 1), turn lever (8) to the right (clockwise). (Fig. 7)
3)While holding the condition of Steps 1) and 2), pull out whole body (7) to disconnect it. (Fig. 8)
2.Connection
q Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)
Type 3
1.Disconnection
1)Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10)
2)While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 11)
3)While holding the condition of Steps 1) and 2), pull out whole body (9) to disconnect it. (Fig. 12)
2.Connection
q Hold the tightening portion and push body (9) straight until the sliding prevention ring contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)
200 Foreword and general information
tightening torque table
Standard tightening torque table 1
1.Table of tightening torques for bolts and nuts
a Unless there are special instructions, tighten metric nuts and bolts to the torque below.
a The following table applies to the bolts in Fig. A.
Thread diameter of boltWidth across flatsTightening torque mmmmNmkgm 61011.8 – 14.71.2 – 1.5 81327 – 342.8 – 3.5 101759 – 746.0 – 7.5 121998 – 12310.0 – 12.5 1422157 – 19616 – 20 1624245 –
1827343 –
–
–
2030490 – 60850 – 62 2232662 – 82967.5 – 84.5 2436824 – 1,03084 – 105 27411,180 – 1,470120 – 150 30461,520 – 1,910155 – 195 33501,960 – 2,450200 – 250 36552,450 – 3,040250 – 310 39602,890 – 3,630295 – 370
a The following table applies to the bolts in Fig. B.
Thread diameter of boltWidth across flatsTightening torque mmmmNmkgm
a Fig. A a Fig. B
Remarks:The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are the ones indicated in the table for bolts shown in Fig. B. (Values of tightening torques shown in the table for Fig. A are applied.)
2.Table of tightening torques for split flange bolts
a Unless there are special instructions, tighten split flange bolts to the torque below.
3.Table of tightening torques for O-ring boss piping joints
a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Nominal No. Thread diameter Width across flatsTightening torque Nm {kgm} mmmm
0214 Varies depending on type of connector.
4.Table of tightening torques for O-ring boss plugs
a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
303032
363636127.4 – 176.4 {13.0 – 18.0}151.9 {15.5}
4242–181.3 – 240.1 {18.5 – 24.5}210.7 {21.5}
5252–274.4 –
200 Foreword and general information Standard tightening torque table
5.Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Nominal No. of hose Width across flats
0219 34 – 54 { 3.5 – 5.5} 44 { 4.5} –9/16-18UN14.3 34 – 63 { 3.5 – 6.5}14––03 22 54 – 93 { 5.5 – 9.5} 74 { 7.5}–11/16-16UN17.5 24 59 – 98 { 6.0 – 10.0} 78 { 8.0}18––0427 84 – 132 { 8.5 – 13.5}103 {10.5}2213/16-16UN20.6 0532128 – 186 {13.0 – 19.0}157 {16.0}241-14UNS25.4
0636177 – 245 {18.0 – 25.0}216 {22.0}301-3/16-12UN30.2 (10)41177 – 245 {18.0 – 25.0}216 {22.0}33––(12)46197 – 294 {20.0 – 30.0}245 {25.0}36––(14)55246 – 343 {25.0 – 35.0}294 {30.0}42––
6.Table of tightening torques for face seal joints
a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to be used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil (wetted).
Outer diameter of pipe (mm) Width across flats (mm) Tightening torque Nm {kgm}Face
Nominal No. –Number of threads, type of thread Thread diameter (mm) (Reference)
81914 – 16 {1.4 – 1.6}15 {1.5}9/16-18UN14.3 102224 – 27 {2.4 – 2.7}25.5 {2.6}11/16-16UN17.5 1224 (27)43 – 47 {4.4 – 4.8}45 {4.6}13/16-16UN20.6 15 (16)30 (32)60 – 68 {6.1 – 6.8}64 {6.5}1-14UN25.4 22 (20)3690 – 95 {9.2 – 9.7}92.5 {9.4}1-3/16-12UN30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
7.Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114 engine series to the torque below.
Thread size
Tightening torque Bolts and nuts mmNmkgm
610 ± 21.02 ± 0.20
824 ± 42.45 ± 0.41 1043 ± 64.38 ± 0.61
1277 ± 127.85 ± 1.22 14——
8.Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine series to the torque below.
9.Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114 engine series to the torque below.
Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1.Convert 55 mm into inches.
1)Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal line from (A).
2)Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B).
3)Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2.Convert 550 mm into inches.
1)The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the left) to convert it to 55 mm.
2)Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3)The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches (B)
1 mm = 0.03937 in 0123456789
000.0390.0790.1180.1570.1970.2360.2760.3150.354
301.1811.2201.2601.2991.3391.3781.4171.4571.4961.536 401.5751.6141.6541.6931.7321.7721.8111.8501.8901.929
(A) 501.9692.0082.0472.0872.1262.1652.2052.2442.2832.323 602.3622.4022.4412.4802.5202.5592.5982.6382.6772.717 702.7562.7952.8352.8742.9132.9532.9923.0323.0713.110 803.1503.1893.2283.2683.3073.3463.3863.4253.4653.504 903.5433.5833.6223.6613.7013.7403.7803.8193.8583.898
Millimeters to inches 1 mm = 0.03937 in 0123456789
501.9692.0082.0472.0872.1262.1652.2052.2442.2832.323 602.3622.4022.4412.4802.5202.5592.5982.6382.6772.717 702.7562.7952.8352.8742.9132.9532.9923.0323.0713.110 803.1503.1893.2283.2683.3073.3463.3863.4253.4653.504 903.5433.5833.6223.6613.7013.7403.7803.8193.8583.898
Kilogram to pound
5013.20913.47313.73714.00114.26514.52914.79515.05815.32215.586 6015.85016.11516.37916.64316.90717.17117.43517.70017.96418.228 7018.49218.75619.02019.28519.54919.81320.07720.34120.60520.870 8021.13421.39821.66221.92622.19022.45522.71922.98323.24723.511 9023.77524.04024.30424.56824.83225.09625.36125.62525.88926.153
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1401012.61019.91027.11034.31041.51048.81056.01063.21070.51077.7
1501084.91092.21099.41106.61113.91121.11128.31135.61142.81150.0 1601157.31164.51171.71179.01186.21193.41200.71207.91215.11222.4 1701129.61236.81244.11251.31258.51265.81273.01280.11287.51294.7 1801301.91309.21316.41323.61330.91338.11345.31352.61359.81367.0 1901374.31381.51388.71396.01403.21410.41417.71424.91432.11439.4
00 14.2 28.4 42.7
10142.2156.5170.7184.9199.1213.4227.6241.8256.0270.2 20284.5298.7312.9327.1341.4355.6369.8384.0398.3412.5 30426.7440.9455.1469.4483.6497.8512.0526.3540.5554.7 40568.9583.2597.4611.6625.8640.1654.3668.5682.7696.9
50711.2725.4739.6753.8768.1782.3796.5810.7825.0839.2 60853.4867.6881.8896.1910.3924.5938.7953.0967.2981.4 70995.61,0101,0241,0381,0531,0671,0811,0951,1091,124 801,1381,1521,1661,1811,1951,2091,2231,2371,2521,266 901,2801,2941,3091,3231,3371,3511,3651,3801,3941,408
1001,4221,4371,4511,4651,4791,4931,5081,5221,5361,550 1101,5651,5791,5931,6071,6211,6361,6501,6641,6781,693 1201,7071,7211,7351,7491,7641,7781,7921,8061,8211,835 1301,8491,8631,8771,8921,9061,9201,9341,9491,9631,977 1401,9912,0052,0202,0342,0482,0622,0772,0912,1052,119 1502,1342,1482,1622,1762,1902,2052,2192,2332,2472,262 1602,2762,2902,3042,3182,3332,3472,3612,3752,3892,404 1702,4182,4322,4462,4602,4752,4892,5032,5182,5322,546 1802,5602,5742,5892,6032,6172,6312,6462,6602,6742,688 1902,7022,7172,7312,7452,7592,7732,7882,8022,8162,830
2002,8452,8592,8732,8872,9012,9162,9302,9442,9582,973 2102,9873,0013,0153,0303,0443,0583,0723,0863,1013,115 2203,1293,1433,1583,1723,1863,2003,2143,2293,2433,257 2303,2713,2863,3003,3143,3283,3433,3573,3713,3853,399 2403,4143,4283,4423,4563,4703,4853,4993,5133,5273,542
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column) of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.
Form No. SEN04982-02
KOMATSU All Rights Reserved Printed in Japan 02-23 (01)
WD600-6 Wheel dozer
©2023
100 Specification and technical data
Specification dimension drawing
Specification dimension drawing 1
Data inside the parentheses represents a value when locked up
Engine
Machine model name
Serial number
100 Specification and technical data Specifications
WD600-6
55001 and up 55001 and up
Standard For NORTH AMERICA
Name SAA6D170E-5
Type
4-cycle, water-cooled, direct injection type with turbocharger, aftercooler and water-cooled EGR
Number of cylinders – Bore × Strokemm 6 – 170 x 170
Total piston displacement l {cc} 23.15 {23,150}
Hosepower
Gross [SAE J1995]
ISO 14396
kW{HP}/rpm396 {530}/1,800
384 {515}/1,700
kW{HP}/rpm396 {530}/1,800 -
Net [ISO 9249/SAE J1349]kW{HP}/rpm393 {527}/1,800
Max. torque
Rated fuel consumption
Nm/rpm {kgm/rpm}
g/kWh {g/HPh}
Power train
Wheel and axle
382 {513}/1,700
2,594/1,000 {264.5/1,000}
227 {169} (In P-mode only)
High idle speed rpm 2,000
Low idle speed rpm 800
Starting motor 24 V, 11 kW × 2
Alternator 24 V, 90 A
Battery 12 V, 200 Ah × 2 pcs
Torque converter
Transmission
Reduction gear unit
Differential system
Final drive
Drive method
Front axle
3-element, 1-stage, 2-phase (with lockup clutch)
Planetary type, multiple disc type, and forward-reverse 4 stages
Spiral bevel gear type and splash lubrication type
Straight bevel gear type
Single-stage planetary gear and splash lubrication type
Front and rear wheel drive
Fixed frame, full floating type
Rear axle Center pin supporting, full floating type
Tire 35/65-33-36PR(L-4)
Wheel rim 28.00 x 33WTB
Tire inflation pressure
Foot brake
kPa {kg/cm2}
Front wheel: 434 {3.5} and rear wheel: 392 {4.0} Brake
Parking brake
Independent front and rear wheel brake system of closed multiple wet disc type
Fully hydraulic type
Drive shaft braking system of wet disc type
Hydraulically released spring-driven brake
100 Specification and technical data
Specifications
Machine model name
Serial number
Steering system
Steering system
Type
Hydraulic system
WD600-6
55001 and up 55001 and up
Standard for NORTH AMERICA
Articulated steering
Structure Fully hydraulic power steering
Hydraulic pump delivery
Control valve
Cylinder
Motor
Work equipment pump l/min 182 + 182 (Variable displacement type piston pump HPV125+125)
Steering pump l/min163 (Variable displacement type piston pump HPV125)
Cooling fan pump l/min57 (Variable displacement type piston pump LPV45)
Torque converter and transmission pump l/min294 (Gear pump SAL(4)160)
Hydraulic oil cooling pump l/min182 (Gear pump SAL(3)100)
EPC and brake pump l/min58 (Gear pump SAL(2)32)
Set pressure for work equipmentMPa {kg/cm2} 3-spool type (with HI valve) 24.5 {250}
Set pressure for steering systemMPa {kg/cm2} Spool valve type 34.3 {350}
Number of lift cylinders – Bore x Stroke mm
Number of pitch and tilt cylinders – Bore x Stroke mm
Number of steering cylinders –Bore x Stroke mm
Fan motor
Double-acting piston type, 1 – 160 x 1,080
Double-acting piston type, 2 – 180 x 236.5
Double-acting piston type, 2 – 130 x 510
Fixed displacement piston type LMF110 (55)
Weight table 1
k This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
Machine model nameWD600-6
Serial number55001 and up
Engine (Dry weight)3,098
Radiator (Dry weight)433
Torque converter (Dry weight)486
Transmission (Dry weight)1,290
Upper drive shaft29.6
Center drive shaft60.5
Front drive shaft65
Rear drive shaft62.8
Center support46.4 Front
Front differential551
Rear differential586
Planetary carrier assembly (1 unit)191 Wheel hub (1 piece)182.5
Axle pivot (Front)136.2
Axle pivot (Rear)190 Wheel (1 piece)409 Tire (Standard: 35/65-33-36PR L-4) (1 piece)1,085
100 Specification and technical data
Table of fuel, coolant and lubricants
Table of fuel, coolant and lubricants 1
a For details of the notes (e.g.,Note. 1, Note. 2 …) in the table, see the Operation and Maintenance Manual.
Form No. SEN04984-01
©2012 KOMATSU All Rights Reserved Printed in Japan 03-12
WD600-6 Wheel dozer
No. Check item
Criteria
Unit: mm
Remedy
2 Standard shim thickness of mount 1.2 (Parallelism of center support coupling and transmission coupling is 0.1 mm) Adjust
Damper 1
1.Breather
2.Flywheel (shaft side)
3.Breather
4.Cover
5.Outer body
6.Inner body
7.Rubber cushion (large)
8.Rubber cushion (small)
9.Shaft
Function
q The damper reduces torsional vibration due to torque fluctuation and protects vibration in the drive system after the engine from torsional vibration.
Operation
q Power from the engine is transmitted to outer body (5) via the flywheel. Rubber cushions (7) and (8) absorb torsional vibration of the engine, and the power is transmitted to the upper drive shaft between the torque converter through shaft (9) via inner body (6).
1.Radiator upper tank
2.Coolant level sensor
3.Radiator core
4.Radiator lower tank
5.Brake oil cooler (if equipped)
6.Brake oil cooler (if equipped)
7.Air conditioner condenser
8.Aftercooler
9.Torque converter oil cooler
10.Coolant sub-tank
11.Hydraulic oil cooler
12.Fan motor
13.Fan
A:Aftercooler outlet port
B:Aftercooler inlet port
C:Coolant inlet port
D:Hydraulic oil cooler inlet port
E:Hydraulic oil cooler outlet port
F:Coolant port
Specifications
Pressure valve
cracking pressure (kPa{kg/cm2}) 70 ± 15 {0.7 ± 0.15}
Vacuum valve
cracking pressure (kPa{kg/cm2}) 0 – 5 {0 – 0.05}
*1): Size of element
Cooling fan pump 1
Type: LPV45
General view
P1: Pump discharge port
PAEPC: EPC output pressure pickup plug
PEPC: EPC valve basic pressure input port
PS: Pump suction port
TO: Drain port
1.Servo valve
2.Air bleeder
100
Sectional view
1.Shaft
2.Oil seal
3.Case
4.Rocker cam
5.Shoe
6.Piston
7.Cylinder block
8.Valve plate
9.Spring
10.Servo piston
Function
q The pump converts the engine rotation transmitted to its shaft to oil pressure and delivers pressurized oil corresponding to the load.
q It is possible to change the discharge amount by changing the swash plate angle.
Structure
q Cylinder block (7) is supported to shaft (1) by spline (11).
q Shaft (1) is supported with front and rear bearings (12).
q The end of piston (6) has a spherical hollow and is combined with shoe (5).
q Piston (6) and shoe (5) form a spherical bearing.
q Shoe (5) is kept pressed against plane (A) of rocker cam (4) and slid circularly.
q Rocker cam (4) slides around ball (13).
q Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7).
q Cylinder block (7) seals the pressurized oil to valve plate (8) and carries out relative rotation.
q This surface is designed so that the oil pressure balance is maintained at a suitable level.
q The oil inside each cylinder chamber of cylinder block (7) is suctioned and discharged through valve plate (8).
Operation of pump
q Cylinder block (7) rotates together with shaft (1), and shoe (5) slides on flat surface (A).
q Rocker cam (4) slants around ball (13). As a result, angle (a) between center line (X) of rocker cam (4) and the axis of cylinder block (7) changes.
q Angle (a) is called the swash plate angle.
q With the condition of center line (X) of rocker cam (4) has swash plate angle (a) to axial direction of cylinder block (7), flat surface (A) functions as cam against shoe (5).
q Piston (6) slides on the inside of cylinder block (7), so a difference between volumes (E) and (F) is created inside cylinder block (7).
q A single piston (6) sucks and discharges the oil by the amount (F) – (E).
q As cylinder block (7) rotates and the volume of chamber (E) becomes smaller, the pressurized oil is discharged.
q On the other hand, the volume of chamber (F) grows larger and, in this process, the oil is suctioned.
q As center line (X) of rocker cam (4) matches the axial direction of cylinder block (7) (swash plate angle (a) = 0), the difference between volumes (E) and (F) inside cylinder block (7) becomes 0.
q Suction and discharge of pressurized oil is not carried out in this state. Namely pumping action is not performed. (Actually, however, the swash plate angle is not set to 0)
Control of delivery
q If the swash plate angle (a) becomes larger, the difference between volumes (E) and (F) becomes larger and pump delivery (Q) increases.
q Swash plate angle (a) is changed with servo piston (10).
q Servo piston (10) reciprocates straight according to the signal pressure of the servo valve.
q This straight motion is transmitted to rocker cam (4).
q Rocker cam (4) supported with ball (13) slides around ball (13).
q Swash plate angle (a) is in proportion to the pump delivery.
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Servo valve
P: EPC valve basic pressure
PE: Control piston pressure
PH: Pump discharge pressure
T: Drain port
1.Plug
Function
q The servo valve controls the current input to the EPC valve and pump delivery (Q) so that they will be related as shown in the diagram.
q The output pressure of the EPC valve flows in the piston chamber to push piston (6).
q Piston (6) pushes spool (5) until it is balanced with the spring.
q The land of the servo piston pressure passage is connected to the pump discharge passage by the notch of spool (5) and the discharge pressure is led to the servo piston.
q When the rocker cam is pushed up by the servo piston, a position feedback is applied and lever (2) moves to compress spring (8).
q When spool (5) is pushed back, the pump discharge circuit and the servo piston circuit are cut off.
q Pressure in the servo piston chamber drops and the rocker cam returns in the direction of a maximum swash plate angle.
q These processes are repeated until the swash plate is fixed to a position where the EPC output pressure is balanced with spring (8) force.
q The greater the EPC output pressure, the smaller the swash plate angle. Conversely, the smaller the EPC output pressure, the greater the swash plate angle.
Cooling fan motor 1
Type: LMF110 (55)
General view
P: From fan pump
T: From cooler to tank
TC: To tank
Specifications
Type: LMF110 (55)
Capacity: 55.0 cc/rev
Rated speed: 980 rpm
Rated flow: 53.9 l/min
Check valve cracking pressure : 78.5 kPa {0.8 kg/cm2}
Sectional view
1.Output shaft
2.Case
3.Thrust plate
4.Piston assembly
5.Cylinder block
6.Valve plate
No. Check
7.End cover
8.Center spring
9.Check valve
10.Pilot valve
11.Spool for reversible valve
12.Safety valve Unit: mm
Hydraulic motor unit
Function
q This hydraulic motor is called a swash platetype axial piston motor. It converts the energy of the pressurized oil sent from the hydraulic pump into rotary motion.
Principle of operation
q The oil sent from the hydraulic pump flows through valve plate (7) into cylinder block (5).
q This oil can flow on only one side of the (Y-Y) line connecting the top dead center and bottom dead center of the stroke of piston (4).
q The oil sent to one side of cylinder block (5) presses pistons (4) (2 or 3 pieces) and generates force (F1).
q Force F1 (F1 kg = P kg/cm2 x xD2/4 cm2)
q This force is applied to thrust plate (2).
q Since thrust plate (2) is fixed to a certain angle (“a” degrees) to output shaft (1), the force is divided into components (F2) and (F3).
q Radial component (F3) generates torque [T = F3 x ri] against the (Y - Y) line connecting the top dead center and bottom dead center.
q The result of this torque [T = s(F3 x ri)] rotates cylinder block (5) through the piston.
q This cylinder block (5) is coupled to output shaft (1) with the spline.
q Output shaft (1) rotates and torque is transmitted.
Suction valve
Function
q When the fan pump stops rotating, hydraulic oil does not flow into the motor.
q Since the motor is revolved by the force of inertia, the pressure rises on the outlet side of the motor.
q When the oil stops flowing in from inlet port (P), suction valve (1) sucks in the oil on the outlet side and supplies it to port (MA) where there is not sufficient oil.
q Cavitation is prevented from being generated accordingly.
Operation
When starting
q When the hydraulic oil from the pump is supplied to port (P) and the pressure on (MA) side rises.
q When starting torque is generated in the motor, the motor starts revolution.
q The oil on outlet (MB) side of the motor returns through port (T) to the tank.
When stopping
q When the engine stops, the fan pump input revolution becomes 0 rpm.
q Hydraulic oil from the pump is not supplied to port (P).
q As the hydraulic oil does not flow to (MA) side of the motor, the motor speed decreases gradually to stop.
q If the motor shaft is revolved by the force of inertia while the oil flow to port (P) decreases, the oil in port (T) on the outlet side is sent by suction valve (1) to (MA) side.
q Cavitation is prevented from being generated accordingly.
Operation of reversible valve
When solenoid valve is de-energized
q When solenoid valve (1) is “de-energized”, hydraulic oil from the pump is cut off by selector valve (2).
q Port (C) is connected to the tank circuit.
q Accordingly, spool (3) is pressed by spring (4) to the right.
q As a result, motor port (MA) opens and the hydraulic oil flows into the motor to revolve it in normal direction (clockwise).
When solenoid valve is energized
q When solenoid valve (1) is “energized”, selector valve (2) switches.
q Hydraulic oil from the pump flows through port (C) into spool chamber (D).
q Hydraulic oil in chamber (D) compresses spring (4).
q Spool (3) moves to the left.
q Motor port (MB) opens and the hydraulic oil flows into the motor to revolve it in reverse (counterclockwise).
Safety valve
Function
q When the engine is started, the pressure in port (P) of the fan motor is heightened in some cases.
q Safety valve (1) is installed to protect the fan system circuit.
Operation
q If the pressure in port (P) rises above the cracking pressure of safety valve (1), valve (2) of safety valve (1) opens to release the pressurized oil into port (T).
q Accordingly, abnormally high pressure is prevented from being generated in port (P).
Form No. SEN04986-00
©2009 KOMATSU All Rights Reserved Printed in Japan 03-09 (01)
WD600-6 Wheel dozer
1.Center drive shaft
2.Transfer (output)
3.Transmission
4.Torque converter
5.Transfer (input)
6.Upper drive shaft
7.Damper
8.Engine
9.Modulation clutch
10.Rear axle
11.Rear drive shaft
12.Center support
13.Front drive shaft
14.Front axle
Outline
q Power from engine (8) is transmitted through the flywheel of engine to damper (7). The damper output shaft is connected to modulation clutch (9) via upper drive shaft (6). The output of the modulation clutch is connected to pump of torque converter (4). The turbine of the torque converter is connected to input shaft of transmission (3).
q The transmission has 6 hydraulic clutches to set itself to 4 forward gear speeds and 4 reverse gear speeds, which is operated through selection of one of them using an electrically controlled switch.
q The output shaft of the transmission is connected to gear of transfer (2) and the power is transmitted to the outp ut shaft. The power from the transfer output shaft is transmitted through center drive shaft (1), center support (12), front drive shaft (13) and rear drive shaft (11) to front axle (14) and rear axle (10), and then transmitted through the wheels to the tires.
Power train system diagram 1
15.Front differential
16.Front brake
17.Front final drive
18.Front tire
19.Emergency steering pump (Only machine with emergency steering system)
20.Parking brake
21.Brake cooling pump (if equipped)
22.Brake and EPC pump
23.Hydraulic oil cooling pump
24.Power train pump
25.Work equipment pump
26.Steering pump
27.Cooling fan pump
28.Rear differential
29.Rear brake
30.Rear final drive
31.Rear tire
201 Power train, Part 1
converter and transmission piping diagram
Torque converter and transmission piping diagram 1
1.Transmission
2.Power train, hydraulic oil cooling, brake and EPC pump
3.Transfer (input)
4.Torque converter
5.Transfer (output)
6.Transmission oil level gauge
7.Torque converter oil cooler
8.Torque converter oil filter
Torque converter 1
(Input transfer, PTO, modulation clutch, and torque converter)
201 Power train, Part 1
A:Modulation clutch oil pressure pickup port
B:From transmission control valve
C:From brake valve (Left)
D:To torque converter regulator valve
E:From lockup clutch ECMV
F:From main relief valve
G:From oil cooler
H:To transfer case
1.Steering, cooling fan pump mounting port
2.Work equipment pump mounting port
3.Modulation clutch output shaft speed sensor
4.Torque converter
5.Input transfer and PTO
6.Modulation clutch
7.Power train, hydraulic oil cooling, brake and EPC pump mounting port
8.Brake cooling pump (If equipped) mounting port
Specifications
(T3/T1)
(T3/T2)
1.Modulation clutch output shaft
2.Modulation clutch piston
3.Modulation clutch outer drum
4.Modulation clutch gear (Number of teeth: 43)
5.Torque converter input shaft
6.Lockup clutch housing
7.Turbine
8.Drive case
9.Stator
10.Pump
11.Stator shaft
12.Transmission input shaft
13.Free wheel
14.Race
15.Boss
16.Lockup clutch disc
17.Lockup clutch plate
18.Lockup clutch piston
19.Modulation clutch disc
20.Modulation clutch plate
1.Coupling
2.PTO gear (Number of teeth: 51)
3.Drive gear (Number of teeth: 54)
4.Input shaft
5.PTO gear (Number of teeth: 51)
Power transmitting route
When lockup clutch is “disengaged”
Drive case (11) is disconnected from boss (15) and turbine (14) and lockup torque converter works as an ordinary torque converter.
The power from engine
Damper
Universal joint
Coupling (1)
Input shaft (2)
Drive gear (3)
Clutch gear (5)
Modulation clutch (6)
(To right top) o
o (from left bottom)
Outer drum (7)
Output shaft (8)
Input shaft (9)
Clutch housing (10), drive case (11) and pump (13) rotate together
Oil is used as medium
Turbine (14) and boss (15)
Transmission input shaft (16)
q The power being transmitted to coupling (1) is then transmitted through input shaft (2), drive gear (3) and PTO gear (4) and then used as the pump driving power.
When lockup clutch is “engaged”
Drive case (11) is connected to boss (15) and turbine (14) and lockup torque converter is locked up.
The power from engine O Damper O Universal joint O
Coupling (1) O
Input shaft (2) O
Drive gear (3) O
Clutch gear (5) O
Modulation clutch (6) O (To right top) o
o (from left bottom) O
Outer drum (7) O
Output shaft (8) O
Input shaft (9) O
Clutch housing (10), drive case (11) and pump (13) rotate together O
Lockup clutch (12) O
Boss (15) O
Transmission input shaft (16)
q The power being transmitted to coupling (1) is then transmitted through input shaft (2), drive gear (3) and PTO gear (4) and then used as the pump driving power.
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q The oil flows through the main relief valve and its pressure is regulated by the torque converter relief valve, and then it flows to the pump (4) through inlet port (A) and the oil passage of housing (1), stator shaft (2) and guide (3).
q The oil is given a centrifugal force by pump (4), and then it enters turbine (5) to transmit its energy to turbine (5).
q The oil from turbine (5) is sent to stator (6), and then returned to pump (4). Part of this oil is sent to the oil cooler through stator (6), oil passage of stator shaft (2) and outlet port (B).
Outline
q The modulation clutch is installed between the input transfer and torque converter.
q Regulating the clutch oil pressure by use of ECMV allows adjusting the clutch connection.
q Sliding the clutch allows reducing the power to be transmitted to the torque converter.
When clutch is “engaged” (fixed)
q The oil sent from the modulation clutch ECMV flows to piston (3) through port (A) of cover (1) and oil passage of output shaft (2). The oil reached there works as back pressure to drive piston (3) in the right direction.
q Rise in the clutch oil pressure increases pressing force of piston (3), closely contacting disc (4) and plate (5) each other and as the result uniting clutch gear (6) and outer drum (7) to transmit the power. In this case, the power from clutch gear (6) is directly transmitted to outer drum (7).
Clutch is in “slip” (partially disengaged)
q As the low clutch oil pressure signal from the controller is received , the modulation clutch ECMV reduces the clutch oil pressure.
q As the clutch oil pressure goes low, pressing force of piston (3) is weakened, causing slippage of disc (4) and plate (5). As the result, speed of outer drum (7) becomes slower than clutch gear (6).
Thus, the power to be transmitted to outer drum (7) is reduced.
q Magnitude of the power to be transmitted is determined by the ratio between the clutch slip ratio and torque converter's speed. Slip ratio (%) = (1 – Output shaft speed/Input shaft speed) x 100
Torque converter regulator valve 1
1 Clearance between spool and valve body
2 Valve spring
3.Torque converter outlet port oil pressure pickup port
4.Spool
5.Valve body
A:From torque converter
B:To oil cooler
C:Drain
Outline
q This valve is provided at the torque converter outlet circuit in order to secure an optimum performance of the torque converter by adjusting its set oil pressure. Set
Operation
q The oil from the torque converter is conducted to chamber (D) through port (A) and orifice (a).
q When the oil pressure force generated in chamber (D) is smaller than the tension of spring (1), spool (2) is pressed leftward, closing port (A) and port (B).
q If the oil pressure force generated in chamber (D) becomes larger than the tension of spring (1), spool (2) is pressed rightward, opening port (A) and port (B).
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Transmission 1 (Transmission, transfer and parking brake)
A:From torque converter
B:To torque converter
C:To lockup clutch
D:From power train pump
E:From oil cooler
F:From parking brake emergency release valve
G:From lockup clutch ECMV
H:From main relief valve
J:From R clutch ECMV
K:From F clutch ECMV
L:From 4th clutch ECMV
M:From 2nd clutch ECMV
N:From 3rd clutch ECMV
P:From 1st clutch ECMV
R:From torque converter relief valve
1.Transmission control valve
2.Lubrication relief valve
3.Drain valve
4.Drain plug
5.Transfer
6.Parking brake
7.Transmission
8.Torque converter drain tube mounting port
9.Transmission lubrication temperature sensor
10.Speed sensor
11.Emergency steering pump mounting port
12.Oil filler tube mounting port
13.Torque converter regulator valve
14.Parking brake oil pressure pickup port
15.Strainer
1.Transmission input shaft
2.R ring gear (Hub)
3.Tie bolt
4.Clutch disc
5.Clutch plate
6.R planetary pinion (Number of teeth: 28)
7.R clutch housing
8.R ring gear (Number of inside teeth: 86)
9.F ring gear (Number of inside teeth: 90)
10.F planetary pinion (Number of teeth: 24)
11.F clutch housing
12.4th planetary pinion (Number of teeth: 24)
13.4th clutch housing
14.2nd hub
15.2nd clutch housing
16.2nd clutch piston housing
17.3rd clutch housing
18.3rd ring gear (Number of inside teeth: 90)
19.3rd planetary pinion (Number of teeth: 20)
20.1st clutch housing
21.1st ring gear (Number of inside teeth: 90)
22.1st planetary pinion (Number of teeth: 20)
23.Transfer input gear (Number of teeth: 46)
24.Transmission output shaft
25.1st sun gear (Number of teeth: 50)
26.1st carrier
27.1st clutch piston
28.3rd sun gear (Number of teeth: 50)
29.1st piston return spring
30.3rd carrier
31.3rd clutch piston
32.3rd piston return spring
33.2nd clutch piston
34.2nd piston return spring
35.4th ring gear (Number of inside teeth: 90)
36.4th clutch piston
37.4th sun gear (Number of teeth: 42)
38.4th piston return spring
39.F clutch piston
40.F and 4th carrier
41.F sun gear (Number of teeth: 42)
42.F piston return spring
43.R clutch piston
44.R carrier
45.R piston return spring
46.Washer spring
47.R sun gear (Number of teeth: 30)
48.Housing
Outline
q The transmission employed consists of the united planetary gear mechanism and disc clutch that provides “4 forward gear speeds and 4 reverse gear speeds”.
q The transmission selects a single rotating direction and a single speed by fixing the planetary gear mechanism and 2 of 6 disc clutches by use of ECMV.
q The transmission transmits the power being transmitted to the transmission input shaft to the output shaft after selecting a single speed from the 1st to 4th speeds both in the forward and reverse travel. In this case, the gear speed change is done by F and R clutches plus combinations of 4 speed clutches.
Number of plates and discs used
Clutch No.Number of platesNumber of discs
Combinations of clutches at respective gear speeds and reduction ratio
1.Transfer idler gear (Number of teeth: 41)
2.Transfer output gear (Number of teeth: 42)
3.Output shaft
4.Front coupling
5.Rear coupling
6.Parking brake
1 R clutch spring (12 springs)
2 F clutch
4
5
6
7
8
of output shaft bearing (Rear)
6
7 Clearance between cage and case
– 1.37 (Standard shim thickness: 1.0)
8 Clearance between cover and cage 0.38 – 1.23 (Standard shim thickness: 0.5)
Disc clutch
Structure
q Disc clutch is used for fixing ring gear (1). It consists of piston (2), plate (3), disc (4), pin (5), return spring (6) and washer spring (8).
q Inside teeth of disc (4) are engaged with outside teeth of ring gear (1).
q Plate (3) is assembled to clutch housing (7) with pin (5).
Operation
When clutch is “engaged” (fixed)
q The oil from ECMV is sent with pressure to the rear side of piston (2) through oil the passage of housing (7) and pushes piston (2) leftward.
q Piston (2) contacts plate (3) closely against disc (4) to stop rotation of disc (4) by use of the friction force generated between them.
q Since inside teeth of disc (4) are engaged with outside teeth of ring gear (1), move of ring gear (1) is stopped.
When clutch is “disengaged” (released)
q As the oil from ECMV is stopped, piston (2) is pushed back rightward by return spring (6).
q Plate (3) and disc (4) are released from the frictional force and ring gear (1), as the result, is also released.
q Washer spring (8) is installed between plate (3). This spring quickens return of piston (2) as the clutch is disengaged by providing smooth separation of plate (3) and disc (4). At the same time, it is used for preventing the dragging.
Power transmitting route Forward 1st gear speed
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F ring gear (4) of F clutch and 1st ring gear (17) of 1st clutch are fixed hydraulically.
The power from torque converter
O Input shaft (1)
O
F sun gear (2)
O
F planetary pinion (3)
O
F and 4th carrier (10)
O
4th planetary pinion (11)
O
4th ring gear (12)
4th sun gear (23) O
2nd clutch piston housing (13)
O
3rd carrier (14)
O
3rd planetary pinion (20)
O
3rd ring gear (21)
O
1st sun gear (15) O
1st planetary pinion (16) O
1st carrier (18)
O Output shaft (24)
3rd sun gear (22)
Forward 2nd gear speed
F ring gear (4) of F clutch and 2nd hub (19) of 2nd clutch are fixed hydraulically.
The power from torque converter O
Input shaft (1) O
F sun gear (2) O
F planetary pinion (3) O
F and 4th carrier (10) O
4th planetary pinion (11) O
4th ring gear (12)
4th sun gear (23) O
2nd hub (19) O
Output shaft (24)
Forward 3rd gear speed
F ring gear (4) of F clutch and 3rd ring gear (21) of 3rd clutch are fixed hydraulically.
The power from torque converter
O Input shaft (1) O
F sun gear (2)
O
F planetary pinion (3) O
F and 4th carrier (10) O
4th planetary pinion (11) O
4th ring gear (12)4th sun gear (23) O
2nd clutch piston housing (13) O
3rd carrier (14) O
3rd planetary pinion (20) O
3rd sun gear (22)
O Output shaft (24)
Forward 4th gear speed
F ring gear (4) of F clutch and 4th ring gear (12) of 4th clutch are fixed hydraulically.
The power from torque converter
Input shaft (1)
F sun gear (2)
F planetary pinion (3)
F and 4th carrier (10)
4th planetary pinion (11)
4th sun gear (23)
Output shaft (24)
Reverse 1st gear speed
R ring gear (7) of R clutch and 1st ring gear (17) of 1st clutch are fixed hydraulically.
The power from torque converter
O Input shaft (1)
O
R sun gear (5)
O
R planetary pinion (6)
O
R ring gear (9)
(R carrier (8) is fixed with R ring gear (7) = R ring gear (9) rotation direction is opposite to input shaft (1))
O
F and 4th carrier (10)
O
4th planetary pinion (11)
O
4th ring gear (12) 4th sun gear (23) O
2nd clutch piston housing (13) O
3rd carrier (14)
O
3rd planetary pinion (20)
O
3rd ring gear (21)
O
1st sun gear (15) O
1st planetary pinion (16)
O
1st carrier (18)
O Output shaft (24)
3rd sun gear (22)
Transfer 1
Outline
q The transfer is installed in the output side of the transmission and fixed to the transmission case with the bolt.
Operation
Power transmitting route
Transmission output shaft (1)
Transfer input gear (2)
Transfer idler gear (3)
Transfer output gear (4)
Output shaft (5)
Center drive shaft
Front drive shaft
Front axle
Rear drive shaft
Rear axle
Transmission control valve 1
Serial No.: (Transmission No. 100091) and up
A:R clutch oil pressure pickup port
B:F clutch oil pressure pickup port
C:4th clutch oil pressure pickup port
D:2nd clutch oil pressure pickup port
E:3rd clutch oil pressure pickup port
F:1st clutch oil pressure pickup port
G:Lockup clutch oil pressure pickup port
H:Modulation clutch oil pressure pickup port
J:From power train pump
K:Main relief oil pressure pickup port
L:Torque converter relief pressure pickup port
M:To input transfer lubrication
N:To parking brake emergency release valve (Pilot pressure)
P:To parking brake emergency release valve (To parking brake piston)
1.R clutch ECMV
2.F clutch ECMV
3.4th clutch ECMV
4.2nd clutch ECMV
5.3rd clutch ECMV
6.1st clutch ECMV
7.Lockup clutch ECMV
8.Modulation clutch ECMV
9.Parking brake solenoid valve
10.Last chance filter
11.Main relief valve and torque converter relief valve
12.Check valve
Operation table of ECMV
Outline
q The oil from the pump flows to the transmission control valve via the oil filter and then oil flow is divided into the main relief circuit and clutch actuation circuit.
q The pressure of the oil sent to the clutch actuation circuit is regulated by the main relief valve, and then used to actuate the clutch and parking brake through the last chance filter. The oil relieved from the main relief valve is supplied to the torque converter.
q When the transmission gear is shifted, the ECMV increases the clutch oil pressure smoothly according to the command current from the transmission controller to reduce the gear shifting shocks. The ECMV also keeps the clutch pressure constant during travel.
q If the F, R, or 1st to 4th ECMV is selected, the regulated oil pressure is supplied to the selected clutch to set the transmission in the desired gear speed.
q In the 2nd, 3rd and 4th speed travel, the lockup clutch ECMV operates at a speed higher than the speed being specified from the transmission controller.
q The modulation clutch ECMV operates at every gear speed.
L/U: lockup clutch ECMV
M/C: modulation clutch ECMV
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a ECMV: Abbreviation for Electronic Control Modulation Valve
For F, R, 1st, 2nd, 3rd, and 4th clutch
a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
A:To clutch
P:From pump
T:Drain
Dr:Drain
P1:Clutch oil pressure pickup port
1.Fill switch connector
2.Proportional solenoid connector
3.Flow rate pickup valve
4.Fill switch
5.Proportional solenoid
6.Pressure control valve
7.Nameplate (*1)
*1: Clutch usedPrinting on name plate
F, R, 1st, 2nd, 3rd, 4th D*******
Outline of ECMV
q The ECMV consists of 1 pressure control valve and 1 fill switch.
q Pressure control valve
This valve receives the current sent from the transmission controller with a proportional solenoid, and then converts it into oil pressure.
q Fill switch
This switch detects that the clutch is filled with oil and has the following functions.
1.Outputs a signal (a fill signal) to the controller to notify that filling is completed when the clutch is filled with oil.
2.Keeps outputting signals (fill signals) to the controller to notify whether oil pressure is applied or not while oil pressure is applied to the clutch.
ECMV and proportional solenoid
q For each ECMV, 1 proportional solenoid is installed.
The proportional solenoid generates thrust shown below according to the command current from the controller.
The thrust generated by the proportional solenoid is applied to the pressure control valve spool to generate oil pressure as shown in the figure below. Accordingly, the thrust is changed by controlling the command current to operate the pressure control valve to control the flow and pressure of the oil.
Current – Propulsion force characteristics of proportional solenoid
Range A:Before shifting gear (When draining)
Range B:During filling
Range C:Pressure regulation
Range D:During filling (During triggering)
Point E:Start of filling
Point F:Finish of filling
a The logic is so made that the controller will not recognize completion of filling even if the fill switch is turned “ON” during triggering (Range D).
Propulsion force – Hydraulic pressure characteristics of proportional solenoid
ECMV and fill switch
q For each ECMV, 1 fill switch is installed. If the clutch is filled with oil, the fill switch is turned “ON” by the pressure of the clutch. The oil pressure is built up according to this signal.
Operation of ECMV
q ECMV is controlled with the command current sent from the controller to the proportional solenoid and the fill switch output signal. The relationship between the proportional solenoid command current of ECMV, clutch input pressure, and fill switch output signal is shown below.
Before shifting gear (when draining) (Range A in chart)
Range A:Before shifting gear (When draining)
Range B:During filling
Range C:Pressure regulation
Range D:During filling (During triggering)
Point E:Start of filling
Point F:Finish of filling
a The logic is so made that the controller will not recognize completion of filling even if the fill switch is turned “ON” during triggering (Range D).
q While no current is flowing in proportional solenoid (1), pressure control valve (3) drains the oil from clutch port (A) through drain port (T). At this time, since no oil pressure is applied to flow rate pickup valve (4), fill switch (5) is turned “OFF”.
During filling (Range B in chart)
q If a current is given to proportional solenoid (1) while there is no oil in the clutch, a hydraulic force balanced with the solenoid force is applied to chamber (B) and it pushes pressure control valve (3) to the left. This conducts oil through pump port (P) and orifice (a) of flow rate pickup valve (4) to start filling the oil to the clutch chamber. At this time, differential pressure is generated between the upper stream and down stream of orifice (a) of flow rate pickup valve (4). This differential pressure pushes flow rate pickup valve (4) leftward. As the clutch chamber is filled up with oil and oil flow from pump port (P) to clutch port (A) is stopped, differential pressure before and after orifice (a) of flow rate pickup valve (4) disappears. As the result, flow rate pickup valve (4) is pushed rightward, turning “ON” fill switch (5).
Pressure regulation (Range C in chart)
q If a current flows in proportional solenoid (1), the solenoid generates thrust in proportion to the current. This thrust of the solenoid is balanced with the sum of the thrust generated by the oil pressure in clutch port and the tension of pressure control valve spring (2), and then the pressure is settled.
ECMV for lockup and modulation clutch
a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
A:To clutch
P:From pump
T:Drain
Dr:Drain
P1:Clutch oil pressure pickup port
1.Proportional solenoid connector
2.Sleeve
3.Proportional solenoid
4.Pressure control valve
5.Nameplate (*1)
*1:
Clutch usedPrinting on name plate Lockup, modulation K*******
Outline
ECMV for lockup clutch
q This valve is used to switch the clutch in order to regulate the clutch oil pressure to the set pressure.
Since the modulation waveform is used for the pressure application characteristics to the clutch, ECMV is capable of connecting the lockup clutch smoothly, thereby reducing shocks resulting from gear shift. Above also prevents generation of peak torque in the power train. These arrangements make the machine comfortable to operator and enhance durability of the power train.
When changing from torque converter travel to direct travel
ECMV for modulation clutch
q This valve is used for regulating the clutch oil pressure to the set pressure. It controls oil pressure by employing the proportional solenoid for adjusting slip ratio of the clutch.
Responding to the command current from the controller, the valve co ntrols oil pressure by applying the thrust generated on the proportional solenoid to the pressure control valve spool.
In order to control the oil pressure, this valve changes levels of the thrust applied to the pressure control valve by controlling the command current.
Oil pressure control of modulation clutch
At gear shift (in direct travel)
Operation
When clutch is “disengaged” (released)
When clutch is “engaged” (fixed)
q While no current is flowing in to proportional solenoid (1), pressure control valve (3) drains the oil from clutch port (A) through drain port (T).
q As current is conducted to proportional solenoid (1), the oil pressure being balanced with the solenoid force is applied to chamber (B), pushing pressure control valve (3) leftward. Above opens pump port (P) and clutch port (A) to start filling oil to the clutch.
q As the clutch is filled with oil, the solenoid thrust is balanced with the sum of the thrust generated from oil pressure of the clutch port and the tension of the pressure control valve spring (2), and then the pressure is settled.
Outline
Torque converter relief valve
q The torque converter relief valve constantly regulates the torque converter inlet circuit pressure below the set pressure to protect the torque converter from abnormally high pressure.
Set pressure:1.02 MPa {10.4 kg/cm2} (Cracking pressure)
Main relief valve
q The main relief valve regulates the pressure in the transmission and parking brake hydraulic circuits to the set pressure.
Set pressure:3.58 MPa {36.5 kg/cm2} (At rated engine speed)
Operation
Operation of torque converter relief valve
Operation
of
main relief valve
q The oil from the hydraulic pump flows to chamber (F) through the filter, port (C) of the relief valve and orifice (a) of main relief valve (1).
q The oil relieved through the main relief valve flows through port (E) into the torque converter. It also flows through orifice (b) of torque converter relief valve (3) into chamber (G).
q As the oil pressure to the torque converter rises beyond the set pressure, the oil conducted to chamber (G) pushes piston (4) and the resulting reaction force pushes torque converter relief valve (3) rightward, opening ports (E) and (A).
As the result, the oil in port (E) is drained to the oil tank through port (A).
q As the oil pressure in the circuit goes beyond the set pressure, the oil conducted to chamber (F) pushes piston (2) and the resulting reaction force pushes main relief valve (1) leftward, opening ports (C) and (E).
Above operation conducts the oil from port (E) to the torque converter.
2 Valve spring
3.Valve body 4.Spool
A:From oil cooler
B:Drain
C:Lubrication pressure pickup port
The lubrication relief valve is installed to the transmission valve and used for maintaining the pressure of the lubrication circuit below the set pressure.
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• You can download the complete manual from: www.heydownloads.com by clicking the link below
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