DOWNLOAD PDF : Komatsu D275A-2 Bulldozer Shop Manual SEBM000207 by www.heydownloads.com

SEBM000207

Shop Manual

BULLDOZER

SERIAL NUMBERS

D275A-2

- 10001

andup

This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America International Company. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision.

November 2000

CONTENTS No. of page

GENERAL ,............,,.....,.........,,,.................................~...........

STRUCTURE

TESTING

DISASSEMBLY

AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-l

MAINTENANCE

STANDARD . . . . . . . . . . . . . . . . . ..*...........................

00-2 0

01-l

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

AND ADJUSTING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l

40-l

The affected pages are indicated by the use of the following marks. Itis requested that necessary actions must

be taken to these pages

according to the list

Mark

Indication

Action required

Page to be newly added

Add

Page to be replaced

Replace

Page to be deleted

Discard

(

)

Pages having no marks

are not revised atthistime.

LIST OF REVISED PAGES Mark Pages

Revision number

Mark Pages

Revision number

IMark

Revision Pages number

Mark

Revision Pages number

Mark Pages

Revision number

oo- 1

IO-IO

IO-52

IO- 93

IO-127

oo- 2

IO-I 1

IO-53

IO- 94

IO-128

oo- 2-l

IO-12

IO-54

IO- 95

10-128-I

oo- 2-2

IO-13

IO-55

IO- 96

10-128-2

00- 2-3

IO-14

IO-56

IO- 97

IO-129

oo- 3

IO-15

IO-57

IO- 98

IO-130

oo- 4

IO-16

IO-58

IO- 99

IO-132

oo- 5

IO-17

IO-60

10-100

10-132-I

00- 6

IO-18

IO-61

10-101

10-132-2

oo- 7

IO-19

IO-62

IO-102

10-132-3

00- 8

10-19-I

IO-63

IO-103

IO-133

oo- 9

10-19-2

IO-64

IO-104

IO-134

00-10

IO-20

IO-65

IO-105

00-11

IO-21

IO-66

00-12

IO-22

IO-67

00-13

IO-23

10-67-I

00-14

IO-24

10-67-2

00-15

IO-25

IO-68

10-111

00-16

IO-26

IO-69

IO-112

00-17

IO-27

IO-70

00-18

IO-28

10-70-I

00-19

IO-29

00-20

0 0

IO-135

IO-106

IO-137

IO-108

IO-138

IO-109

IO-140

10-110

IO-141

IO-142

IO-143

10-112-1

IO-144

10-112-2

IO-145

IO-71

10-112-3

IO-146

IO-30

IO-72

IO-114

IO-147

00-21

IO-31

IO-73

IO-115

IO-148

00-22

IO-32

IO-74

IO-116

IO-149

Ol- 1

IO-33

IO-75

IO-117

IO-150

Ol- 2

IO-34

IO-76

IO-118

IO-151

Ol- 3

IO-35

IO-77

10-118-1

IO-152

Ol- 4

IO-36

IO-78

10-118-4

IO-153

Ol- 5

IO-37

IO-79

10-118-5

IO-154

Ol- 6

IO-38

IO-80

10-118-6

IO-155

Ol- 7

IO-39

IO-81

10-118-7

IO-156

Ol- 8

IO-40

IO-82

10-118-9

IO-157

Ol- 9

IO-42

IO-83

10-118-10 0

IO-158

01-10

IO-43

IO-84

IO-119

IO-159

IO-I

IO-44

IO-85

IO-120

IO-160

IO-46

IO-86

IO-121

IO-161

IO- 2 IO-3

IO-47

IO-88

IO-122

IO-162

IO-4

IO-48

IO-89

IO-123

20-

IO-49

IO-90

IO-124

20-

IO-50

IO-91

IO-125

20-

2-l

IO-51

1o-92

IO-126

20-

IO- 5 IO- 7 IO-8

D275A-2

00-2-l 0

Mark Pages

Revision number

Mark Pages

number

Mark Pages

Revision number

Mark Pages

Revision number

Mark Pages

Revision number

20-

20-108

20-140-15

30-

20-

20-109

20-140-16

30-

20-

20-110

20-140-17

30-

14-I

20-

20-I

20-140-18

30-

20-

20-I

20-141

30-

20-

20-I

20-142

30-

16-1

20-

20-I

20-143

30-

@ @

20-10

Revision

20-11

20-

20-115

20-144

30-

17-I

20-13

20-

20-116

20-145

30-

20-13-I

20-

20-117

20-146

30-

18-1

20-14

20-

20-118

20-147

30-

20-15

20-

20-119

20-148

30-

20-16

20-

20-120

20-149

30-

20- 150

30-

20-151

30-

20-151-I

30-

20- 152

30-

20-17

20-

20-121

20-17-I

20-

20-122

20-17-2

20-

20-123

20-18

20-

20-124

20-

20-125

20- 153

30-

25-l

20-20

20-

20-126

20-154

30-

20-21

20-

20-127

20-155

30-

20-22

20-

20-128

20-156

30-

20-23

20-

20-130

20-157

30-

20- 158

30-

20-159

30-

20-19

20-23-I

20-

20-131

20-23-2

20-

20-132

20-23-3

20-

20-160

30-

20-23-4

20-

20-134

20-161

30-

20-24

20-

20-134-I

20-162

30-

20-25

20-

82-l

20-134-2

20-201

30-

34-l

20-133

20-

82-2

20-134-3

20-202

30-

20-28

20-

82-3

20-134-4

20-203

30-

20-29

20-

82-4

20-134-5

20-204

30-

20-30

20-

20-134-6

20-205

30-

20-31

20-

20-134-7

20-206

30-

20-32

20-

84-l

20-134-8

20-207

30-

20-33

20-

84-2

20-134-g

20-208

30-

20-34

20-

20-134-10

20-209

30-

20-35

20-

20-134-I

1 @

20-210

30-

@ @

20-26

20-35-I

20-

20-135

20-211

30-

20-36

20-

20-136

20-212

30-

20-37

20-

20- 137

20-213

30-

20-38

20-

20-138

20-214

30-

20-39

20-

20-139

20-215

30-

20-40

20-

20-140

20-216

30-

20-41

20-

20-140-I

20-217

30-

20-42

20-

20-140-2

30-

20-43

20-

20-140-3

30-

20-44

20-

20-140-4

30-

2-l

30-

20-45

20-

20-140-5

30-

20-46

20-

20-140-6

30-

20-47

20-

20-140-7

(J)

30-

20-48

20-100

20-140-8

30-

20-48-I

20-101

20-140-9

30-

20-48-2

20-102

20-140-10

30-

20-49

20-103

20-140-11

30-

20-50

20-105

20-140-12

30-

20-51

20-106

20-140-13

30-

20-52

20-107

20-140-14

30-

00-2-2 0

D275A-2

Mark Pages

Revision number

Mark Pages

Revision number

30- 64

30-122

30-170

30-230

40- 46

30- 65

30-123

30-171

30-231

40- 47

30- 66

30-124

30-172

30-232

40- 48

30- 67

30-125

30-173

30-233

40- 49

30- 68

30-126

30-174

30-234

40- 50

30- 69

30-127

30-175

30-235

40- 51

30-128

30-176

30-236

40- 52

30-129

30-177

30-237

40- 54

30-130

30-178

30-238

40- 55

30-131

30-179

30-239

40- 56

30- 74

30-132

30-180

30-240

40- 58

30- 75

30-133

30-181

30-241

40- 59

30- 76

30-134

30-182

30-242

40- 60

30- 77

30-135

30-184

40-

40- 61

30- 78

30-136

30-185

40-

2 4

30- 70 30- 71 30- 72 30- 73

0 0 0 0

30- 79

30-137

30-186

40-

30- 80

30-138

30-187

40-

30- 81

30-139

30-188

40-

30- 82

30-140

30-189

40-

30- 83

30-141

30-190

40-

30- 84

30-142

30-191

40- 10

30- 85

30-143

30-192

40- 11

30- 86

30-144

30-193

40- 12

30- 87

30-145

30-194

40- 13

30- 88

30-146

30-195

40- 14

30- 89

30-147

30-196

40- 15

30- 90

30-148

30-197

40- 16

30- 91

30-148-I

30-198

40- 17

30- 92

30-148-2

30-198-I

40- 18

30- 93

30-148-3

30-199

40- 19

30- 94

30-149

30-200

40- 20

30- 95

30-150

30-201

40- 21

30- 96

30-150-I

30-202

40- 22

30- 97

30-150-2

30-203

40- 23

30- 98

30-150-3

30-204

40- 24

30- 99

30-150-4

30-206

40- 25

30-100

30-151

30-207

40- 26

30-101

30-152

30-208

40- 27

30-102

30-153

30-209

40- 28

30-103

30-154

30-210

40- 29

30-104

30-155

30-212

40- 30

30-105

30-156

30-213

40- 31

30-106

30-157

30-214

40- 32

30-107

30-158

30-215

40- 33

30-108

30-159

30-216

40- 34

30-109

30-160

30-218

40- 35

30-110

30-161

30-219

40- 36

30-111

30-162

30-220

40- 37

30-112

30-163

30-221

40- 38

30-113

30-163-I

30-222

40- 39

30-114

30-163-2

30-223

40- 39-l

30-115

30-164

30-224

40- 39-2

30-116

30-165

30-225

40- 40

30-117

30-166

30-226

40- 41

30-118

30-167

30-227

40- 43

30-119

30-168

30-228

40- 44

30-120

30-169

30-229

40- 45

D275A-2

00-2-3 0

SAFETY

NOTICE

SAFETY SAFETY

NOTICE

IMPORTANT SAFETY NOTICE Proper

service

and

repair

is extremely

service and repair techniques are both effective designed

manual.

for the specific

injury to workers,

The cautions

by Komatsu

take the necessary

situation

machine

operation.

and described

in this manual

require the use of tools specially

is used to mark safety precautions

these symbols

should

arises or may possibly

always

arise, first consider

Read the Operation carefully

6. Decide

are extremely and

Manual

the machine.

out any greasing

read all the precautions which

dangerous.

Maintenance

BEFORE operating

1. Before carrying

a place

in the

repair

the tools Always

and parts in their

or repairs,

correct

to keep

places.

keep the work area clean and make

sure that there

given on the decals

workshop

parts. Always

is no dirt or oil on the floor.

Smoke only in the areas provided ing. Never smoke

while

for smok-

working.

are fixed to the machine.

2. When

carrying

out any

operation,

always

wear safety shoes and helmet.

Do not wear

loose work clothes,

with buttons

or clothes

missing. . Always

wear

safety glasses

when

hitting

parts with a hammer. . Always

wear

safety

3. If welding trained,

glasses

when

grind-

etc.

repairs are needed, experienced

welder

adding

oil or making

on hard, level ground,

and

block the wheels

or tracks to prevent

the

8. Before

from

moving.

starting

work,

carrying

out welding

welding

gloves,

out the work,

apron,

al-

hand

shield, cap and other clothes suited for welding work.

blade,

ripper, to the

If this

equipment

is not

from falling.

to lock all the control

with two

or more workers,

always

agree on the oper-

ating procedure

before

starting.

Always

in-

before starting any

Before starting

work,

REPAIR signs on the controls

in the operator’s

compartment. in good condition

the correct way to use them.

and learn

possible,

insert

In addition,

the

be sure

levers and hang warn-

ing signs on them. 9. When disassembling

out any operation

step of the operation.

lower

bucket or any other work equipment ground.

wear

form your fellow workers

repairs,

safety pin or use blocks to prevent the work

When

carrying

any

park the machine

carry

ways

5. Keep all tools

7. Before

FOR WORK

always have a

work.

hang UNDER

PREPARATIONS

machine

ing parts with a grinder,

4. When

care-

safety, and

actions to deal with the situation.

PRECAUTIONS in operation

in this

be followed

keep tools and removed Mistakes

The

purpose.

the symbol

accompanying

fully. If any dangerous

GENERAL

recommended

for safe

and safe. Some of these techniques

by Komatsu

To prevent

important

the

machine

with

before starting 10. Remove

or assembling, blocks,

jacks

support or stands

work.

all mud and oil from

the steps or

other places used to get on and off the machine. Always

use the handrails,

ladders

steps when

getting

Never

on or off the machine.

jump

impossible

on or off the machine.

to use the handrails,

steps, use a stand to provide

If it is

ladders

safe footing.

00-3

SAFETY

PRECAUTIONS

DURING

19. Be sure to assemble

WORK

original 11. When or

removing

hydraulic

loosen them spurting

the oil filler cap, drain plug pressure

slowly

measuring

to prevent

plugs,

the oil from

out. disconnecting

nents

of the oil, water the

or removing

pressure

compo-

or air circuits, completely

first

from

the

circuit. 12. The

and

oil in the

the engine

circuits

is stopped,

are hot

so be careful

not to get burned. Wait

out any work

to cool before

on the oil or water

circuits.

the negative

(-) terminal

first. use a hoist

Check that the wire rope, chains and hooks are free from damage. Always

use

ample

capacity.

Install

the lifting

lifting

equipment

places.

Use

slowly

to prevent

a hoist

which

has

sure

installing

high pressure

that

are

they

ful when

installing

circuits.

Also,

or crane

and

the component

operate

part. Do not work with part still raised by the hoist or crane.

any

ting any other

21. When

assembling

removing

covers which are under in-

ternal

pressure

or under

spring,

always

leave

pressure

from

two

bolts in position

sides. Slowly

release the pres-

sure, then slowly loosen the bolts to remove. removing

to break

components,

or damage

be careful not

the wiring.

may cause electrical

Damaged

fires.

17. When

removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto

the floor, wipe it up immediately.

Fuel or oil

on the floor can cause you to slip, or can even start fires. 18. As a general

rule, do not use gasoline

wash

parts. In particular,

use only the mini-

mum

of gasoline

washing

when

or parts which

22. When

that

electrical

connecting

tightening parts

vibrate

aligning

fingers

caught

or rotate at

careful to check

correctly.

Be careful

not to get your

in a hole.

measuring

hydraulic

pressure,

that the measuring

tool is correctly

bled before taking

any measurements.

removing

tracks of track-type removing

When

such as guards,

two holes, never insert your

or hand.

When

parts

parts, always torques.

violently

be particularly

fingers

23. When

care-

tubes for high pressure

protective

high speed,

Damaged

so be extremely

or installing

use the specified

rates suddenly,

15. When

is be-

hoses, make

not twisted.

check

24. Take care when

hit-

on opposite

be sure

by contact

installed.

at the correct from

00-4

20. When

that they are installed

14. When raising heavy components, or crane.

parts.

hoses and wires,

ing operated.

installing

13. Before starting work, remove the leads from the battery. Always remove the lead from

wiring

installing

parts with new parts.

that they will not be damaged

are correctly

for the oil and water

carrying

16. When

Replace any damaged . When

tubes are dangerous,

water

when

all parts again in their

places.

with other parts when the machine

Before remove

NOTICE

check assem-

or installing

the

machines.

the track,

the track

sepa-

so never let anyone stand at

either end of the track.

GENERAL

FOREWORD

FOREWORD GENERAL This

shop

serviceman

manual

has been

an accurate

prepared

as an aid to improve

understanding

repairs and make judgements.

of the product

the quality

and by showing

Make sure you understand

of repairs

by giving

the

him the correct way to perform

the contents

of this manual

and use it to full

information

for operations

performed

in a

into the following

chapters;

these

effect at every opportunity.

This shop manual

mainly

service workshop.

For ease of understanding,

chapters

are further

STRUCTURE

contains

divided

AND

is divided

FUNCTION

an understanding

the structure

and function

of the structure,

In addition,

this section

maintenance

standards.

This

technical

the manual

into the each main group of components.

This section explains

TESTING

the necessary

of each component.

but also serves as reference

may contain

hydraulic

It serves not only to give

material

for troubleshooting.

electric

circuit diagrams,

and

AND ADJUSTING section

adjustments

explains

Troubleshooting DISASSEMBLY

checks

to be made

to be made at completion charts correlating

before

and after

performing

repairs,

as well

of the checks and repairs.

“Problems”

with “Causes” are also included

in this section.

AND ASSEMBLY

This section

explains

each component, MAINTENANCE

the procedures

for removing,

as well as precautions

installing,

disassembling

and assembling

for them.

STANDARD

This section

gives the judgment

The contents

of this section may be described

standards

for inspection

of disassembled

in STRUCTURE

AND

parts.

FUNCTION.

OTHERS This section

mainly

gives hydraulic

In addition,

this section

circuit diagrams

and electric

may give the specifications

circuit diagrams.

of attachments

and options together.

NOTICE The

specifications

contained

time

and

without

with

the

latest

any

advance

in this notice.

shop Use

manual the

are subject

specifications

to change given

in the

at any book

date.

00-5

HOW TO READ THE SHOP MANUAL

FOREWORD

HOW TO READ THE SHOP MANUAL VOLUMES

REVISED EDITION MARK

Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:

When

Chassis volume: issued for every machine model Engine volume: Issued for each engine series

pages.

Electrical volume: Attachments volume:

Each issued as one volume to cover all models

These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available.

a manual

(@@@...J

is revised,

is recorded

an edition

on the

bottom

mark of the

REVISIONS Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.

SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.

DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work.

FILING METHOD the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume): 1. See

Symbol

Item

Safety

Special safety precautions are

Example

cated

pages:

by a hyphen

page number. Example: IO-4 10-4-I k 1O-4-2 IO-5

00-6

Additional

pages -c~f~~~~~~ 12-204

performing

Weight

Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.

‘ighteninc torque

Places that require special attention for the tightening

torque during assembly.

Coat

Places to be coated with adhesives and lubricants, etc.

Xl, water

Places where oil, water or fuel must be added, and the capacity.

Drain

Places where oil or water must be drained, and quantity to be drained.

after the

12-203

when

Caution

pages are indi-

(-1 and number

File as in the example.

Added

el kg

2 (Engine volume):

Unit number (I. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item.

3. Additional

necessary the work.

Special technical precautions or other precautions for preserving standards are necessary when performing the work.

10 -3 Item number (IO. Structure and Function) Consecutive page number for each item.

Remarks

HOISTING INSTRUCTIONS

FOREWORD

HOISTING INSTRUCTIONS HOISTING

Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.

Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol &

If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: I)

Check for removal

of all bolts fastening

the part to the relative 2) Check for existence

of another

ing interference

the

with

71%

41%

part caus-

part to be re-

3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. Slinging with one 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.

WIRE ROPES 1) Use adequate

ropes

depending

of parts to be hoisted,

the table

on the

referring

below: 4)

Wire ropes (Standard “Z” or “S” twist ropes without galvanizing) Rope diameter

79%

88%

SAD00479

moved.

weight

100%

parts.

Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load kN {kg) when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN (1000 kg) vertically, at various hanging angles.

Allowable

load

tons

9.8

1.0

11.2

13.7

1.4

12.5

15.7

1.6

21.6

2.2

27.5

2.8

suspended.

35.3

3.6

(1000

43.1

4.4

hanging

22.4

54.9

5.6

98.1

10.0

176.5

18.0

274.6

28.0

392.2

40.0

When two ropes sling a load vertically, to 19.6 kN (2000 kg) of total weight This weight

kg) when angle.

two

becomes

ropes

make

On the other

ropes are subjected

can be 9.8 kN a 120”

hand,

to an excessive

two force

as large as 39.2 kN (4000 kg) if they sling a 19.6 kN (2000 kg) load at a lifting angle

The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used.

2) Sling wire ropes from the middle of the hook.

portion

Lifting

anele

tdeoree)

120

150 SAD00460

00-7

FOREWORD

METHOD OF DISASSEMBLING,

CONNECTING

PUSH-PULL TYPE COUPLER

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER * There are 2 types of push-pull type coupler. The method of disassembling and connecting is different, so see the table below when disassembling

and connecting

the coupler.

Type 2

Twe 1 1)

Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (I) contacts contact surface a of the hexagonal portion at the male end.

Hold in the condition in Step I), and push until cover (3) contacts contact surface a of the hexagonal portion at the male end.

Hold in the condition in Step I), and turn lever (4) to the right (clockwise).

-r 2 $ % .E 0

CWPO6394

CWPO6393

Hold in the condition in Steps 1) and 21, and pull out whole body (2) to disconnect it.

CWPO6395

00-8

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

CWPO6396

FOREWORD

METHOD OF DISASSEMBLING,

Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (I) contacts contact surface a of the hexagonal portion at the male end to connect it.

PUSH-PULL TYPE COUPLER

Type 2

Tvw 1 l

CONNECTING

Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.

00-9

COATING

FOREWORD

COATING

MATERIALS

t The *

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

Category

1 Komatsu code 1

Part No.

Q’ty

790-I 29-9070

LG-7

150 g

Container

Main

Tube

Silicon

based,

features

Features:

type Used as sealant for flywheel housing, intake manifold, oil an, thermostat housing,

Gasket sealant

quick

hardening

etc.

Three bond 1211

790-129-9090 I

100 g

Tube

LM-G

50 g

Can

Used as heat-resisting engine.

sealant

for repairing

I l

Molybdenum disulphide lubricant

applications,

09940-00051

Used as lubricant for sliding portion vent from squeaking).

(to pre-

Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting. Used as lubricant for linkage, bearings, etc.

General

LM-P

09940-00040

G2-LI

SYG2-4OOLI SYG2-35OLI SYG2-4OOLI-A SYG2-16OLI SYGA-IGOCNLI

GP-CA

SYG2-400CA SYG2-350CA SYGP-4OOCA-A SYG2-16OCA SYGA-15OCNCA

200 g

Various

Tube

type

Various

Grease

purpose

Used for normal bearing at places

temperature, light load in contact with water or

steam. Various

Various

Belows

Used for places with heavy

load

type

00-l1

STANDARD TIGHTENING TORQUE

FOREWORD

STANDARD

TIGHTENING

TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) *

In the case of metric nuts and bolts for which there is no special instruction,

tighten

to the torque

given in the table below.

Thread diameter of bolt

Width across flats

1.35~0.15 3.2+ 0.3 6.7kO.7 11.5il 1822

10 12 14

17 19 22

13.2+ 1.4 3153 66r7 113*10 177219

16 18 20 22 24

24 27 30 32 36

279230 382+39 549+59 745+83 927*103

28.5* 3 3924 5626 76~8.5 94.5* 10.5

27 30 33 36 39

41 46 50 55 60

1320~140 1720~190 2210~240 275Ok290 32901t340

135215 175220 225k25 280230 335235

, Thread

diameter

Width

of bolt

across flats

6 8 IO 12

10 13 14 27

7.852 1.95 18.62 4.9 40.225.9 82.3527.85

0.8kO.2 1.9kO.5 4.1 20.6 8.42 0.8

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS Sr In the case of flared nuts for which there is no special instruction,

tighten

to the torque

given in the table below. SAD00483

Thread

diameter

Tightenin! j torque

U-n

18 22

24 30

32 36 41

24.5 2 4.9 49* 19.6 78.5~ 19.6 137.3 * 29.4 176.5 + 29.4 196.12 49 245.2 z 49 294.2 2 49

2.5 2 0.5 522 822 1423 1823 2055 2525 3025

33 36 42

00-l 2

Width across flat T

46 55

STANDARD TIGHTENING TORQUE

FOREWORD

TABLE OF TIGHTENING +

TORQUES FOR SPLIT FLANGE

In the case of split flange

bolts for which

there

BOLTS

is no special

instruction,

tighten

to the torque

given in the table below.

Thread

diameter

Width

Tightening

across flat

torque

kgm

10 12 16

14 17 22

65.7r 6.8 11229.8 279229

6.72 0.7 11.551 28.5+3

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS * Unless there are special instructions, tighten the O-ring boss piping joints to the torque

Nominal

No.

Thread

diameter

Width

mm 02 03,04 05,06 10, 12 14

14 20 24 33 42

TABLE OF TIGHTENING

Unless there

Nominal 08 10 12 14 16 18 20 24 30 33 36 42 52

TORQUES

are special

No.

Varies depending type of connector.

torque

kom

34.3* 4.9 93.1k9.8 142.12 19.6 421.4258.8 877.1k132.3

3.5+ 0.5 9.5*1 14.522 4326 89.52 13.5

FOR O-RING BOSS PLUGS

instructions,

Thread

Tightening

across flat

below.

diameter

tighten

the O-ring

boss plugs to the torque

Width

across flat

-r

Tighteni

below.

I torque

kgm

8 10 12 14 16 18 20 24 30 33 36 42 52

14 17 19 22 24 27 30 32 32 -

7.352 1.47 II.272 1.47 17.64k1.96 22.54k1.96 29.4k4.9 39.2* 4.9 492 4.9 68.62 9.8 107.8k14.7 127.42 19.6 151.9524.5 210.7229.4 323.4~ 44.1

0.75kO.15 1.15~0.15 1.8r0.2 2.32 0.2 3r0.5 420.5 5%0.5 721 llT1.5 1322 15.52 2.5 21.5*3 33k 4.5

36 -

00-l 3

STANDARD TIGHTENING TORQUE

FOREWORD

TIGHTENING TORQUE FOR 102 ENGINE SERIIES (BOLT AND NUTS) Use these torques Thread

for bolts and nuts (unit: mm) of Cummins

diameter

Engine.

Tightening

6 8

torque

kgm

IO +2

1.02 _'0.20 2.45 ST0.41 4.38 2 0.61 7.85 f 1.22

24 k 4 43 + 6 77 f 12

10 12

TIGHTENING TORQUE FOR 102 ENGINE SERIIES (EYE JOINTS) Use these torques Thread

for eye joints (unit: mm) of Cummins

diameter

Engine. Tightening

torque

kgm

6 8 IO 12 14

822 10 22 12 k2 24 2 4 36 2 5

0.81 + 0.20 1.02 + 0.20 1.22 + 0.20 2.45 + 0.41 3.67 -'0.51

TIGHTENING TORQUE FOR 102 ENGINE SERIIES (TAPERED SCREWS) Use these torques Thread

00-14

for tapered

screws

(unit: inch) of Cummins

diameter

Engine.

Tightening

torque

inch

kgm

I/ 16 118 II4 318 l/2 314 1

321 822 12 i2 15 k2 24 2 4 36 k 5 60 2 9

0.31 r 0.10 0.81 f 0.20 1.22 + 0.20 1.53 + 0.41 2.45 r 0.41 3.67 2 0.51 6.12 +-0.92

ELECTRIC WIRE CODE

FOREWORD

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

CLASSIFICATION

BY THICKNESS Copper wire

N;tyaf;sof

Curre&rating

Applicable

Ca17kZjD.

circuit

0.85

0.32

0.88

2.4

Starting,

lighting,

0.32

2.09

3.1

Lighting,

signal etc.

0.32

5.23

4.6

Charging

and signal

0.45

13.36

7.0

Starting

(Glow

0.80

42.73

11.4

135

Starting

127

0.80

63.84

13.6

178

Starting

100

217

0.80

109.1

17.6

230

Starting

CLASSIFICATION

Dia. $$tr$nds Crosm$tion

signal etc.

plug)

BY COLOR AND CODE

1 Instrument

Signal

(

Other

Ground

Starting

Lighting

mary Color

White

Black

Red

Yellow

Green

Blue

Code

Black &White

Red & White

Rri_

Code

2 Color

White

& Red

Code

Color

White & Black

Black & Yellow

Red & Black

Ami-

Code

liary

Black & Red

Yellow & Red Green & White Blue & White YB

Color

White

& Blue

Yellow & Black Green & Red YG

Blue & Red LY

Red & Yellow Yellow & Green Green & Yellow Blue & Yellow

RG Red & Green RL Red & Blue

Yellow & Blue Green & Black Blue & Black YW Yellow &White Green

GL & Blue

00-l5

CONVERSION TABLE

FOREWORD

CONVERSION

TABLE

METHOD OF USING THE CONVERSION The

Conversion

details

Table

of the method

Convert (I)

is provided

of using the Conversion

EXAMPLE . Method of using the Conversion 1.

TABLE

in this section

to enable

Table,

Table to convert

simple

conversion

see the example

from millimeters

given

of figures.

For

below.

to inches

55 mm into inches.

Locate the number

50 in the vertical column at the left side, take this as @, then draw a horizontal

line from @. (2) Locate the number

5 in the row across the top, take this as @I, then draw a perpendicular

line

down from @. (3) Take the point where from millimeters 2.

the two lines cross as 0.

to inches.

Therefore,

This point @ gives the value when

converting

55 mm = 2.165 inches.

Convert 550 mm into inches.

(I) The number 550 does not appear in the table, so divide by IO (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

1 mm = 0.03937 in

0 0.394 0.787 1.181 1.575

0.039 0.433 0.827 1.220 1.614

0.079 0.472 0.866 1.260 1.654

0.118 0.512 0.906 1.299 1.693

0.157 0.551 0.945 1.339 1.732

0.197; 0.591 i 0.984: 1.378: 1.772; @ ;

0.236 0.630 1.024 1.417 1.811

0.276 0.669 1.063 1.457 1.850

0.315 0.709 1.102 1.496 1.890

0.354 0.748 1.142 1.536 1.929

.. . 50 . . .. . . . . . .. . .1.969. . . . .. . . . . . .. . .2.008 . . . . . . .. . . .. . .2.047 . . . .. . . .. . . . . . .2.087 . . . . . . .. . . .. . .2.126 . . . .. . .. . . . 12.1651 60 2.362 2.402 2.441 2.480 2.520 2.559 70 2.756 2.795 2.835 2.874 2.913 2.953 80 3.150 3.189 3.228 3.268 3.307 3.346 90 3.543 3.583 3.622 3.661 3.701 3.740

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.032 3.425 3.819

2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

0 10 20 30 40

00-l6

to inches

CONVERSIONTABLE

FOREWORD

Millimeters to inches

1 mm

= 0.03937

0.039

0.079

0.118

0.157

0.197

0.236

0.276

0.315

0.354

0.394

0.433

0.472

b.512

0.551

0.591

0.630

0.669

0.709

0.748

0.787

0.827

0.866

0.906

0.945

0.984

1.024

1.063

1.102

1.142

1.181

1.220

1.260

1.299

1.339

1.378

1.417

1.457

1.496

1.536

1.575

1.614

1.654

1.693

1.732

1.772

1.811

1.850

1.890

1.929

1.969

2.008

2.047

2.087

2.126

2.165

2.205

2.244

2.283

2.323

2.362

2.402

2.441

2.480

2.520

2.559

2.598

2.638

2.677

2.717

2.756

2.795

2.835

2.874

2.913

2.953

2.992

3.032

3.071

3.110

3.150

3.189

3.228

3.268

3.307

3.346

3.386

3.425

3.465

3.504

3.543

3.583

3.622

3.661

3.701

3.740

3.780

3.819

3.858

3.898

. Kilogram to Pound

1 kg = 2.2046

2.20

4.41

6.61

22.05

24.25

26.46

44.09

46.30

66.14

8.82

11.02

13.23

15.43

17.64

19.84

28.66

30.86

33.07

35.27

37.48

39.68

41.89

48.50

50.71

51.91

55.12

57.32

59.53

61.73

63.93

68.34

70.55

72.75

74.96

77.16

79.37

81.57

83.78

85.98

88.18

90.39

92.59

94.80

97.00

99.21

101.41

103.62

105.82

108.03

110.23

112.44

114.64

116.85

119.05

121.25

123.46

125.66

127.87

130.07

132.28

134.48

136.69

138.89

141.10

143.30

145.51

147.71

149.91

152.12

154.32

156.53

158.73

160.94

163.14

165.35

167.55

169.76

171.96

174.17

176.37

178.57

180.78

182.98

185.19

187.39

189.60

191.80

194.01

196.21

198.42

200.62

202.83

205.03

207.24

209.44

211.64

213.85

216.05

218.26

00-17

CONVERSIONTABLE

FOREWORD

Liter to U.S.Gallon

le = 0.2642

U.S. Gal

0.264

0.528

0.793

1.057

1.321

1.585

1.849

2.113

2.378

2.642

2.906

3.170

3.434

3.698

3.963

4.227

4.491

4.755

5.019

5.283

5.548

5.812

6.076

6.340

6.604

6.869

7.133

7.397

7.661

7.925

8.189

8.454

8.718

8.982

9.246

9.510

9.774

10.039

10.303

10.567

10.831

11.095

11.359

11.624

11.888

12.152

12.416

12.680

12.944

13.209

13.473

13.737

14.001

14.265

14.529

14.795

15.058

15.322

15.586

15.850

16.115

16.379

16.643

16.907

17.171

17.435

17.700

17.964

18.228

18.492

18.756

19.020

19.285

19.549

19.813

20.077

20.341

20.605

20.870

21.134

21.398

21.662

21.926

22.190

22.455

22.719

22.983

23.247

23.511

23.775

24.040

24.304

24.568

24.832

25.096

25.361

25.625

25.889

26.153

le = 0.21997

U.K. Gal

Liter to U.K. Gallon

0.220

0.440

0.660

0.880

1.100

1.320

1.540

1.760

1.980

2.200

2.420

2.640

2.860

3.080

3.300

3.520

3.740

3.950

4.179

4.399

4.619

4.839

5.059

5.279

5.499

5.719

5.939

6.159

6.379

6.599

6.819

7.039

7.259

7.479

7.969

7.919

8.139

8.359

8.579

8.799

9.019

9.239

9.459

9.679

9.899

10.119

10.339

10.559

10.778

10.998

11.281

11.438

11.658

11.878

12.098

12.318

12.528

12.758

12.978

13.198

13.418

13.638

13.858

14.078

14.298

14.518

14.738

14.958

15.178

15.398

15.618

15.838

16.058

16.278

16.498

16.718

16.938

17.158

17.378

17.598

17.818

18.037

18.257

18.477

18.697

18.917

19.137

19.357

19.577

19.797

20.017

20.237

20.457

20.677

20.897

21.117

21.337

21.557

21.777

00-18

CONVERSIONTABLE

FOREWORD

kgm to ft. lb 1 kgm = 7.233 ft. lb 0

7.2

14.5

.21.7

28.9

36.2

43.4

50.6

57.9

65.1

72.3

79.6

86.8

94.0

101.3

108.5

115.7

123.0

130.2

137.4

144.7

151.9

159.1

166.4

173.6

180.8

188.1

195.3

202.5

209.8

217.0

224.2

231.5

238.7

245.9

253.2

260.4

267.6

274.9

282.1

289.3

296.6

303.8

311.0

318.3

325.5

332.7

340.0

347.2

354.4

361.7

368.9

376.1

383.4

390.6

397.8

405.1

412.3

419.5

426.8

434.0

441.2

448.5

455.7

462.9

470.2

477.4

484.6

491.8

499.1

506.3

513.5

520.8

528.0

535.2

542.5

549.7

556.9

564.2

571.4

578.6

585.9

593.1

600.3

607.6

614.8

622.0

629.3

636.5

643.7

651.0

658.2

665.4

672.7

679.9

687.1

694.4

701.6

708.8

716.1

100

723.3

730.5

737.8

745.0

752.2

759.5

766.7

773.9

781.2

788.4

110

795.6

802.9

810.1

817.3

824.6

831.8

839.0

846.3

853.5

860.7

120

868.0

875.2

882.4

889.7

896.9

904.1

911.4

918.6

925.8

933.1

130

940.3

947.5

954.8

962.0

969.2

976.5

983.7

990.9

998.2

1005.4

140

1012.6

1019.9

1027.1

1034.3

1041.5

1048.8

1056.0

1063.2

1070.5

1077.7

150

1084.9

1092.2

1099.4

1106.6

1113.9

1121.1

1128.3

1135.6

1142.8

1150.0

160

1157.3

1164.5

1171.7

1179.0

1186.2

1193.4

1200.7

1207.9

1215.1

1222.4

170

1129.6

1236.8

1244.1

1251.3

1258.5

1265.8

1273.0

1280.1

1287.5

1294.7

180

1301.9

1309.2

1316.4

1323.6

1330.9

1338.1

1345.3

1352.6

1359.8

1367.0

190

1374.3

1381.5

1388.7

1396.0

1403.2

1410.4

1417.7

1424.9

1432.1

l439.b

00-19

CONVERSIONTABLE

FOREWORD

kg/cm*

to lb/in* Ikg/cm2 = 14.2233lb/in2 0

14.2

28.4

42.7

56.9

71.1

85.3

99.6

113.8

128.0

142.2

156.5

170.7

184.9

199.1

213.4

227.6

241.8

256.0

270.2

284.5

298.7

312.9

327.1

341.4

355.6

369.8

384.0

398.3

412.5

426.7

440.9

455.1

469.4

483.6

497.8

512.0

526.3

540.5

554.7

568.9

583.2

597.4

611.6

625.8

640.1

654.3

668.5

682.7

696.9

711.2

725.4

739.6

753.8

768.1

782.3

796.5

810.7

825.0

839.2

853.4

867.6

881.8

896.1

910.3

924.5

938.7

953.0

967.2

981.4

995.6

1010

1024

1038

1053

1067

1081

1095

1109

1124

1138

1152

1166

1181

1195

1209

1223

1237

1252

1266

1280

1294

1309

1323

1337

1351

1365

1380

1394

1408

100

1422

1437

1451

1465

1479

1493

1508

1522

1536

1550

110

1565

1579

1593

1607

1621

1636

1650

1664

1678

1693

120

1707

1721

1735

1749

1764

1778

1792

1806

1821

1835

130

1849

1863

1877

1892

1906

1920

1934

1949

1963

1977

140

1991

2005

2020

2034

2048

2062

2077

2091

2105

2119

150

2134

2148

2162

2176

2190

2205

2219

2233

2247

2262

160

2276

2290

2304

2318

2333

2347

2361

2375

2389

2404

170

2418

2432

2446

2460

2475

2489

2503

2518

2532

2546

180

2560

2574

2589

2603

2617

2631

!646

2660

2674

2688

190

2702

2717

2731

2745

2759

2773

2788

2802

2816

2830

200

2845

2859

2873

2887

2901

,916

2930

2944

2958

2973

210

,987

3001

3015

3030

3044

3058

3072

3086

3101

3115

220

3129

3143

3158

3172

3186

3200

3214

3229

3243

3257

230

3271

3286

3300

3314

3328

3343

3357

3371

3385

3399

240

3414

3428

3442

3456

3470

3485

3499

3513

3527

3542

00-20

CONVERSION TABLE

FOREWORD

Temperature Fahrenheit-Centigrade ture reading

; a simple

Conversion

way to convert

or vice versa is to enter the accompanying

a Fahrenheit

table

temperature

reading

into a Centigrade

tempera-

in the centeror boldface column of figures.

These figuresrefertothetemperature in eitherFahrenheitor Centigrade degrees. If it is desired temperatures

to convert

from

Fahrenheit

and read the corresponding

If it is desired to convert

from Centigrade

and read the corresponding

Fahrenheit

to Centigrade Centigrade

to Fahrenheit temperature

degrees,

temperature degrees,

consider

the center

in the column

column

as a table

of Fahrenheit

at the left.

consider the center column

as a table of Centigrade

values,

on the right. 1°C = 33.w

“C

“F

“C

“F

“C

“F

“C

“F

-40.4

-40

-40.0

-11.7

51.8

7.8

114.8

27.2

117.8

-37.2

-35

-31.0

-11.1

53.6

8.3

116.6

27.8

179.6

-34.4

-30

-22.0

-10.6

55.4

8.9

118.4

28.3

181.4

-31.7

-25

-13.0

-10.0

57.2

9.4

120.2

28.9

183.2

-28.9

-20

-4.0

-9.4

59.0

10.0

122.0

29.4

185.0

-28.3

-19

-2.2

-8.9

60.8

10.6

123.8

30.0

186.8

-27.8

-18

-0.4

-8.3

62.6

11.1

125.6

30.6

188.6

-27.2

-17

1.4

-7.8

64.4

11.7

127.4

31.1

190.4

-26.7

-16

3.2

-7.2

66.2

12.2

129.2

31.7

192.2

-26.1

-15

5.0

-6.7

68.0

12.8

131.0

32.2

194.0 195.8

-25.6

-14

6.8

-6.1

69.8

13.3

132.8

32.8

-25.0

-13

8.6

-5.6

71.6

13.9

134.6

33.3

197.6

-24.4

-12

10.4

-5.0

73.4

14.4

136.4

33.9

199.4

-23.9

-11

12.2

-4.4

75.2

15.0

138.2

34.4

201.2

-23.3

-10

14.0

-3.9

77.0

15.6

140.0

35.0

203.0

-22.8

-9

15.8

-3.3

78.8

16.1

141.8

35.6

204.8

-22.2

-6

17.6

-2.8

80.6

16.7

143.6

36.1

206.6

-21.7

-7

19.4

-2.2

82.4

17.2

145.4

36.7

208.4

-21.1

-6

21.2

-1.7

84.2

17.8

147.2

37.2

210.2

-20.6

-5

23.0

-1.1

86.0

18.3

149.0

37.8

100

212.0

-20.0

-4

24.8

-0.6

87.8

18.9

150.8

40.6

105

221.0

-19.4

-3

26.6

89.6

19.4

152.6

43.3

110

230.0

-18.9

-2

28.4

0.6

91.4

20.0

154.4

46.1

115

239.0

-18.3

-1

30.2

1.1

93.2

20.6

156.2

48.9

120

248.0

-17.8

32.0

1.7

95.0

21.1

158.0

51.7

125

257.0

-17.2

33.8

2.2

96.8

21.7

159.8

54.4

130

266.0

-16.7

35.6

2.8

98.6

22.2

161.6

57.2

135

275.0

-16.1

37.4

3.3

100.4

22.8

163.4

60.0

140

284.0

-15.6

39.2

3.9

102.2

23.3

165.2

62.7

145

293.0

-15.0

41.0

4.4

104.0

23.9

167.0

65.6

150

302.0

-14.4

42.8

5.0

105.8

24.4

168.8

68.3

155

311.0

-13.9

44.6

5.6

107.6

25.0

170.6

71.1

160

320.0

-13.3

46.4

6.1

109.4

25.6

172.4

73.9

165

329.0

-12.8

48.2

6.7

111.2

26.1

174.2

76.7

170

338.0

-12.2

50.0

7.2

113.0

26.7

176.0

79.4

175

347.0

00-21

UNITS

FOREWORD

UNITS In this manual,

the measuring

units are indicated

conventionally

used Gravitational

As for reference,

Example: N {kg} Nm {kgm} MPa (kg/cm21 kPa ImmHzOI kPa {mmHg) kw/rpm

IHP/rpmI

glkwh @/I-W-i1

00-22

with lnternatinal System

System

of units (SI).

of units are indicated

in parentheses

{

GENERAL

............... General assembly drawing .......................... Specifications Weight table ........................... ............... List of lubricant and water

D275A-2

Ol- 2 01- 3 Ol- 8 01-10

01-l

GENERAL ASSEMBLY DRAWING SEMI U-DOZER WITH VARIABLE

MULTIPLE

RIPPER

17MF02001

01-2

D275A-2

SPECIFICATIONS

Machine

D275A-2

model

Serial numbers

10168 and up

10001 - 10167

Operating weight l

Bare tractor

37200

With semi U-dozer

44180

Semi U-dozer with variable multiple ripper

48830 50000

+ with ROPS cab assembly Minimum turning radius

3.9

Grade ability

degree

Stabilitiy (Front, rear, left, right)

degree

1st

2nd

3rd

$ 1st & 2 2nd

km/h

3.8

6.7

O-11.8

km/h

4.9

8.7

0 - 14.9

cT 3rd Bare tractor

8.63 IO.881

With Semi U-dozer

10.29 (1.05)

kPa Semi U-dozer with variable multiple ripper Semi U-dozer with variable multiple ripper (kg/cm*}

11.67 {1.19}

11.37 11.16)

+ with ROPS cab assembly Bare tractor With Semi U-dozer

5445 mm

Semi U-dozer with variable multiple ripper Bare tractor

Track gauge

2260 mm

Show width Minimum ground clearance

3875 2880

Except exhaust pipe, operatior’s seat

Length of track on ground

2935 4300

Wtih Semi U-dozer To top of exhaust pipe

7085 9055

3450 610

507

01-3 @

Machine

D275A-2

model

Serial numbers Engine

10001

Piston displacement

Flywheel

horsepower

Max. torque

S6D170-2

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

6-170x170

23150

kW/rpm :HP/rpmI

302/l ,800 141 O/l ,800)

302/I ,800 (41 O/l ,800)

Nm/rpm cgmlrpm

2,079/l

,300 (2 12/l ,300)

High idling speed

rpm

2,000

Low idling speed

rpm

630

214 {I581

224 {I651

Min. fuel consumption Starting

ration

$-cycle, water-cooled, in-line vertical, direct injection type with turbocharger

Type

x stroke

and

S6D170-1

model

No. of cylinders-bore

10168

- 10167

g/kWh {glpshl

motor

24V, 7.5kw x 2

Alternator

24V, 50A

Battery

12V, 170Ah x 2 ZG

Radiator

core

Torque

converter

D type 3-element,

l-stage, single phase (with lock-up clutch)

Transmission

Planetan/ gear, multiple disc clutch, hydraulically actuated, force-feed lubrication pump, forward B-speed, reverse 3-speed

Bevel gear

Spiral bevel gear, splash type lubrication

Steering

clutch

Wet type, multiple clutch disc, spring boosted, hydraulically actuated (manual type), interconnected with brake

Steering

brake

Wet type, multiple clutch disc, spring boosted, hydraulically actuated (pedal operated, manual type), interconnected with clutch Spur gear l-stage, planetary gear l-stage reduction, splash type lubrication

Final drive Suspension Carrier

Semi-rigid

roller

balancing beam type 2 (each)

Track roller

8 (each)

Track shoe type

Assembly type, single grouser

No. of shoes

39 (each)

Pitch

260.35

Width

610

01-4 @

2 ;;

Machine

model

D275A-2

Serial numbers

RPafkglcm:

Relief valve setting Hydraulic

pump type

Delivery

(at engine

. Blade

lift control

. Blade tilt control Ripper

high valve

Hydraulic

cylinder

10001

- 10167

1,800 rpm)

L?/min

valve

x 2EARlOO

+ 050)

288

Single spool type with demand spool

and ripper low valve

3-tandem spool type 2-tandem pilot spool type

type

Cylinder

bore

Outside

diameter

Reciprocal, piston type 130

of Piston rod

80 mm

Piston stroke

1,420

Max. distance

between

Pins

2,365

Min. distance

between

Pins

945

Cylinder

bore

Outside

diameter

200 of Piston rod

100 mm

Piston stroke Max.

and

20.6 (210) Gear type, 2 tandem

speed

10168

190

distance

between

Pins

1,555

Min. distance

between

Pins

1,365

Cylinder

bore

Outside

diameter

200 of Piston rod

100 mm

Piston stroke

465

Max. distance

between

Pins

1,565

Min. distance

between

Pins

1,100

01-5 @

‘efformance limension

Dozer equipment

Wrk.equipment o

017M02

Jin puller cylinder

cylinder

Dual tilt cylinder

Hydraulic Gpper tilt cylinder

D L¶

Machine

model

D275A-2

Serial numbers

10001

Type

- 10167

10168

Variable angle type, parallelogram

Weight

4,490

Beam length

2,495

No. of shanks Ripping

angle

Ripping

depth

Max. digging

(standard)

degree

51.7 (Possible to adjust steplessly 36.9 - 61.2) P-stage selection possible

depth

900

955 Variable angle type, parallelogram

Type Weight

3,640

Beam length

1,252

No. of shanks angle

Ripping

depth

Max. digging Max. lifting

type

Max. lifting height

Ripping

and up

type

1 (standard)

degree

52.7 (Possible to adjust steplessly 39.7 - 62.2) 3-stage selection possible

depth height

1.300

870

01-7 @

WEIGHT TABLE

A This weight table is a guide for use when transporting or handling components. Machine model

D275A-2

Serial numbers

10001 and up

Engine and damper assembly

2810

Engine assembly

2580

Damper assembly

160

Engine mounting parts

Radiator assembly

350

Oil cooler assembly

100

Fuel tank assembly (Full)

Unit: kg

390 (1150)

Power train unit Power train assembly

3360

Torque converter and PTO assembly

740

Transmission

assembly

890

Transmission

control valve assembly

Steering clutch and brake assembly Steering control valve assembly

1600 60

Final drive assembly (each side)

1940

Main frame assembly

4200

Track group assembly (each side)

4100

Track frame

1200

Idler assembly

340

Track roller assembly (single) (each)

110

Track roller assembly (double) (each)

120

Carrier roller assembly (each)

Track shoe assembly (width 610 mm)

6800

Pivot shaft (each side)

145

Equalizer bar

255

Bolster

195

Hydraulic tank assembly

350

Blade lift control valve assembly

Blade tilt and ripper low valve assmebly

01-8

D275A-2

Unit: kg Machine model Serial numbers

Semi-U dozer assembly

D275A-2

10001 and up 6330

Blade

2980

L.H. straight frame

780

R.H. straight frame

780

Tilt cylinder assembly

220

Variable multiple shank ripper assembly l

Shank assembly (each)

350

Lift cylinder assembly

205

Tilt cylinder assembly

185

Variable giant ripper assembly

3600

Shank assembly

500

Lift cylinder assembly

205

Tilt cylinder assembly

185

Radiator guard assembly (with cylinder yoke)

1700

Radiator guard

750

Blade lift cylinder assembly (each side)

210

Front guard (with grille)

330

Engine under guard

260

Power train under guard

330

Engine hood

L.H. fender

300

R.H. fender

320

ROPS mount assembly

500

ROPS assembly

580

Floor frame assembly

320

Cab assembly

490

Operator’s seat assembly

D275A-2

01-9

TABLE OF FUEL, COOLANT AND LUBRICANTS

KIND OF FLUID

RESERVOIR

AMBIENT TEMPERATURE -22

-4

Engine oil pan

Power train oil pan (Incl. torque converter, transmission and bevel gear case) Engine oil

Hydraulic tank

Gear oil

Fuel tank

Diesel fuel

Cooling system

Add antifreeze

Coolant

ASTM: SAE: API:

l/4 of regular interval

American Society of Testing and Material Society of Automotive Engineers American Petroleum Institute

(2) When starting the engine in an atmospheric temperature of lower than O”C, be sure to use and SAEIOW-30 oil of SAEIOW, engine even though an atmospheric temSAEl5W-40 perature goes up to 10°C more or less in the day time. (3) Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half. (4) There is no problem if single grade oil is mixed with multigrade oil (SAEIOW-30, 15W-40), but be sure to add single grade oil that matches the temperature in the table on the left. Komatsu genuine oil which (5) We recommend has been specifically formulated and approved for use in engine and hydraulic work equipment applications.

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

01-10 @ .*-

ASTM D975 No. 1

NOTE: (1) When fuel sulphur content is less than 0.5 %, change oil in the oil pan every periodic maintenance hours described in this manual. Change oil according to the following table if fuel sulphur content is above 0.5 %.

Above 1 .O %

136

STRUCTURE AND FUNCTION

General ...................................................... IO- 2 Power train ............................................... IO- 3 Power train unit.. ...................................... IO- 4 Power train unit mount ........................... IO- 5 Power train piping ................................... IO- 7 Power train hydraulic circuit diagram ... IO- 8 Damper and universal joint .................... IO-IO Torque converter . PTO ........................... IO-12 Torque converter valve ........................... IO-16 Transmission ............................................ IO-24 Transmission control ............................... IO-29 Transmission control valve ..................... IO-30 Transmission lubrication relief valve.. ... IO-37 Scavenging pump .................................... IO-38 Oil strainer ................................................ IO-39 Power train oil filter and lubrication oil filter.. ....................... IO-40 Steering unit ............................................. IO-42 Transfer, bevel pinion.. ............................ IO-44 Bevel gear, steering clutch and steering brake ................................. IO-46 Steering control ........................................ IO-51 Steering control valve ............................. IO-52 Final drive ................................................. IO-60 Main frame ............................................... IO-63 Track group.. ............................................. IO-64 Recoil spring ............................................. IO-65 Suspension ............................................... IO-66 Hydraulic piping ....................................... IO-69 l Blade .................................................... IO-69 l Variable multiple shank ripper.. ........ IO-70 l Variable giant ripper.. ......................... 10-70-I Hydraulic control ...................................... IO-71 l Blade control ....................................... IO-71 l Blade control (for dual tilt dozer). ..... IO-72 l Ripper control ..................................... IO-73 Hydraulic circuit system .......................... IO-74 Hydraulic circuit diagram ........................ IO-75 Hydraulic tank.. ......................................... IO-77

D275A-2

Blade lift control valve ............................. IO- 78 Blade tilt control and ripper low valve ... IO- 82 Ripper high valve ................................... IO- 84 Ripper tilt suction valve.. ....................... IO- 86 Piston valve ............................................ IO-104 Quick drop valve .................................... IO-105 Cylinder stay.. ......................................... IO-106 Semi U-dozer .......................................... IO-108 10-110 Ripper ...................................................... l Variable multiple shank ripper.. ...... IO-I 10 l Variable giant ripper.. ....................... IO-I 12 Pin-puller solenoid valve.. ..................... IO-I 12-2 Electrical circuit diagram ....................... IO-I 14 l Chassis electrical circuit diagram.. .. IO-I 14 l Cab electrical circuit diagram.. ........ 10-118-4 l Air conditioner electrical circuit diagram ............... IO-I 18-6 EVMS (Electrical vehicle monitoring system) ... IO- 119 APS control system ............................... IO-132 Torque converter lock-up control system ...................................... IO-133 For SSC system Machine monitor system (with SSC system) ............................... IO-137 Model selection system.. ....................... IO-I 42 Engine control system ........................... IO-157 ELPC controller.. ..................................... IO-152 ELPC actuator ......................................... IO-I 54 Torque converter lock-up control system ...................................... IO-161

10-l 0

GENERAL

1. Engine (S6D170) 2. Damper 3. Universal joint 4. Torque converter 5. TORQFLOW transmission

The power produced by diesel engine (1) goes from the engine flywheel to torque converter (4) through damper (2) and universal joint (3). The torque converter (4) transmits the power to transmission (5) by converting the mechanical energy - fluid energy mechanical energy. The transmission (5), with a planetary gear mechanism and a hydraulic control unit combined, allows an easy selection of three forward speeds and three reverse speeds. Through the drive shaft, the power is transmitted from transmission (5) to transfer drive gear (6) on the rear of the machine body. The transfer gears reduce the speed and, then, the power is transmitted to bevel pinion. Bevel pinion and bevel gear direct the power to the right and left, and the power is transmitted to the left and right steering clutches (7) and final drives (9).

1 o-2

6. 7. 8. 9. 10. 11.

Transfer Steering clutch Steering brake Final drive Sprocket Track

F19702001

The steering clutch connects and disconnects the power from the bevel gear shaft to final drive (9). SO that the traveling direction of the machine is controlled (steering). For example, when the R.H. steering lever is pulled, the steering control valve linked to the lever is operated, the power is disconnected, and the machine turns to the right. Steering brake (8) is installed between steering clutch (7) and final drive (9). It is the same type as the steering clutch. Steering brake (8) not only stops the machine, but also controls the turning radius of the machine. Final drive reduces the revolution speed by spur gear single reduction and planetary gear system, and the revolution speed is transmitted to sprocket (10). Sprocket (10) drives track (11).

D275A-2

POWER TRAIN

17 M F02002A

1. 2. 3. 4. 5.

Engine (S6D170) Damper Universal joint Torque converter Transmission

6. 7. 8. 9. 10.

Transfer Steering clutch Steering brake Final drive Sprocket

11. 12. 13. 14. 15.

Track shoe PTO Power train pump (BALI 00 + 140) Scavenging pump (BAR63 + 200) Hydraulic pump (SAR(3)lOO + (2)50)

10-3 0

POWER TRAIN UNIT

I4 D275A-2 10061 and up

A 6 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

PTO Torque converter Torque converter valve Transmission control valve Transmission Steering clutch and brake Steering control valve Power train pump Power train oil filter Power train oil strainer Scavenging pump Power train oil tank

OUTLINE 0 The power train unit can be broadly divided into the torque converter and transmission unit and the steering unit. Therefore, after removing the power train as a unit, it can be disassembled into the torque converter and transmission unit and the steering unit. The steering unit consists of the transfer, bevel gear shaft, steering clutch, and steering brake. 17MF02003B

POWER TRAIN UNIT MOUNT

9 10 11

A-A 17MF02004

1. 2. 3. 4. 5. 6.

D275A-2

Main frame PTO Torque converter Transmission Steering clutch and brake Cage

7. 8. 9. 10. 11.

Clamp Seal Cover Coupling Cap

1o-5

Oil cooler Power train lubrication oil filter Power train oil filter Torque converter valve Transmission control valve Steering control valve Oil tank Power train oil strainer Power train pump Scavenging pump

D275A-2

1 o-7

setpressure 2.7 kg/cm2

! r

pressure i--J Se 1!7I f 1 kg/cm2

Cracking pressw 1.4 kg/cm2

:racking ,VZS”E

ir i

.4 kg/cm*

; 46 F17M02001A

Plug for transmission main relief pressure Plug for torque converter relief pressure Plug for torque converter regulator pressure Plug for torque converter stator clutch modulating pressure Plug for torque converter lock-up pressure Plug for transmission reducing pressure Plug for R.H. steering clutch pressure Plug for R.H. brake pressure Plug for L.H. brake pressure Plug for L.H. steering clutch pressure

1 O-8 0

1. Oil tank 2. Power train oil strainer 3. Power train pump (BALI401 4. Power train lubrication pump (BALIOO) 5. Power train oil filter 6. Main relief valve 7. Modulating valve 8. Quick return valve 9. Reducing valve 10. Transmission F-R valve 11. Transmission speed valve 12. Reverse clutch 13. Forward clutch 14. 3rd speed clutch 15. 2nd speed clutch 16. 1st speed clutch 17. Power train lubrication oil filter 18. PTO lubrication 19. Transmission lubrication valve 20. Transmission lubrication 21. Transmission case 22. Torque converter relief valve 23. Torque converter case 24. Torque converter 25. Torque converter lock-up modulating valve 26. Torque converter lock-up clutch 27. Stator clutch modulating valve 28. Stator clutch 29. Torque converter lock-up selector valve 30. Torque converter lock-up solenoid valve 31. Stator and clutch lubrication 32. R.H. steering clutch valve 33. R.H. brake valve 34. L.H. brake valve 35. L.H. steering clutch valve 36. Pin puller solenoid valve 37. Pin puller cylinder 38. Steering clutch and brake lubrication 39. R.H. Steering clutch 40. R.H. Brake 41. L.H. Brake 42. L.H. Steering clutch 43. Steering case 44. Scavenging pump (BAR63 + 200) 45. Oil cooler 46. Oil filler

E 6

DAMPER AND UNIVERSAL JOINT

r-7

17MF02007

10-10

D275A-2

OUTLINE The damper acts as a cushion to prevent the vibration of the engine from being transmitted directly to the torque converter and transmission. The power from the engine is transmitted to damper outer body (1) through flywheel (9). The power is absorbed the engine vibration by rubber coupling (7), and is transmitted to shaft (8) and universal joint (4), and then is transmitted to the torque converter. As the damper uses rubber, it absorbs the vibration by the vibration-reducing effect of rubber, and the twist by the friction-reducing effect of the deformation of the rubber. The number of part is fewer than the friction plate type damper.

I. 2. 3. 4. 5. 6. 7. 8. 9.

Outer body Oil level gauge Coupling Universal joint Flange Cover Rubber coupling Output shaft Engine flywheel

D275A-2

10-11

TORQUE CONVERTER

PTO 1

‘C.

A. B. C.

17MF02008

Mount of hydraulic pump Mount of power train pump Mount of scavenging pump

1. Coupling 2. Seal cage 3. Input shaft [PTO drive gear (61 teeth)] 4. Front housing 5. Idler gear (77 teeth) 6. Idler gear shaft 7. Clutch housing 8. Drive case 9. Turbine IO. Rear housing 11. Stator 12. Pump

10-12

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.

Stator shaft Bearing cage Retainer Shaft Transmission input shaft Stator shaft boss Stator clutch housing Return spring Stator clutch plate Stator clutch disc Stator clutch piston Turbine boss Lock-up clutch disc

26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37.

Lock-up clutch plate Lock-up clutch piston Scavenging pump gear (63 teeth) Scavenging pump boss Seal seat Spacer Cover Hydraulic pump gear (57 teeth) Power train pump gear (57 teeth) Drive shaft Cover Cover

37'

z-z

17MF02009

D275A-2

OUTLINE 0 The torque converter is a 3-element, singlestage, l-phase torque converter, and it forms a single structure with the transmission. To improve the fuel consumption and ease of operation and to reduce consumption of the engine horsepower, a wet-type, multiple-disc clutch type torque converter lock-up device and a wettype, double-disc stator clutch device are assembled inside it. 0 When the machine is carrying out continuous low-load dozing or grading operations, it is more efficient if the motive power of the engine is transmitted directly to the transmission input shaft. To achieve this, a lock-up clutch actuated by hydraulic pressure is assembled inside the torque converter. When the torque converter is locked up (the pump and turbine form one unit), the oil supplied from the torque converter relief valve does not stop, so the oil leaving the turbine from the pump is given unneeded direction by the stator, and this resists the rotation of the pump and turbine (the oil is churned). To prevent this, a stator clutch similar to the lock-up clutch is built in. This allows the stator to rotate freely when the torque converter is locked up. The oil then moves together with rotation of the pump and turbine; it is discharged from the pump and turbine with little resistance, and is returned to the pump. * The condition for the torque converter to enter the lock-up range and torque converter range are as follows. 0 Lock-up range When both of the following conditions are fulfilled: Torque converter output shaft speed: Above 1170 rpm Transmission set pressure: ‘_ Above 19.5 kg/cm2 0 Torque converter range When either of the following conditions are fulfilled. Torque converter output shaft speed: Below 1110 rpm Transmission set pressure: Below 15 kg/cm2

D275A-2

STRUCTURE 0 Pump (12) forms one unit with coupling (I), shaft (3), clutch housing (7), and drive case (8); and is rotated by the motive force from the engine. l Turbine (9) forms one unit with turbine boss (24) and transmission input shaft (turbine shaft) (17), and is rotated by oil from the pump. 0 Stator (11) forms one unit with stator shaft (13) and stator shaft boss (18), and is locked to rear housing (10) by the stator clutch. 0 The lock-up clutch consists of three parts: clutch plate (26) (meshed with drive case (8)), clutch disc (25) (meshed turbine boss (24)), and clutch piston (27) (that slides inside housing (7) that forms one unit with the drive case). l The stator clutch consists of three parts: clutch disc (22) (meshed with boss (18) that is connected by a spline to stator shaft (13)), clutch plate (21) (supported by a pin to clutch housing (19) and rear housing (IO)), and clutch piston (23) (that slides inside the rear housing). 0 The PTO consists of a drive gear forming one unit with input shaft (3), idler gear (5), scavenging pump drive gear (28), hydraulic pump drive gear (33), and power train pump drive gear (34).

10-13

PATH OF TRANSMISSION

OF MOTIVE

FORCE

1. Lock-up clutch OFF, stator clutch ON When the lock-up clutch is OFF, the connection between drive case (8) and turbine (9) is cut; and when the stator clutch is ON, rear housing (IO) and stator shaft (13) are connected, so stator (11) is locked and the torque converter provides the normal functions of a torque converter. The motive force generated by the engine passes through the damper and universal joint, and is transmitted to coupling (1). Input shaft (3), clutch housing (7), drive case (8), and pump (12) rotate as one unit. The motive force from the pump uses oil to rotate turbine (9), and is transmitted to transmission input shaft (17), that forms one unit with the turbine.

Lock-up clutch

Stator Clutch 17MF02010

2. Lock-up clutch ON, stator clutch OFF When the lock-up clutch is ON, drive case (8) and turbine (9) are connected to form one unit; and when the stator clutch is OFF, the connection between rear housing (10) and stator shaft (13) is cut, so stator (11) follows the rotation of pump (12) and turbine (9). The motive force generated by the engine passes through the damper and universal joint, and is transmitted to coupling (1). Input shaft (3), clutch housing (7), drive case (8), and pump (12) rotate as one unit. In addition, the drive case and turbine (9) _ are connected by the clutch, so the oil is 4 not used. The motive force is transmitted directly to the turbine and transmission input shaft (17).

3!3

Lock-up clutch

110 ,,,I

Stator clutch 17MF02011

10-14

D275A-2

FLOW OF OIL 0 Oil set to within Max. 10 kg/cm2 by the torque converter relief valve flows from port A, passes through the oil hole inside rear housing (IO), and enters pump (12). The pump is always being rotated by the motive force from the engine, so the oil entering the pump is given centrifugal force, and enters turbine (9). The turbine is rotated by the centrifugal force of the oil. The turbine forms one unit with transmission input shaft (17), so the motive force received by the turbine is transmitted to the transmission. The oil leaving the turbine is sent to stator (11) and enters the pump again, but some of the oil passes from the stator through port B and is sent to the oil cooler.

D275A-2

10-15

TORQUE CONVERTER VALVE

A-A Pl \

17MF02013

1. Valve body 2. Torque converter relief valve 3. Valve spring 4. Valve spring 5. Main relief valve 6. Cover 7. Piston 8. Piston spring 9. Piston IO. Stator clutch modulating valve 11. Lock-up clutch modulating valve 12. Cover 13. Piston 14. Piston spring (Small) 15. Piston 16. Valve spring (Outer) 17. Valve spring (Inner)

lo-16

18. Stopper 19. Load piston 20. Cover 21. Cover 22. Valve spring 23. Valve body 24. Lock-up selector valve 25. Piston 26. Cover Lock-up solenoid valve assembly 27. Push pin 28. Valve seat 29. Return spring 30. Valve body 31. NO valve 32. Return spring 33. Cap

Stator clutch pressure pickup port P,: Torque converter relief pressure pickup port P.3‘ Lock-up clutch pressure pickup port P,: Main relief pressure pickup port P10'. Lock-up clutch initial pressure pickup port P11'* Stator clutch initial pressure pickup port P:

D275A-2

E-E

E 6

17MF02014

OUTLINE 0 The torque converter valve is installed at the top of the rear housing of the torque converter and consists of the following six types of valves. 1. Main relief valve Main relief valve (5) sets the hydraulic pressure to 25.4 28.0 kg/cm2 in the transmission, steering clutch, brake and torque converter lock-up clutch, and stator clutch circuits. 2. Torque converter relief valve Torque converter relief valve (2) sets the inlet pressure of the torque converter to within 8.7 kg/cm2 to protect the torque converter from abnormally high pressure. 3. Torque converter lock-up valve Lock-up selector valve (24) acts to switch the lock-up clutch and stator clutch ON * OFF.

4. Torque converter lock-up solenoid valve Solenoid valve receives an electrical signal from the lock-up controller and switches the pilot pressure to lock-up selector valve (24). It operates lock-up selector valve (24) and switches the two clutches ON * OFF. 5. Stator clutch modulating valve Modulating valve (10) sets the clutch pressure to 26 - 28 kg/cm* to protect the stator clutch from abnormally high pressure and acts to raise the pressure of oil from lock-up selector valve (24) gradually until it reaches the set pressure. 6. Lock-up clutch modulating valve Modulating valve (11) acts in the same way as stator clutch modulating valve (IO) and sets the clutch pressure to 13 - 14 kg/cm* to protect the stator clutch from abnormally high pressure.

10-17 0

OPERATION OF MAIN RELIEF VALVE The oil from the power train pump passes through the oil filter, and enters port A of the main relief valve. It then passes through orifice a and enters port B. When the oil from the pump fills the circuit, the pressure starts to rise. When the pressure in the circuit rises, the oil entering port B pushes piston (9). The reaction force compresses spring (4), moves main relief valve (5) to the left in the direction of the arrow, and opens ports A and C. When this happens, the oil from the pump is relieved from port A to port C, and flows port C to the torque converter. The pressure in the circuit at this point is 25.4 - 28.0 kg/cm*.

To torque converter

To oil tank

Q From pump

To torque converter

OPERATION OF TORQUE CONVERTER RELIEF VALVE The oil relieved from the main relief valve flows into the torque converter from port C, and at the same time passes through orifice b and enters port D. When the oil fills the torque converter, the pressure starts to rise. If the pressure in the torque converter rises abnormally high, the oil entering port D pushes piston (9). The reaction force compresses spring (3), moves relief valve (2) to the right in the direction of the arrow, and opens ports C and E. When this happens, the oil at port C is relieved to port E, and is drained to the oil tank. The pressure in the circuit at this point is below 8.7 kg/cm*.

To oil tank

From pump F19702005 To torque converter

To oil tank

From pump

lo-18

F19702004

F19702006

D275A-2

OPERATION OF TORQUE CONVERTER LOCK-UP VALVE, SOLENOID VALVE The torque converter lock-up valve supplies oil to switch the lock-up and stator clutch built.into the torque converter ON - OFF. The lock-up valve is actuated by the pilot pressure from the solenoid valve that is actuated when it receive an electrical signal from the lock-up controller. When the lock-up switch on the switch panel at the side of the operator’s seat is pressed ON (the indicator lamp inside the switch lights up), the auto-lock-up system is actuated, and when the torque converter reaches the lock-up range, the lock-up controller, that has received signals from the two sensors, connects the solenoid to the ground and current flows. The hydraulic circuit is switched and pilot pressure is sent to the lock-up valve to lock up the torque conveter. 0

E 6

The diagram on the right shows the electrical circuit for the torque converter lock-up system. (For details, see the electrical circuit diagram) The electricity from the battery flows from the relay box to the panel switch. When the lock-up switch is pressed ON, the switch is connected to the ground, and this actuates the relay inside the relay box. The electricity from the battery passes through the pilot lamp and acts as the power source for the lockup controller. In this condition, if both the torque converter output shaft speed detected by the speed sensor is above 1170 rpm, and the transmission modulating pressure detected by the hydraulic sensor is above 19.5 kg/cm* (AND circuit), the controller connects the pilot lamp and solenoid to the ground, and they light up or are excited respectively. If either the torque converter output shaft speed Transm,ss,o is below 1110 ram or the modulating pressure is pressure sens below 15 kg/cm* (OR circuit), the controller cuts the circuit connecting the pilot lamp and solenoid to the ground, and they go out or are deactivated respectively. In other words, when the torque converter %% comes close to the stall range or tries to shift gear, the machine changes to torque converter drive, and when there is continuous light operation, the machine changes to direct drive.

LOC~.“P power LocL-“pgro”“d

197FO26

10-19 0

OPERATION OF TORQUE CONVERTER LOCKUP VALVE, SOLENOID VALVE (with SSC system) . The torque converter lock-up valve supplies

oil to switch ON ++ OFF the lock-up clutch and stator clutch built into the torque converter. The lock-up valve is actuated by the pilot pressure from the solenoid valve. The solenoid valve itself is actuated when it receives an electrical signal from the lock-up controller. When the lock-up switch on the mode selection panel at the side of the operator’s compartment is pressed ON (the indicator lamp inside the switch lights up), the autolock-up mechanism is actuated. When the torque converter reaches the lock-up range, the lock-up controller, which has received signals from the two sensors, connects the solenoid to the ground and current flows. The hydraulic circuit is switched and pilot pressure is sent to the lock-up valve to lock up the torque converter.

10-19-l 0

The diagram shows the electrical circuit for the torque converter lock-up mechanism. (For details, see the electrical circuit diagram.) When the starting switch is turned ON, the lock-up relay inside the relay box is actuated. The electricity from the battery passes through the pilot lamp and flows to the lockup controller to act as the power source. In this condition, if both the torque converter output shaft speed detected by the speed sensor is above 1,170 rpm and the transmission modulating pressure detected by the hydraulic sensor is above 1.9 MPa i19.5 kg/cm21 (AND circuit), the lock-up controller connects the pilot lamp and solenoid to the ground, and they light up and are energized respectively. If either the torque converter output shaft speed is below 1,100 rpm or the modulating pressure is below 1.5 MPa (15 kg/cm*} (OR circuit), the lock-up controller cuts the circuit connecting the pilot lamp and solenoid to the ground, and they go out or are deenergized respectively. In other words, when the torque converter comes close to the stall range or tries to shift gear, the machine changes to torque converter drive, and when there is continuous light operation, the machine changes to direct drive. The torque converter speed sensor is connected to the SSC controller and transmits the rotation speed of the torque converter to the SSC controller. The SSC controller receives the ON signal from the mode selection panel (lock-up mode switch) and transmits the input torque converter speed to the lock-up controller.

0275A-2

LOCK-UP

SYSTEM

(SSC SPECIFICATION

MACHINE)

Battery Battery

n Relax

-b

relax

box

Pilot

Lock-up

controller

converter

speed

lamp Torque

Transmission Pressure

oil sensor

Transmission

oil

Torque

converter

Lock-up

Power

Lock-up

GND

Lock-up

valve

Lock-up

valve

t+)

Pressure

speed

sensor

t-1

source

Lock-up solenoid

SSC

source

controller

Lock-up

switch @I

+.-I-

t Torque speed

power

Mode

selection

Panel

converter sensor SWD03772

D275A-2

10-19-2 a

1. Travel in torque converter

drive

:lutch

197FO2023

When the machine is in the torque converter range, the solenoid valve is deactivated, so valves (28) and (31) are pushed to the right in the direction of the arrow by the tension of spring (29). Ports N and M close and ports N and P open.

When this happens, oil from the pump flows ports P and N into port L of the lock-up valve. When the pressure inside the circuit rises, piston (25) is pushed to the left in the direction of the arrow, and the piston pushes out lock-up selector valve (24) to the left.

197FO2024

When lock-up selector valve (24) moves to the left in the direction of the arrow, ports F and G and ports H and K close, and ports F and H and ports G and J open. When this happens, the oil from the pump flows from port F to port H, and becomes the back pressure of the stator clutch piston. When the pressure

1O-20

in the circuit rises, the stator clutch is engaged. At the same time, the oil that is the back pressure of the lock-up clutch piston is drained from port G to port J, and the lock-up clutch is disengaged.

D275A-2

2. Travel in direct drive

197FO2025

When the machine is in the direct drive range, the solenoid valve is excited, so push pin (27) is pushed to the left in the direction of the arrow and valves (28) and (31) are moved. Ports N and P close and ports N and M open. When this happens, oil from the pump stops at P. The high-pressure oil at port L is drained from port N to port M. When the pilot pressure at port L is lost, piston (25) and lock-up selector valve (24) are returned to the right in the direction of the arrow by the tension of spring (22).

D275A-2

Ports F and H and ports G and J close, and ports F and G and ports H and K open. When this happens, the oil from the pump flows from port F to port G, and becomes the back pressure of the lock-up clutch piston. When the pressure in the circuit rises, the lock-up clutch is engaged. At the same time, the oil that is the back pressure of the stator clutch piston is drained from port H to port K, and the stator clutch is disengaged.

10-21

Operation of stator clutch, lock-up clutch modulating valve 0 The modulating valves are in the circuit between the lock-up selector valve and the inlet ports of the two sets of clutches. When the clutch is switched ON, the modulating valve acts to raise the pressure on the piston gradually until it reaches the set pressure so that the clutch is engaged smoothly, thereby reducing any shock to the torque converter or transmission. j, The following explanation of operation takes the stator clutch as the example, but the operation of the lock-up clutch is the same. However, the oil flow to the clutch during direct drive or torque converter drive is the reverse. 1. Travel in direct drive When the machine enters the direct drive range, the oil at port L of lock-up selector valve (24) returns to the solenoid valve and is drained. When this happens, lock-up selector valve (24) is pushed to the right in the direction of the arrow by the tension of spring (22). Ports F and H close, and ports H and K open, and the oil at port H is drained from port K. When the hydraulic pressure at port H is lost, modulating valve (10) is returned to the right in the direction of the arrow by the tension of spring (16), and ports H and 0 open fully. At this point, the actuating pressure of the stator clutch is drained from port H to port K, and the clutch is disengaged.

Frompump

TO solenoid valve

197FO2026

1o-22

D275A-2

2. Travel in torque converter drive When the machine is in the torque converter drive range, the oil from the solenoid valve enters port L of lock-up selector valve (24) and moves the lock-up selector valve to the left in the direction of the arrow. Ports F and G, and ports H and K close, and ports F and H open. A circuit is then formed from port F through modulating valve (10) to the stator clutch. The oil from the pump flows from port F to the stator clutch, and the pressure in the circuit starts to rise. As the hydraulic pressure in the circuit rises, the oil passing through orifice d in modulating valve (IO) pushes piston (13), and the reaction force moves the modulating valve to the left in the direction of the arrow to throttle ports Q and H. Port Q is connected with port S that applies back pressure to load piston (19), and moves the load piston to the right in the direction of the arrow to compress spring (16). The tension of the spring opens ports Q and H. This operation is repeated intermittently to increase the load of spring (16). While this is happening, the hydraulic pressure gradually increases, and finally stops at the position where ports Q and H are closed to complete the rise in hydraulic pressure. The hydraulic pressure at this point is 26 - 28 kg/cm2. The hydraulic pressure of the lock-up clutch is 13 - 14 kg/cm2.

From pump

D275A-2

197FO2027

_ II

From pump

//I

To solenoid valve

197FO2028

1 O-23

TRANSMISSION

17MF02015

OUTLINE The D275A-2 bulldozer is equipped with a planeand 3-reverse speed” transtary type, “3-forward mission which is a combined structure of a planetary gear mechanism and disc clutches. of the direction and the revolution The rotational output shaft is selected by fixing two transmission disc clutches out of five disc cluthes by means of control valve operation.

1 O-24

No. 1 clutch is fixed in reverse, No. 2 clutch in forward, No. 3 clutch in third speed, No. 4 clutch in second speed, and No. 5 clutch in first speed. Any speed can be selected from three forward speeds and three reverse speeds by fixing either No. 1 or No. 2 clutch and one clutch among No. 3, No. 4 and No. 5 clutches and by combining two of the above.

D275A-2

40/////I 39

8 \

9 \

1,s

I 34

/ 33

I 32

‘17

I 31

I 30

l,B

I 29

I 28

I 27

/23

1. Input shaft 2. Transmission valve 3. Front case 4. Rear case 5. Front cover 6. Reverse sun gear (34 teeth) 7. Reverse ring gear (91 teeth) 8. Pinion shaft 9. Reverse planetary pinion (25 teeth) 10. Reverse ring gear (84 teeth) 11. Forward sun gear (41 teeth) 12. Forward planetary pinion (25 teeth) 13. Forward ring gear (91 teeth) 14. Pinion shaft 15. 3rd speed ring gear (91 teeth) 16. 3rd speed planetary pinion (25 teeth) 17. 3rd speed sun gear (41 teeth) 18. 2nd speed ring gear (93 teeth) 19. 2nd speed planetary pinion (23 teeth) 20. Pinion shaft 21. 2nd speed sun gear (47 teeth) 22. No. 5 gear (1 st speed gear) 23. No. 5 clutch piston 24. No. 5 clutch piston housing 25. Output shaft 26. Spacer 27. Block 28. No. 5 clutch spring 29. Seal seat 30. No. 4 carrier 31. Plate 32. No. 2, 3 carrier 33. No. 2, 3 piston housing 34. No. 1 carrier 35. No. 1 piston housing 36. Clutch piston 37. Clutch spring 38. Clutch plate 39. Clutch disc 40. Tie bolt 41. Reverse carrier gear (91 teeth)

Speeds and operating

clutches

Speed

Operating

Neutral

Forward

No. 5 clutch

First speed

No. 2 and

Second

No. 2 and No. 4 clutches

Third

speed speed

No. 5 clutches

No. 2 and No. 3 clutches

Neutral Reverse

clutch

No. 5 clutch

First speed

No. 1 and No. 5 clutches

Second

No. 1 and No. 4 clutches

Third

speed speed

No. 1 and No. 3 clutches

Number of discs and plates on each clutch

Clutch

No.

Number

of plates

Number

of discs

No. 1 clutch

No. 2 clutch

No. 3 clutch

No. 4 clutch

No. 5 clutch

17MF02016

D275A-2

1 o-25

FUNCTION

OF PISTON

To lock ring gear (7), the discs (39) and plates (38) are brought into close contact. The clutch consists of a clutch piston (36), clutch plates (38), clutch discs (39), pins (42) and piston return springs (37). The disc’s internal teeth engage with the ring gear’s external teeth. The plates, whose notch on the outside diameter engage with pins (42) on housing (35), are locked against the rotating direction. Piston (36) also is locked against the rotating direction.

Clutch engaged (oil pressure is acting) Oil from the control valve flows under pressure through the port in housing (35) to the piston (36). The piston presses clutch plates (38) and clutch discs (39) together, and the frictional force developed stops clutch discs (39) revolution, thus ring gear (7) meshing with the disc’s internal teeth is locked.

3.7

4.2

3.!

36C

Clutch disengaged (oil pressure is not acting) When the supply of pressure oil from the control valve is shut off, piston (36) returns to the initial position by the force of piston return spring (37), thus relieving the frictional force between plates (38) and discs (39), making the ring gear (7) free.

F19702010

1 O-26

D275A-2

POWER

TRAIN

FIRST

FORWARD

OF TRANSMISSION SPEED

30 17MF02017

For FORWARD Ist, No. 2 clutch and No. 5 clutch are engaged. The motive force transmitted from the torque converter to input shaft (1) is transmitted to output shaft (25). No. 2 clutch is actuated by the hydraulic pressure applied by the clutch piston and locks ring gear (13) in position. No. 5 clutch is actuated by hydraulic pressure applied by the clutch piston and engages No. 5 gear (22) and No. 4 ring gear (18) in position. The motive force from the torque converter is transmitted to the input shaft. The rotation of the input shaft is transmitted through sun gear (11) to planet gear (12).

D275A-2

Ring gear (13) is locked in position by No. 2 clutch, so planet gear (12) rotates carrier (32), which is on the inside of ring gear (13). No. 5 clutch is also engaged, so the No. 5 gear (22), sun gears (17) and (21), planet gears, ring gears (15) and (18), and No. 4 carrier (30) form one unit, and carrier (32) rotates as one unit with the gears of No. 3, 4 and 5 clutches to rotate output shaft (25). Output shaft (25) rotates at the same speed as carrier (32).

1 O-27

17MF02018

For REVERSE Ist, No. 1 clutch and No. 5 clutch are engaged. The motive force transmitted from the torque converter to input shaft (1) is transmitted to output shaft (25). No. 1 clutch is actuated by the hydraulic pressure applied by the clutch piston and locks carrier (34) in position. No. 5 clutch is actuated by hydraulic pressure applied by the clutch piston and engages No. 5 gear (22) and No. 4 ring gear (18) in position. The motive force from the torque converter is transmitted to the input shaft (1). The rotation of the input shaft is transmitted through sun gear (6) to planet gear (9).

1 O-28

Carrier (34) is locked in position by No. 1 clutch, so the rotation of planet gear (9) rotates ring gear (IO). Ring gear (IO) rotates in the opposite direction from the input shaft, and it rotates carrier (32). No. 5 clutch is engaged, so the No. 5 gear, sun gears, planet gears, ring gears, and No. 4 carrier form one unit, and carrier (32) rotates as one unit with the gears of No. 3, 4 and 5 clutches to rotate output shaft (25).

D275A-2

TRANSMISSION

1. 2. 3. 4. 5.

Gear shift lever Safety lever F-R spool linkage Speed spool linkage Transmission control

D275A-2

CONTROL

17MF02019

valve

1 O-29

TRANSMISSION

CONTROL VALVE

E-E

17MF02020

Modulating pressure Reducing pressure

1O-30

26-28 20.5 -

22.5

A B C D E F G H J K

From power train pump To speed valve G To speed valve J To forward clutch port (No. 2) To reverse clutch port (No.1) To 1st speed clutch port (No. 5) From reducing valve B To 2nd speed clutch port (No. 4) From reducing valve C To 3rd speed clutch port (No. 3)

D275A-2

A-A

H B-B

1. Piston 2. Modulating valve 3. Modulating valve load piston 4. Modulating valve spring (Inner) 5. Modulating valve spring (Outer) 6. Quick return valve 7. Cover 8. Piston spring 9. Piston 10. Piston

D275A-2

17MF :02021

11. Reducing valve 12. Stopper 13. Reducing valve spring 14. Stopper 15. Modulating sleeve spring (Small) 16. Stopper 17. Piston 18. F-R valve 19. Speed valve

10-31

MODULATIING

VALVE

OUTLINE l The modulating valve consists of a modulating relief valve and a quick return valve, and acts to modulates the pressure. l When the gear shift lever is operated to shift gear, the clutch is pushed into close contact by the piston. However, if high pressure is suddenly applied, the piston will suddenly engage the clutch. This will make the machine suddenly start, and it will receive an excessive shock. To prevent this, the modulating valve is installed. When the gear shift lever is operated to shift gear, the pressure on the piston gradually rises to the set pressure and the clutch is engaged smoothly. This allows the machine to start without any shock, thereby improving the durability of the power train and at the same time providing a comfortable ride for the operator. l The figure shows the relationship between the time and the increase in the hydraulic pressure of the modulating valve. For example, when the gear is shifted from Fl and F2, the oil from the pump passes through the speed valve spool, flows to the second clutch and fills the circuit up to the clutch piston port. The time taken for the circuit to be filled up to the clutch piston port is called the “filling time”, and the oil pressure during this time is 0 - 3 kg/cm2. When the circuit up_to the clutch piston port is filled with oil, the oil pressure starts to rise. The time taken for the pressure to rise to the set pressure is called the “built-up time”. The filling time and build-up time together are called the “modulating time”.

Modulating

time

(kg/cm? 30 27 (Set pressure)

2 20.? 2 5i is 10 -

(Sec.) 1

0.5

1.0

Time 1JMF02022

1 O-32 0

Operation

From pump

1. Immediately after shifting When the transmission shift lever is operated and the clutch is engaged, the passage from the pump to the clutch piston port is opened and the oil flows to the clutch piston port. When this happens, the passage between port B and port D is restricted by orifice b, so a difference in pressure is generated, and quick return valve (6) is moved to the left in the idrection of the arrow by the pressure at port B. This connects port E and drain port F, and removes the back pressure of load piston (3). 2. Pressure starting to rise, during rise When the oil sent under pressue from the pump fills the circuit from port A to the clutch piston port, the hydraulic pressure starts to rise. When this happens, the difference in pressure on the two sides of orifice b of quick return valve (6) is lost, and the quick return valve is moved to the right in the direction of the arrow to close the passage between port E and drain port F. The oil flows form orifice a of modulating valve (2) to port C, and pushes piston (1). Because of the reaction force, the modulating valve compresses springs (4) and (5), and moves to the right in the direction of the arrow to drain the oil from port A to port G. At the same time, the oil flowing from orifice e in quick return valve (6) through the central port passes through orifice d and enters port E. It becomes the back pressure of load piston (3), moves the load piston to the left in the direction of the arrow and compresses springs (4) and (5).

TO clutch cylinder

Drain

6 A

17MF02023

From pump

“F

To clutch cylinder

Drain

17MF02024

\ 6 17MF02025

D275A-2

1o-33

During rise in oil pressure, completion of rise As the pressure rises, the back pressure of load piston (3) increases. When the movement of the load piston to the left increases, modulating valve (2) closes the passage between port A and port G because of the tension of springs (4) and (5). As the pressure at port C pushing piston (1) increases, modulating valve (2) moves to the right in the direction of the arrow due to the reaction force, compresses springs (4) and (5), and opens the passage between port A and port G. By repeating this operation intermittently, the load of springs (4) and (5) increases and the pressure rises slowly. Finally, load piston (3) contacts the valve body and does not move any further. When this happens, modulating valve (2) stops at the position where the passage from port A to port G is closed, and the rise in hydraulic pressure is completed. The hydraulic pressure at this point is 26 “0 kg/cm2. The oil frbm the pump is relieved through the main relief valve assembled to the torque converter assembly.

From

pump

17MF02026

\From PumA /

To clutchcylinder

17MF02027

1o-34

D275A-2

REDUCING

VALVE

OUTLINE The reducing valve is in the circuit between the modulating valve and the 1st speed valve spool. It reduces the pressure applied to the 1st clutch to 20.5 - 22.5 kg/cm*. The hydraulic pressure in the circuit as a whole is set to 26 - 28 kg/cm* by the modulating valve.

From modulating valve

OPERATION 1. Valve OPEN The oil from the modulating valve flows from port A. Some passes through port B and flows to the 1st valve spool and clutch, and at the same time, passes through orifice a and enters port D. The oil also flows from port A through port C, and flows to the 2nd and 3rd spools and the directional spool. When the circuit up to the clutch that has been shifted becomes filled with oil and the pressure rises according to the operation of the modulating valve, the oil entering through orifice a of reducing valve (11) pushes piston (12). The reaction force compresses spring (13) and moves reducing valve (11) slowly to the left in the direction of the arrow in accordance with the rise in the hydraulic pressure, and starts to throttle port B.

C’

To F-R spool To 2nd & 3rd spool

To 1st spool 17MF02028

From modulating valve

13 1

To F-R s;ool To 2nd & 3rd spool

To 1;t spool 17MF02029

2. Valve CLOSED When the pressure in the whole circuit rises further because of the action of the modulating valve, reducing valve (11) moves further to the left and closes the circuit from the modulating valve, so the pressure in the 1st clutch circuit stops rising. The pressure at this point is 20.5 - 22.5 kg/cm*.

From modulating

To F-R spool To 2nd & 3rd spool

To 1st spool 17MF02030

D275A-2

10-35

If the pressure in the 1st clutch circuit drops because of leakage from the transmission Iubrication or seal ring, the reaction force of the spring of reducing valve (11) opens the circuit. This raises the pressure to the set pressure of reducing valve (11) and maintains the set pressure. Except for the 1st clutch circuit, the pressure in all the circuits continues to rise to the set pressure of the modulating valve. The 1st clutch is farthest from the control valve, and the piping to the cylinder is longer, so it takes a longer time for the oil to fill the piping. For this reason, even when the gearshift lever is in neutral, oil still flows to the 1st clutch. Therefore, when moving the gearshift lever from neutral to Fl, it is only necessary for the oil from the pump to fill the FORWARD clutch. When the gearshift lever is moved from Fl to F2, the FORWARD clutch is already filled with oil, so the oil from the pump only needs to fill the 2nd clutch. By using the oil in this way, the time lag when shifting gear is reduced.

From reducing valve

1st clutch piston 17MF02031

1 O-36

D275A-2

TRANSMISSION

LUBRICATION

RELIEF VALVE

A-A

1. Valve body 2. Lubrication relief spool a. Lubrication pressure measurement

D275A-2

561 FO3032

plug

FUNCTION l This valve is installed to the right transmission and prevents abnormal the transmission lubrication circuit. Cracking pressure: 2.7 kg/cm2

side of the pressure in

1o-37

SCAVENGING (BAR63

PUMP

BARZOO)

197 F058A

A. Discharge port B. Small pump suction C. Large pump suction 1. Small pump 2. Large pump

port port

OUTLINE This pump is installed on the lower of the PTO l case, and consists of a small pump and a large l

pump. The small pump sucks the torque converter case oil and the large pump sucks the steering case oil, and this oil is returned to the oil tank.

Discharge

pressure (kg/cm2)

At rated speed

1 O-38 0

(rpm)

OIL STRAINER

17MF02032

1. 2. 3. 4. 5.

Cover Spring Magnet Screen Case

A. From oil tank B. TO power train pump and lubrication

pump

Passage flow

600 a/min

Screen mesh

D275A-2

OUTLINE l The strainer is installed on the front and left of the power train unit. l Open the fender located at the front of operator’s seat, and maintain the strainer. l The oil from the oil tank is filtered by screen (4), and is sucked by the power train pump and the lubrication pump.

1o-39

POWER TRAIN

OIL FILTER AND LUBRICATION

OIL FILTER

z 17MF02033

1. Cover 2. Element 3. Body 4. Valve (Setting 5. Spring

pressure:

I.4 kg/cm*)

A. Inlet B. Outlet

Cracking

pressure

1.4 kg/cm*

Passage flow

273 Illmin.

Filter ability

30 microns

1O-40

OUTLINE The two filters are the same part, and are installed on the front of power train unit. Open the fender located at the right and front of operator’s seat, and maintain the filter. The oil from the oil tank is sucked by the power train pump and the lubrication pump through the strainer, and is sent to each filter. If element (2) is clogged or the oil temperature is low, the oil pressure increase, so valve (4) is installed to prevent the filter from breaking.

D275A-2

STEERING

UNIT

II% =

---

----

17MF02034

OUTLINE The steering unit consists of the transfer, bevel gear shaft, steering clutch, and steering brake.

1 O-42

D275A-2

A-A

F-F

E-E 17MF02035

D-D

1. 2. 3. 4.

Transmission Breather Steering unit Torque converter

output

shaft speed sensor

A. Mount of steering control valve B. Center of bevel gear shaft C. Center of crank shaft D. Center of bevel pinion

D275A-2

1o-43

TRANSFER,

BEVEL PINION

17MF02036

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Input shaft Drive shaft Drive gear (33 teeth) Rear cover support Torque converter output Bearing cage Drum Cover Bearing cage Driven gear (34 teeth) Bevel pinion Bevel gear

1o-44

shaft speed sensor

OUTLINE l The transfer and bevel pinion are installed at the rear inside the steering case and receive the motive force from the transmission output shaft with input shaft (1). The transfer consists of drive gear (3) and driven gear (11). It reduces the speed of the motive force from input shaft (1) and transmits it to bevel pinion (12). Drive shaft (2) rotates drum (8), which sends a pulse signal to torque converter speed sensor (6).

D275A-2

OUTLINE Bevel gear shaft The motive force from the engine - torque converter -+ transmission -, transfer enters the bevel gear system. The bevel pinion and bevel gear are meshed and act both to reduce the speed of rotation and to send to the power at right angles to the left and right. The bevel gear system uses spiral bevel gears for the bevel pinion and bevel gear, and a splash-type lubrication system is employed that uses the oil from the power train oil cooler. The bevel gear system consists of the following: bevel gear (17) that meshes with the bevel pinion, bevel gear shaft (16). two steering shafts (15) that are connected to the bevel gear shaft by a spline, the bearing that supports the bevel gear shaft, and bearing cages (14) and (18). Steering clutch l The steering clutches are connected by a spline to the left and right steering shafts, and act to engage or disengage the motive force to the final drive, thereby changing the direction of travel of the machine. l The steering clutches are wet, multiple-disc clutches with a spring booster. They are interconnected with the brakes and are hydraulically actuated by a steering valve that is actuated when the steering lever is operated. A forced lubrication system is employed in which the oil from the power train oil cooler passes through the passage inside the steering case, enters the housing and cage, and is then sent to the discs and plates. l The steering clutch consists of the following: hub (19) that is connected with the steering shaft by a spline, disc (23) that meshes with the hub, plate (22) and housing (27) that are mated at the outside circumference with torque pin (24), piston (25) that presses the discs and plates together, spring (26) and stopper (20), and cage (28) that supports these parts. Housing (27) and cage (28) are connected with brake hub (12), and send the motive force from the bevel gear through the brake hub to output shaft (1).

D275A-2

Steering brake l The steering brakes are connected with the left and right steering clutches, and act to brake the machine or change the direction of travel by braking or connecting the motive force from the steering clutches to the final drive. l The steering brakes are wet, multiple-disc clutches with a spring booster. They are interconnected with the brakes and are hydraulically actuated by a steering valve that is actuated when the brake pedal and steering lever are operated. A forced lubrication system is employed in which the oil from the power train oil cooler passes through the passage inside the steering case, enters the housing and cage, and is then sent to the discs and plates. The steering brakes are designed so that when the engine has stopped, the back pressure of the brake piston drops and the brake are applied without the brake pedal being depressed. However, when the engine is started again, the brake is released as the hydraulic pressure inside the circuit rises, so the brake pedal must always be locked. l The steering brakes consist of the following: clutch housing (27), hub (12) that is connected with cage (28) and output shaft (I), disc (10) that is meshed with the hub, plate (8) and housing (5) that are mated at the outside circumference by torque pin (7), piston (6) that presses the discs and plates together, spring (4) and stopper (II), and cage (3) that supports these parts. Housing (5) and cage (3) are secured to the steering case.

1o-47

OPERATION

OF STEERING

CLUTCH

1. When steering clutch is engaged When the steering lever is at the neutral position, the steering valve is also at the neutral position, so no back pressure is applied to piston (25). In this condition, the piston is pushed to the right by the tension of spring (26), and disc (23) and plate (22) are brought into close contact with stopper (20). The stopper is connected with housing (27) by torque pin (24). Therefore, the motive force from steering shaft (15) is transmitted from hub (19) to housing (27) through the discs and plates that are held together. The motive force is then transmitted from brake hub (12), which forms one unit with the housing, through the output shaft (1) to the final drive.

27 26

F19702025

2. When steering clutch is disengaged When the steering lever is pulled, the steering valve is switched and oil enters the area behind piston (25). When the hydraulic pressure rises, it pushes the piston to the left, and compresses spring (26) to release the pressure holding disc (23) and plate (22) together. When this happens, the motive force from steering shaft (15) rotates only hub (19) and the disc, so the motive force is not transmitted beyond housing (27) and does not go to the final drive. When the steering lever is released, the steering valve opens the drain circuit, and the tension of spring (26) pushes piston (25) back to its original position to return the clutch to the engaged condition explained is Section 1. When the left steering clutch is disengaged, the motive force is transmitted only to the right steering clutch, so the machine turns to the left (travels to the left).

F19702026

1 O-48

D275A-2

OPERATION

OF STEERING

BRAKE

1. When steering brake is released When the steering lever and brake pedal are at the neutral position, the steering valve is also at neutral, so the steering clutch is engaged, and oil enters the back pressure port of steering brake piston (6). When the hydraulic pressure rises, it pushes the piston to the left, compresses spring (4), and releases the pressure holding disc (10) and plate (9) together. When this happens, the motive force transthe shaft (15) through mitted from steering steering clutch to housing (27) is transmitted from hub (12) to output shaft (I), and goes to the final drive.

1’1

-27

1.5

F19702027

2. When steering brake is applied (steering lever pulled) lever is pulled fully, the When the steering and the steering valve is switched steering At the same time, the oil clutch is disengaged. back pressure to piston (6) is conapplying nected to the drain circuit. the piston is pushed to the In this condition, right by the tension of spring (4), and disc (10) and plates (9) are brought into close contact with stopper (11). The stopper is connected to case (5) by torque pin (7), so it is locked in position. even if the steering clutch is disenTherefore, gaged, the rotation of output shaft (I), that is the rotation of hub (12) caused by inertia, is stopped when the disc and plate are pushed into contact. The hydraulic force applied to spring (4) is controlled by the amount that the steering lever is pulled, so it is possible to adjust the braking speed the turning controlling force, thereby and turning radius.

D275A-2

F1970202%

1o-49

3. When steering brake is applied (brake pedal depressed) When the brake pedal is depressed, the steering valve is switched, and the oil applying back pressure to piston (6) is connected to the drain circuit. The steering clutch remains engaged, and only the brake is actuated to stop the rotation of output shaft (1).

I#I II I

1 O-50

1’1

1’2

F19702029

D275A-2

STEERING CONTROL

17MF02038

1. L.H. steering lever 2. R.H. steering lever 3. Brake lock lever 4. Brake pedal 5. Brake pedal return spring 6. Steering control valve

D275A-2

10-51

STEERING CONTROL VALVE

z 1. Plug 2. Return spring 3. Piston 4. Valve body 5. R.H. steering valve 6. Modulating spring 7. Shaft ass’y 8. Cover 9. Return spring 10. R.H. brake valve 11. Modulating valve

1 o-52

197FO2045

‘CL

12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

Shaft ass’y Guide L.H. brake valve L.H. steering valve Plug Return spring Piston Seat Check valve Spring

To R.H. steering clutch piston port B. To R.H. steering brake piston port C. To steering case D. From power train pump E: To L.H. steering brake piston port F: To L.H. steering clutch piston port CL: Plug for L.H. steering clutch pressure CR: Plug for R.H. steering clutch pressure BL: Plug for L.H. steering brake pressure BR: Plug for R.H. steering brake pressure A.

D275A-2

197FO2046

OUTLINE The steering control valve consists of two steering valves and brake valves, and is in the circuit between the steering clutch and brake pistons and the power train pump passing through the main relief valve. When the steering lever is pulled, the steering clutch is disengaged. If it is pulled further, the brake is engaged and the machine stops. When the lever on one side is pulled, it is possible to adjust the angle of turning to give gradual turns or sharp turns. If the brake pedal is depressed, the brake is engaged and the machine stops.

D275A-2

These operations are made possible by switching the steering control valve which is interconnected with the lever and pedal. The steering control valve sends oil from the power train pump to the steering clutch and brake, and operates the disc clutch of each.

1o-53

VALVE CONTROL

LEVER

D-D

I97FO72

22. 23. 24. 25. 26. 27. 28. 29.

R.H. steering lever shaft L.H. and R.H. brake lever shaft Lever box Roller R.H. steering lever Brake lever L.H. steering lever L.H. steering lever shaft

1o-54

OUTLINE l The steering control valve is operated by lever shafts (22) and (29) and levers (26) and (28) interconnected with the steering lever in the operator’s compartment, and lever shaft (23) and lever (27) interconnected with the brake pedal. l The steering valve and brake valve inside the steering control valve are interconnected by cam (25) of levers (26) and (28) to enable the steering lever system to be operated.

D275A-2

OPERATION 1. When steering lever, brake pedal are at neutral (clutch engaged, brake released)

To toI que converter val ve, To tri lnsmission control valve

flnnnnn

From

F19702030

When the steering lever and brake pedal are at levers (26), (27), and neutral (not operated), (28) are also at neutral, and the oil ports of each valve are opened or closed by the tension of the spring. The oil from the power train pump passes through the main relief valve and enters port A of check valve (20). Some of the oil entering port A enters port B of left and right steering valves (5) and (15), and stops. When this happens, the oil from the back pressure port of the clutch piston returns from port C to drain port H, and the clutch is engaged by the tension of the clutch spring.

D275A-2

The rest of the oil pushes open check valve (20), enters port E of left and right brake valves (10) and (14), and then flows from port F to the back pressure port of the brake piston. When the hyin the circuit rises, the piston draulic pressure the brake spring, moves to the left, compresses and the brake is released.

1o-55

2. When steering lever is pulled (clutch disengaged, brake released)

From power train pump

F19702031

When the left steering lever is pulled, roller (25) of lever (28) pushes shaft (7) to the left and compresses modulating spring (6). The reaction to this moves steering valve (15) to the left. When this happens, the circuit between port C and drain port H is closed, and the circuit between ports B and C is opened. The oil from the power train pump flows from port B and enters port C. Some of the oil flows to the clutch piston port and becomes the back pressure, and the rest of the oil passes through orifice b and enters port D. The oil entering port D pushes piston (3). and the reaction compresses spring (6) and moves valve (15) to the right. This closes the circuit between ports B and C, so the oil cannot flow beyond port C. As a result, the hydraulic pressure does not rise and is maintained at the same level. If the steering lever is pulled further, the above operation is repeated, and when roller (25) of lever (28) reaches the position where it contacts shaft (12) of the brake valve, the hydraulic pressure beyond port C rises to the set pressure of the main relief valve (26 kg/cm*), and the clutch is fully disengaged.

1 O-56

The hydraulic pressure beyond port C is determined by the tension of modulating spring (6), which changes the load in accordance with the amount the steering lever is operated. Therefore, if the steering lever is moved a short distance, the hydraulic pressure beyond port C is set low and the clutch remains partially engaged, and if it is moved a large distance, the hydraulic pressure is set high and the clutch is fully disengaged.

D275A-2

3. When steering lever is pulled (clutch disengaged, brake applied)

From

pump

F19702032A

When the left steering lever is pulled further from the condition in Item 2, roller (25) of lever (28) pushes shaft (12) to the left and compresses modulating spring (11). The reaction to this moves brake valve (14) to the left. When this happens, the circuit between ports E and F is closed, and the circuit between port F and drain port H is opened. The oil from the power train pump flows from port A, pushes open check valve (20), and enters port E, where is stops. Some of the oil that flows to the brake piston port and becomes the back pressure flows from port F and is drained to port H, and the rest of the oil passes from port F through orifice c and enters port G. However, when the oil beyond port F is drained to port H and the hydraulic pressure drops, the oil enters port G and pushes piston (18). The reaction force pushing valve (14) to the left also becomes smaller, so valve (14) is returned to the right by the tension of return spring (17). This closes the circuit between ports F and H, so the hydraulic pressure beyond port F does not drop, but is maintained at the same level.

D275A-2

If the steering lever is pulled further, the above operation is repeated, and when it reaches the end of its travel, the brake is fully applied. The hydraulic pressure beyond port F is determined by the tension of return spring (17) which changes the load in accordance with the amount the steering lever is operated. Therefore, if the steering lever is moved a short distance, the hydraulic pressure beyond port F is set high and the brake is partially applied, and if it is moved a large amount, the hydraulic pressure is set low and the brake is fully applied. Port J is connected to port F, and this reduces the operating force of lever (28) that pushes out shaft (12) to the left. However, the hydraulic pressure at port J, that is, the booster pressure, follows the hydraulic pressure of port F that changes in accordance with the change in the amount that the steering lever is moved, so the operating force of the steering lever also changes.

1o-57

4. When brake pedal is depressed (clutch engaged, brake applied)

To torque converter To transmission

valve,

From power train pump

~--fCG%

F19702033

When the brake pedal is depressed, the two rollers (25) of lever (27) push left and right shafts (12) to the left, and left and right brake valves (IO) and (14) are actuated in the same way as in Item 3. Therefore, the hydraulic pressure is set in accordance with the amount the brake pedal is depressed, and it is possible to adjust the braking effect. The left and right steering levers are not being operated, so the clutch is engaged.

1 O-58

D275A-2

FINAL DRIVE

17MF02039

GENERAL The reduction system consists of one stage using spur gears and another using planetary gears. The lubrication system uses the gears to splash up the oil in the final case to lubricate all the parts. The rotating and sliding parts of the sprocket have floating seals (19) to prevent dirt from getting in from the outside, and to prevent the oil from leaking out.

1 O-60

Between inner body (15) and outer body (13) of the sprocket and sprocket boss (12), there are rubber bushings (20) installed equally spaced around the circumference at ten places on each side. These rubber bushings are cylindrical with a two layer construction of rubber and metal. The rubber bushings are deformed when there is external force such as impact force of drawbar pull during operations. This reduces the load on the final drive components. In addition, seal (14) is assembled to separate rubber bushings (20) completely from the outside in order to prevent the entry of dirt or water from outside.

D275A-2

17MF02040

1. 2. 3. 4. 5. 6. 7. 8.

Bearing cage Final drive case No. 1 pinion (20 teeth) No. 1 gear hub No. 1 gear (77 teeth) Cover Ring gear (67 teeth) Planet gear (25 teeth)

D275A-2

9. Cover 10. Sun gear (17 teeth) 11. Sprocket teeth 12. Sprocket bos 13. Outer body 14. Seal 15. Inner body 16. Cover

17. 18. 19. 20. 21. 22. 23.

Hub Carrier Floating seal Rubber bushing Wear guard Shaft Pivot shaft

lo-61

TRANSMISSION

OF MOTIVE

FORCE

The motive force from the bevel gear shaft and steering clutch is transmitted to No. 1 pinion (3). It is then transmitted through No. 1 gear (5) and No. 1 gear hub (4) to rotate sun gear (10). The rotation of sun gear (10) is transmitted to planet gear (8). However, ring gear (7), which is meshed with the planet gears, is fixed to cover (9). Therefore, planet gear (8) rotates on its own axis and moves along the ring gear in orbit around sun gear (10). The rotation of sun gear (10) is transmitted to carrier (18), and then passes through hub (17) to rotate inner body (15). The inner body rotates in the same direction as sun gear (10). Rubber bushing (20) is installed between inner body (15) and outer body (13) and sprocket boss (12), so the rotation of inner body (15) is transmitted through rubber bushing (20) to outer body (13), sprocket boss (12), and sprocket teeth (11).

17MF02041

1 O-62

D275A-2

MAIN FRAME

A-A

B-B

1. Main frame

D-D 17MF02042

D275A-2

1 O-63

A-A

1. 2. 3. 4. 5. 6.

Idler Idler yoke Carrier roller Track frame Sprocket Track roller (Single flange)

1 O-64

17MF02043

7. 8. 9. 10. 11. 12.

Track roller (Double flange) Track roller guard Cap Bushing Pivot shaft Bushing

D275A-2

RECOIL SPRING

B-B

17MF02044

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Idler yoke Front pilot Recoil spring Piston shaft Track frame inner cylinder Track frame outer cylinder Rear pilot Adjustment cylinder Adjustment valve Outer cylinder bushing

D275A-2

OUTLINE l

Recoil spring (3) is assembled inside track frame inner cvlinder (5). One end is connected to idler yoke (I) through front pilot (2), and the other end is connected to inner cylinder (5) through rear pilot (7). Adjustment cylinder (8) is fixed to track frame outer cylinder (6), and moves inner cylinder (5) backwards or forwards by pumping in or releasing grease from valve (9) to adjust the track tension.

1O-65

SUSPENSION

(l/Z)

Serial No. : 10001 - 10127

----,

../-___.--.--------

___.-~’

\..

rT-cM_I17MF02045

1. 2. 3. 4. 5. 6. 7.

Pivot shaft assembly Equalizer bar Seal cage Pivot shaft Thrust plate Cover Thrust plate

Joint

1O-66 @

9. 10. 11. 12. 13. 14. 15.

Side pin Lock plate Bushing Center pin Bolster Small cushion Large cushion

D275A-2

[Right side of pivot shaft]

[Left side of pivot shaft] *

For machines with the dual tilt specification, the right side is also the same.

I) Front

Rear 6

B-B

Y 17MF02046

D275A-2

1 O-67

Serial No. : 10128 and up

17MF02045

1. 2. 3. 4. 5. 6. 7. 8.

Pivot shaft assembly Equalizer bar Seal cage Pivot shaft Thrust plate Cover Thrust plate Joint

1 O-67- 1 @

9. 10. 11. 12. 13. 14. 15.

Side pin Lock plate Bushing Center pin Bolster Small cushion Large cushion

Left

side

A-A of

pivot

shaft

Right

side

pivot

shaft

c Rear

Front

B-B

SBDOl511

10-67-2 @

SUSPENSION

(2/2)

/ 13

/ 16

REAR 17

-'-

E-E

D-D

16. 17. 18.

'16

F-F

17MF02047

Rod Rod pin Bushing

1 O-68

D275A-2

HYDRAULIC

PIPING

BLADE

17MF02048

1. Blade tilt cylinder 2. Blade lift cylinder 3. Hydraulic pump 4. Blade lift valve 5. Ripper low valve 6. Hydraulic tank 7. Hydraulic filter 8. Ripper high valve

D275A-2

1O-69

VARIABLE

MULTIPLE

SHANK

RIPPER

17MF02049

9. 10.

Ripper tilt cylinder Ripper lift cylinder

1O-70

D275A-2

VARIABLE

GIANT

RIPPER

198FlO89

9. 10. 11. 12.

Ripper tilt cvlinder Ribber lift cilinder Pin puller cylinder Pin puller solenoid valve

10-70-l 0

HYDRAULIC BLADE

CONTROL

/ 197FO2069

1. Blade control 2. Lock lever

lever

A. RAISE B. LOWER C. FLOAT D. L.H. TILT E. R.H. TILT

D275A-2

1o-71

BLADE

CONTROL

(For dual

tilt

dozer)

17MF02050

1. Blade control lever IA. Dual tilt switch 1 B. Pitch switch 2. Lock lever

Dual tilt operation l Dual left tilt : Switch l Dual right tilt : Switch l Pitch back : Switch l Pitch dump : Switch

IA +position IA fposition 1 B fposition 1 B -l-position

D E D E

A. RAISE B. LOWER C. FLOAT D. L.H. TILT E. R.H. TILT

1 O-72

D275A-2

RIPPER CONTROL

3. 4.

Ripper control Lock lever

lever

A. RAISE B. LOWER C. TILT ON D. TILT BACK

D275A-2

1o-73

HYDRAULIC

CIRCUIT SYSTEM

ENGINE

HYDRAULIC

RUNNING,

CONTROL

LEVER IN “HOLD”

I-%

M I#

33 /

1o-74

17MF02051

D275A-2

HYDRAULIC

CIRCUIT DIAGRAM

ENGINE

HYDRAULIC

RUNNING,

C6NTROL

LEVER IN “HOLD”

Ripper high val\ie

Blade-tilt

ripper

low valve

I i

Pi3Y

2’

r-----

-------

! I

[

5 Blade

lift valve

i___________________--______

&I -t------

l-l

----------------_____

1:I‘I

‘2 -I

D-&__ _-_

----------7

.---------$----f--,

,I I(

Fr 11

f-----

/ \

Lower

-1

e -

)(

L ----

B Float 0

-II-

100 -1

-’

, .

/ \

(Engine

at 1915 rpm)

1. Hydraulic tank 2. Hydraulic pump 3. Main relief valve 4. Check valve 5. Check valve 6. Demand spool 7. Blade lift valve spool 8. Shuttle valve 9. Shuttle valve IO. Blade lift suction valve 11. Quick drop valve 12. Blade lift cylinder 13. Main relief valve 14. Check valve 15. Blade tilt valve spool 16. Check valve 17. Ripper tilt valve spool 18. Check valve 19. Ripper lift valve spool 20. Shuttle valve 21. Blade tilt cylinder 22. Fixed differential pressure valve (for ripper tilt) 23. Shuttle valve 24. Fixed differential pressure valve (for ripper tilt) 25. Shuttle valve 26. Ripper tilt valve spool 27. Fixed differential pressure valve (for ripper lift) 28. Shuttle valve 29. Fixed differential pressure valve (for ripper lift) 30. Shuttle valve 31. Ripper lift valve spool 32. Check valve 33. Ripper lift suction valve 34. Ripper tilt cylinder 35. Ripper lift cylinder 36. Ripper tilt suction valve 37. Hydraulic filter

17MF02052

D275A-2

1o-75

FOR DUAL TILT DOZER ENGINE RUNNING, HYDRAULIC

CONTROL

LEVER IN “HOLD” 38 A

Wooer hiah valve

Blade-tilt

ripper

low valve

r-l-i-----+

---3

-5-z ---

L--J

Low

__~&._*

1+- + r--

Tilt

+{____T= ++-_----____+l,9~

_.IA

Bz,

0 I.

i-i

I4 1 -4

I 1

I t

-_c_--_--

I 11%

_---_---I

*f-R-

-4 .-1

---__----_--

--__

---__----

____

--1

-----_------~-----_----------~~~ -_-_ -7

r-----

----7

1 Blade liftvalve

I---_-__ -t------

-i,

-0

g.E+( I

I----,,

1O-76

______ __ _____ -------~~--------____

-_ ______

_----------1 _ __---__--+---__

---I! “-+--_

P‘2

I--,

\ I

E E

12.

_ _

1 -_

I 5

L ______ -_ ________----_____

-----___A

. I

I I

/ Ll

1. Hydraulic tank 2. Hydraulic pump 3. Main relief valve 4. Check valve 5. Check valve 6. Demand spool 7. Blade lift valve spool 8. Shuttle valve 9. Shuttle valve IQ. Blade lift suction valve 11. Quick drop valve 12. Blade lift cylinder 13. Main relief valve 14. Check valve 15. Blade tilt valve spool 16. Check valve 17. Ripper tilt valve spool 18. Check valve 19. Ripper lift valve spool 20. Shuttle valve 21. Dual tilt solenoid valve 22. Blade pitch solenoid valve 23. Blade tilt cylinder 24. Fixed differential pressure valve (for ripper tilt) 25. Shuttle valve 26. Fixed differential pressure valve (for ripper tilt) 27. Shuttle valve 28. Ripper tilt valve spool 29. Fixed differential pressure valve (for ripper lift) 30. Shuttle valve 31. Fixed differential pressure valve (for ripper lift) 32. Shuttle valve 33. Ripper lift valve spool 34. Check valve 35. Ripper lift suction valve 36. Ripper tilt cylinder 37. Ripper lift cylinder 38. Ripper tilt suction valve 39. Hydraulic filter

17MF02053

D275A-2

HYDRAULIC

TANK

-I----“\

1 i

=:_._.-. LL.il_.‘,

17MF02054

7. 2. 3. 4. 5. 6. 7. 8.

Oil lever gauge Oil filler Valve Hydraulic oil filter Baffle Tube Blade tilt, ripper low valve Blade lift valve

D275A-2

P : P, : A : B: A, : B, : A,: B, : A,: B, : T:

From small pump From large pump To blade lift cylinder head To blade lift cylinder bottom To blade tilt cylinder bottom To blade tilt cylinder head To ripper tilt cylinder head To ripper tilt cylinder bottom To ripper lift cylinder head To ripper lift cylinder bottom From ripper high valve

1o-77

BLADE LIFT CONTROL VALVE

I97FOSS

OUTLINE l Demand valve (14) is assembled in the blade lift valve, and the oil from the two hydraulic pumps is merged by check valve (4). The demand valve uses the oil from the two hydraulic pumps effectively: the oil from the large pump becomes the pilot pressure; the oil from the ripper circuit and the blade lift circuit through shuttle valve (18B) becomes the pilot pressure.

1 O-78

P, : From large pump P, : From small pump A : To blade lift cylinder head B : To blade lift cylinder bottom T : To hydraulic tank

D275A-2

1'1

B-B

A-A

18 18

E-E

1. 2. 3. 4. 5. 6. 7.

Valve body Check valve spring Check valve Check valve (for small pump) Check valve spring Blade lift valve spool Shuttle valve seat (plug)

D275A-2

F-F

8. 9. 10. 11. 12. 13. 14.

Shuttle valve ball Return spring Detent spring Detent ball Detent shaft Demand valve spring Demand valve spool

I97FO99

15. Suction valve spring 16. Suction valve (for LOWER side) 17. Suction valve (for RAISE side) 18. Main relief and shuttle valve assembly 18A. Main relief valve 18B. Shuttle valve

1 o-79

MAIN

RELIEF VALVE,

SHUTTLE

VALVE

A-A

1. Adjustment screw for main relief pressure 2. Sleeve 3. Main relief valve spring 4. Main relief valve poppet 5. Valve seat 6. Plug 7. Valve body

1 O-80

197FlOO

Piston

9. Shuttle valve 10. Shuttle valve spring

PL. From shuttle valve in ripper valve PB. From shuttle valve in blade lift valve P To demand valve pilot port TY’ To hydraulic tank

D275A-2

OUTLINE The main relief valve is in the circuit between l the hydraulic tank and the ripper circuit and blade lift circuit (which passes through shuttle valve (9)). The main relief valve sets the hydraulic pressure in the large pump circuit that is, the blade lift cylinder to 210 kg/cm*. The shuttle valve is in the circuit between the l demand valve (which passes through the main relief valve) and the blade lift and ripper circuit. It selects the two circuits to apply pilot pressure to the demand valve. In other words, it selects either the blade lift circuit or the ripper circuit. When the work equipment is not being used (control lever at HOLD), the tension of spring (IO) in the shuttle valve connects the pilot port of the demand valve and the blade lift circuit.

Operation of main relief valve Chamber A forms a pump circuit and chamber l C forms a tank drain circuit. The oil flows into chamber B through the main relief valve orifice to keep the chamber filled. Pilot valve is set in the valve seat. 204FO81

If the pressure in chamber B reaches the pilot valve spring force (set pressure), the pilot valve moves, allowing the oil in chamber B to flow into chamber C through chamber D. In addition, the oil flows from chamber A to B through orifices. If the oil flows through the orifice of valve, a differential pressure occurs between the chambers A and B, moving valve to the right. This allows the oil in chamber A to flow into chamber C.

D275A-2

204FO82

204FO83

lo-81

BLADE TILT CONTROL AND RIPPER LOW VALVE

197FIOI

OUTLINE l The ripper low valve consists of a 3-spool valve. It acts to reduce the hydraulic loss in the independent blade tilt circuit when the blade is being tilted. In the ripper lift and tilt circuits, the pilot pressure switches the demand valve when the control lever is operated. At the same time, the oil which passes through the low valve operates the ripper high valve (fixed differential pressure type valve) at the rear, and improves the response of the ripper.

1 O-82

P : From small pump A, : To blade tilt cylinder bottom B, : To blade tilt cylinder head A, : To ripper tilt cylinder head B, : To ripper tilt cylinder bottom A, : To ripper tilt cylinder head B, : To ripper tilt cylinder bottom C, : To demand valve P,: To shuttle valve in blade lift valve

D275A-2

B-B

D-D 197FlO2

1. 2. 3. 4. 5. 6. 7.

Blade tilt valve spool Ripper tilt valve spool Ripper lift valve spool Valve body Valve joint Return spring Bolt

D275A-2

8. Adjustment screw for main relief pressure 9. Sleeve 10. Main relief valve body 11. Poppet spring 12. Main relief valve poppet 13. Valve seat 14. Main relief valve spring

15. Main relief valve 16. Valve seat 17. Check valve 18. Check valve spring 19. Valve seat 20. Shuttle valve seat (plug) 21. Shuttle valve ball 22. Shuttle valve seat

1 O-83

RIPPER HIGH VALVE

61-l \

BZ-1

AI-2

AZ-2

: PAI : PB, : PA2 : P :

From large pump From low valve tilt on From low valve tilt back From low valve ripper raise From low valve ripper lower A::, : To left tilt cylinder bottom B,., : To left tilt cylinder head A,, : To right tilt cylinder bottom B,., : To right tilt cylinder head A,., : To left tilt cylinder bottom B,., : To left tilt cylinder head A,., : To right tilt cylinder bottom B,., : To right tilt cylinder head P

197FlO3

1 O-84

D275A-2

A-A

B-B

D-D 197FlO4

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Valve body Shuttle valve seat Shuttle valve ball Valve body Plug Fixed differential pressure valve spring Fixed differential pressure valve Fixed differential pressure valve Fixed differential pressure valve Fixed differential pressure valve

D275A-2

11. Plug 12. Check valve spring 13. Check valve 14. Valve return spring 15. Plug 16. Ripper lift valve spool 17. Suction valve spring 18. Suction valve 19. Ripper tilt valve spool

1 O-85

RIPPER TILT SUCTION

VALVE

1. 2. 3. 4. 5.

Valve body Valve Spring Stopper Plug

1 O-86

A-A 17MF02055

A. To hydraulic tank B. From ripper high valve C. To ripper tilt cylinder bottom

D275A-2

OPERATION 1. Blade lever at HOLD, ripper lever at HOLD

,.Gz

II’

t. r.

‘a

R. -

17MF02056

1O-88

D275A-2

When the blade lever is at the HOLD position, blade lift spool (5) closes the circuit from port B to ports C and D, and opens the circuits of ports H and E and ports J and F. Blade tilt spool (16) closes the circuit from port B, to ports C, and D,. Therefore, the circuits for blade lift cylinder (9) and blade tilt cylinder (17) become closed circuits, and the cylinders are held in the same position. If the ripper lever is placed at the HOLD position, ripper tilt spool (19) closes the circuit from port B, to ports C, and D4, and ripper lift spool (21) closes the circuit from port B, to ports C, and D,. Therefore, the circuits for ripper tilt cylinder (45) and ripper lift cylinder (33) become closed circuits through the two ripper valves, and the cylinders are kept in the same position. If the engine is started in this condition, the oil from the large pump enters port A of the blade lift valve. Some of the oil pushes open check valve (3) and enters port B where it stops. The rest of the oil passes through orifice a of demand valve (I), and enters ports L and M. (The demand valve is pushed to the right by the tension of spring (2).) The oil from the large pump flows to the blade lift valve, but it also enters port A, of the ripper Hi valve, pushes open the two check valves (23) and (35), then enters ports B, and B,, and stops. The oil from the small pump flows from port A, of the ripper Lo valve and blade tilt valve to ports A,, A,, and A,. Some of the oil pushes open check valves (15), (18), and (20), then enters ports B,, B,, and B,, and stops. The rest of the oil flows from port A,, enters port R of the blade lift valve, pushes open check valve (4), and flows to port A, where it merges with the oil from the large pump.

D275A-2

1 O-89

Blade lever at HOLD, ripper lever at HOLD (oil being drained) In the condition in Item 1, if the hydraulic pressure in the circuit rises, the surface pressure (force pushing the demand valve to the left) on port L of demand valve (1) becomes greater than the combined force (force pushing the demand valve to the right) of the surface pressure bearing on port M and tension of spring (2), it moves the demand valve to the left, opens the circuits between ports A and E, and ports R and F. The oil from the large and small pumps is then relieved to ports E and F, and is drained from port G to the hydraulic tank. Therefore, both the large and small pumps are put in an unload condition.

From shuttle I/

ripper Lo valve 17MF02057

1O-90

D275A-2

3. Blade lever at RAISE (blade operating at high speed) When the blade lever is moved fully to the RAISE position, spool (5) moves to the left, and fully opens the circuits between ports B and C, ports C and H, and ports D and F. When this happens, the oil from the two pumps passes from ports A and B and enters port C. Some of the oil flows to the head end of cylinder (9), and the rest flows from port H, pushes shuttle valve (8) to the right and opens it, flows to port K, and enters ports N, 0, and P of shuttle valve (10). It then enters port Q of demand valve (1) and becomes the pilot pressure. At the same time, the oil from the pump passes through orifice a of demand valve (I), enters ports L and M, and becomes the pilot pressure. The oil at the bottom end of cylinder (9) flows from port D to port F, and returns from port G to the hydraulic tank. When the hydraulic pressure in the circuit rises in this way, spool (5) opens the circuit between ports B and C fully, so the resistance of the oil flowing from port B to port C is small, and there is little pressure difference generated between port B and port C. Therefore, no pressure difference is generated between port L and ports M and Q of the demand valve. The surface pressure acting on the left and right of the demand valve is equal, so the demand valve is moved to the right by the tension of spring (2). When this happens, the circuits between ports A and E, and ports R and F are closed, and all the oil from both the large and small pumps flows to the head end of the cylinder to increase the speed of movement of the cylinder. -

From shuttle valve inside ripper Lo valve

17MF02058

D275A-2

10-91

Blade lever at RAISE (blade operating at low speed) When the blade lever is moved finely to the RAISE position, spool (5) moves slightly to the opens the circuit between left, and partially ports B and C, ports C and H, and ports D and F. the oil from the two When this happens, pumps passes from ports A and B, is throttled by spool (5), and enters port C. Some of the oil flows to the head end of cylinder (9), and the rest flows from port H, pushes shuttle valve (8) to the right and opens it, flows to port K, and enters ports N, 0, and P of shuttle valve (IO). It then enters port Q of demand valve (1) and becomes the pilot pressure. At the same time, the oil from the pump passes through orifice a of demand valve (I), enters ports L and M, and becomes the pilot pressure. The oil at the bottom end of cylinder (9) flows from port D to port F, and returns from port G tank. When the hydraulic to the hydraulic pressure in the circuit rises in this way the situation is different from in Item 3: spool (5) is throttling the circuit between ports B and C, so the flow of oil from port B to port C is restricted, and a pressure difference is generated port B and port C. The hydraulic between pressure in the circuit up to port B becomes higher. when the surface pressure acting Therefore, on port L of the demand valve (1) becomes greater than the combined force of the surface pressure acting on port M, the surface pressure acting on port Q and the tension of spring (2), the demand valve is moved to the left. When this happens, the circuits between ports A and E and ports R and F are opened, and the oil from both the large and small pumps is retank. This suppresses lieved to the hydraulic pressure at ports A the rise in the hydraulic and B, and the cylinder moves slowly. As explained in Items 3 and 4 above, the speed by of the cylinder is determined of movement the amount of opening of ports B and C correof the lever. If it is sponding to the movement wide open, the flow of oil beyond port C inpressure rises, and the creases, the hydraulic becomes faster. If it is opspeed of movement ened only slightly, the flow of oil beyond port so the oil flow is reduced, the C is throttled, low, and the becomes pressure hydraulic is slow. speed of movement In other words, the hydraulic pressure and oil so this proflow beyond port C is proportional, of the blade that folvides not only operation of the blade lever, lows the fine movements but reduces the pulling force (flow force) acting on spool (5), so the operating force of the spool does not increase.

1 O-92

ripper to Lo valve

17MF02059

D275A-2

5. Blade lever at RAISE (cylinder at stroke end) If cylinder (9) moves to the end of its stroke from the condition in Items 3 and 4, the hydraulic pressure in the whole circuit rises. Therefore, the hydraulic pressure beyond port C rises, and the oil entering the main relief valve (45) through shuttle valves (8) and (IO), that is, the oil at port P, pushes open poppet (13) and is relieved to port T. At this point, the circuit from port 0 to port P is throttled by orifice c, so the supply of oil to port P is delayed. As a result, the hydraulic pressure of pilot port Q of demand valve (1) drops, and the demand valve moves to the left. When this happens, the circuit between ports A and E and ports R and F are opened, and the oil from the two pumps is relieved to prevent the hydraulic pressure from rising any further. The hydraulic pressure at this point is 210 kg/ cm2.

t :...:.:.:.:.:.:.:.:.:.:.:.:.:!/

4% 1 il.,.,.,.,...

1'0

From small pump through ripper valve

From large pump

From shuttle valve inside ripper Lo valve

i 17MF02060

D275A-2

1o-93

6. Blade lever at LEFT TILT

To ripper

Hi valve IS

A’

17MF02061

When the ripper lever is moved to the LEFT TILT position, spool (16) moves down, opens the circuits of ports B, and C, and ports D, and F,, and closes the circuit of ports A, and A,. When this happens, the oil from the small pump flows from port A,, pushes open check valve (15), flows from port B,, and enters port C,. It flows to the bottom end of cylinder (17), and when the hydraulic pressure in the circuit rises, it extends the cylinder. At this point, the oil at the head end of the cylinder returns from port D, to port F,, and is drained from port E, to the hydraulic tank.

1o-94

The oil from the large pump enters port A of the blade lift valve, and actuates demand valve (1) in the same way as in Item 2. It is relieved from port A to E, and is drained to the hydraulic tank. When the blade tilt is operated, the circuit between ports A, and A, is closed, so the oil does not enter the ripper circuit, and it is impossible to operate the ripper. In other words, the blade tilt circuit is given priority over the ripper circuit.

D275A-2

Blade lever at LEFT TILT (cylinder at stroke end)

To ripper Hi valve

17MF02062

From the condition in Item 6, if cylinder (17) is moved to the end of its stroke, the hydraulic pressure in the whole circuit rises. When this happens, the oil from the small pump flows from port A,, and pushes open main relief valve poppet (14). It is then relieved to port E,, so the hydraulic pressure does not rise any further. The hydraulic pressure at this point is 210 kg/ cm*.

D275A-2

1 o-95

8. Ripper lever at TILT ON (ripper Lo valve, shuttle valve actuated)

/Hs ---22

17MF02063

When the ripper lever is moved to the TILT ON position, spool (19) moves up, opens the circuits between ports B, and D,, ports C, and E,, and ports A, and G,, and closes the circuit between ports A, and A,. When this happens, the oil from the small pump enters port A, and A,. Some of the oil pushes open check valve (18), flows from port B, into port D,, and the flows to port G, of the ripper Hi valve. The rest of the oil passes through the groove in spool (19), enters port G,, pushes shuttle valve (22) down fully, then flows from port H, to port S of shuttle valve (IO).

1 O-96

The oil entering port S passes through orifice b, and pushes piston (11). The reaction moves shuttle valve (IO) to the left, closes the circuit between ports N and 0, and opens the circuit between ports S and 0. The oil entering port 0 from port S then passes through orifice c, and enters ports P and 0. It becomes the pilot pressure of demand valve (I), and moves the demand valve to the right. When this happens, the circuit between ports A and E is closed, so the oil from the large pump is not drained to the hydraulic tank. The whole amount of the oil flows to port A, of the ripper Hi valve.

D275A-2

9. Ripper lever at TILT ON (ripper Hi valve actuated) As explained in Item 8, the oil from the large pump enters A, of the ripper Hi valve, pushes open check valves (23) and (35), flows to ports B, and B,, and stops. The oil from the small pump flows from port D4 of the ripper Lo valve and enters port G,. Some of the oil entering port G, passes through the passage inside valve (39), flows to port L,, and pushes shuttle valve (41) up fully. It then enters port N,, pushes spool (36) to the right, and becomes the pilot pressure. The rest of the oil is throttled by orifice f and enters port C,. Some of the oil entering port C, passes through the passage inside valve (39), flows to port J,, and pushes shuttle valve (44) down fully. It then enters port 0,, pushes spool (36) to the left, and becomes the pilot pressure. The rest of the oil flows from port C, to the bottom end of ripper tilt cylinder (45). When all the above hydraulic circuits are filled with oil, the hydraulic pressure starts to rise.

17MF02064

D275A-2

1o-97

From the condition previously explained, if the hydraulic pressure continues to rise,the oil at port G, is throttled by orifice f and enters port C,. Because of the resistance, the hydraulic pressure at port G, becomes higher than the pressure beyond port C,. Therefore, the hydraulic pressure at pilot port N, of spool (36) becomes higher than the hydraulic pressure at port 0,, so when this pressure difference becomes greater than the tension of spring (38), it pushes spool (36) out to the right. When this happens, the circuits between ports B, and C,, and ports D, and F, open, the oil from the large pump flows from port B, to port C,, enters the bottom end of ripper tilt cylinder (45), and merges with the oil from the small pump to extend the cylinder. Some of the oil at the head end of the cylinder returns from port D, to port F,, and is drained to the hydraulic tank. The rest of the oil flows from port D,, is throttled by orifice g of valve (42), and returns to port H,. It then flows from port C, of the ripper Lo valve, returns to port E,, and is drained to the hydraulic tank.

17MF02065

1 O-98

D275A-2

10. Ripper level at LOWER (ripper Lo valve, shuttle

valve actuated)

ripper

Hi valve

(A, port)

17MF02066

When the ripper lever is moved to the LOWER position, spool (21) moves down, opens the circuits of ports B, and C,, ports D, and F,, and ports A, and G, and closes the circuit of ports A, and A,. When this happens, the oil from the small pump enters ports A,, A,, and A4. Some of the oil pushes open check valve (20), flows from port B, into port C,, and then flows to port H, of the ripper Hi valve. The rest of the oil passes through the groove in the spool, enters port G,, pushes shuttle valve (22) up fully, then flows from port H, to port S of shuttle valve (IO).

D275A-2

1o-99

11. Ripper lever at LOWER (ripper Hi valve actuated) As explained in Item 10, the oil from the large pump enters port A, of the ripper Hi valve, pushes open check valves (23) and (35), flows to ports B, and B,, and stops. The oil from the small pump flows from port C, of the ripper Lo valve and enters port H,. Some of the oil entering port H, passes through the passage inside valve (30), flows to port M,, and pushes shuttle valve (32) down fully. It then enters port 0,, pushes spool (24) to the left, and becomes the pilot pressure. The rest of the oil is throttled by orifice e and enters port D,. Some of the oil entering port D, passes through the passage inside valve (30), flows to port K,, and pushes shuttle valve (29) up fully. It then enters port N,, pushes spool (24) to the right, and becomes the pilot pressure. The rest of the oil flows from port D, to the bottom end of ripper lift cylinder (33). When all the above hydraulic circuits are filled with oil, the hydraulic pressure starts to rise.

From CS 17MF02067

10-100

D275A-2

From the condition previously explained, if the hydraulic pressure continues to rise, the oil at port H, is throttled by orifice e and enters port D,. Because of the resistance, the hydraulic pressure at port H, becomes higher than the pressure beyond port D,. Therefore, the hydraulic pressure at pilot port 0, of spool (24) becomes higher than the hydraulic pressure at port N,, so when this pressure difference becomes greater than the tension of spring (25), it pushes spool (24) out to the left. When this happens, the circuits between ports B, and D, and ports C, and E, open, the oil from the large pump flows from port 6, to port D,, enters the bottom end of ripper lift cylinder (33), and merges with the oil from the small pump to extend the cylinder. Some of the oil at the head end of the cylinder returns from port C, to port E,, and is drained to the hydraulic tank. The rest of the oil flows from port C,, is throttled by orifice d of valve (27), and returns to port G,. It then flows from port D, of the ripper Lo valve, returns to port E,, and is drained to the hydraulic tank.

17MF02068

D275A-2

10-101

12. Ripper lever at LOWER (cylinder at stroke end)

-1

I I

17MF02069

D275A-2

From the condition in Items 10 and 11, if cylinder (33) is moved to the end of its stroke, the hydraulic pressure in the whole circuit rises. When this happens, in the same way as in Item 7, the oil from the small pump flows from port A, and pushes open main relief valve poppet (14). It is then relieved to port E,, so the hydraulic pressure does not rise any further. The hydraulic pressure at this point is 210 kg/ 2

oil passing through shuttle valves (22) and (IO), and flowing from ports S and 0 to port P also pushes open main relief valve poppet (13), and is relieved to port T. The circuit from port 0 to port P is throttled by orifice c, so the supply of oil to port P is delayed. As a result, the hydraulic pressure at pilot port 0 of demand valve (1) also drops, and the demand valve moves to the left. When this happens, the circuit between ports A and E opens, and the oil from the large pump is relieved, so the hydraulic pressure in the circuit of the large pump does not rise any further. The hydraulic pressure at this point is 210 kg/ cm2. When the hydraulic pressure in the whole circuit is set at 210 kg/cm2, the pressure difference on both sides of orifice e of valve (30), that is, the difference in pressure between ports H, and D,, disappears. The pilot pressure at port 0, that is pushing spool (24) to the left becomes the same pressure as the pressure at port N,. When this happens, spool (24) is returned to the right by the tension of spring (25) to a position where it is in balance with the tension of spring (26). At this point, the circuits between ports B, and D, and ports C, and E, are closed. The oil from the large pump goes as far as port B,, and stops. The oil at the head end of cylinder (33) flows from port C,, passes through orifice d of valve (27), and returns only to port

;Te’

G,.

D275A-2

10-103

PISTON VALVE (Blade lift and dual tilt cylinder)

STRUCTURE AND FUNCTION The piston valve is installed on the piston in the blade lift cylinder. When the piston reaches its stroke end, the valve releases the oil from the hydraulic pump to reduce the oil pressure being exerted on the piston. When the blade on a dual tilt dozer is tilted, the blade is subject to a tortional force owing to the uneven position of the pistons in the two cylinders; that is the piston one side is still moving while the piston on the other side has reached its stroke end. The piston valves are installed to prevent the tortional force from occurring. When one of the pistons reaches its stroke end, its piston valve opens to relieve the oil pressure. In addition, the piston valve relieves the shock which occurs when the piston comes into contact with the cylinder head or the bottom and serves to reduce the subsequent surge pressure in the cylinder by letting the oil escape from the cylinder before the piston reaches its stroke end.

OPERATION Piston valve CLOSED Pressurized oil from the hydraulic pump acts on piston (4) and piston valve (5). The piston valve is pushed in the direction of the arrow until piston valve seat (3) comes into snug contact with the tapered section, thereby, this causing the pressure in the cvlinder to rise of the and moving piston (4) in the direction arrow.

1. 2. 3. 4. 5.

17MF02070

Piston rod Cylinder Piston valve seat Piston Piston valve

17MF02071

Piston valve OPEN Just before piston rod (1) reaches its stroke end, the front end of piston valve (5) comes into contact with the cylinder bottom (or the cylinder head) and is prevented from moving any further while piston (4) alone keeps on moving ahead. Then, the oil sealed within the piston valve on the cylinder head side will escape from piston valve seat (3) so that the oil pressure in the cylinder is prevented from rising. Strike 17MF02072

10-104

D275A-2

QUICK DROP VALVE

STRUCTURE The quick drop valve consists of valve body (I), spring (2), spool (3), check valve (4). The quick drop valve serves to increase the blade lowering speed and to reduce the occurrence of vacuum when the blade is lowering, thereby shortening the time lag before digging is started. The blade lowering speed,- which is generally determined by the pump discharge, can be made faster with the quick drop valve. 1. Valve body 2. Spring 3. Check valve

4. Spool

OPERATION 1. Start of lowering When the blade lever is operated to LOWER, the oil from the control valve enters the cylinder bottom through port A and pushes the piston. In the mean time, the oil in the cylinder head is pushed out into the piston, enters valve port B, and flows into the tank.

2. While lowering Pressurized oil from the cylinder head flows into port C through port B. At this time, the oil flow is restricted by an orifice provided along the way, causing a differential pressure before and after the orifice. When the differential pressure becomes greater than the force of spring (2), it compresses the spring and moves spool (3) and valve (4) to the right. With the spool and the valve have moved, part of the oil flowing from the cylinder head to the tank enters the passage to the cylinder bottom together with the oil from the control valve. Thus, the blade lowering speed increases in accordance with the amount of oil that flows to the bottom of the cylinder and reduces the formation of vacuum at the bottom of the cylin-

17MF02073

I75F209

der. 175F210

D275A-2

10-105

CYLINDER

STAY

17MF02074

1. Yoke 2. Oil seal 3. Bushing 4. Bushing 5. Air bleeding plug

1 O-l 06

D275A-2

SEMI

U-DOZER

A-A

1. 2. 3. 4. 5.

Cutting edge Arm End bit Straight frame Trunnion

lo-108

6. Arm 7. Blade 8. Brace 9. Blade tilt cylinder 10. Blade lift cylinder

17MF02075

OUTLINE l The dozing attachment can be broadly divided into the blade and the hydraulic control which operates the blade. the diagram shows the semi U-dozer. The table shows the dimensions and specifications of the semi U-dozer.

D275A-2

D-D

B-B

F-F

E-E

G-G

J-J

K-K

H-H

M-M

L-L

17MF02076

OPERATION l The blade is moved by hydraulic cylinders. l RAISE: The left and. right lift cylinders retract and raise the frame and blade together. l LOWER: The left and right lift cylinders extend and lower the blade to the ground. . LEFTTILT: The tilt cylinder extends and lowers the left side of the blade to the ground. l RIGHT TILT: The tilt cylinder retracts and lowers the right side of the blade to the ground.

D275A-2

Table of comparisons Unit: mm Semi U-dozer Distance between left and right frame

3636

Length of frame

3775

Width of blade

4300

Height of blade

1910

Max. blade raise

1505

Max. blade lower

660

Max. blade tilt

1025

10-109

VARIABLE

MULTIPLE

SHANK

RIPPER

A-A

C-C

D-D

17MFOi077

10-l 10 0

OUTLINE l The ripping attachment can be broadly divided into the ripper and the hydraulic control which operates the shank. The diagram shows the variable multiple shank ripper. The table shows the dimensions and specifications of the variable multiple shank ripper.

OPERATION l The shank is moved bv hvdraulic cvlinders. The left and’right . RAISE: lift cylinders retract and raise the beam and shank together. . LOWER: The left and right lift cylinders extend and lower the beam and shank together to the ground. . TILT ON: The left and right tilt cylinders extend and move the shank forward. . TILT BACK: The left and right tilt cylinders retract and move the shank to the rearward.

Table of comparisons

Unit: Multiple Length of beam

No. of shanks 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Tilt cylinder Lift cylinder Beam Shank Protector Point Arm Pin Bushing Pin

D275A-2

shank ripper 2495 3

Shank pitch (with 3 shanks installed)

1130

Shank pitch (with 2 shanks installed)

2260

Ripping

)

depth

2-stage selection possible

10-l11

8 f 6

_ Section

A-A

Section

C-C

Section

B-B

P-

Section

D-D

__.-

Detail

P F197UR034A

10-112 0

OUTLINE l The ripping attachment can be broadly divided into the ripper and the hydraulic control which operates the shank. The diagram shows the variable giant ripper. The table shows the dimensions and specifications of the variable giant ripper.

OPERATION l The shank is moved by hydraulic cylinders. . RAISE: The left and right lift cylinders retract and raise the beam and shank together. The left and right lift cylinders ex. LOWER: tend and lower the beam and shank together to the ground. l TILT ON: The left and right tilt cylinders extend and move the shank forward. . TILT BACK: The left and right tilt cylinders retract and move the shank to the rearward.

Table of comparisons

Unit: mm \ Length of beam No. of shanks 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Tilt cylinder Lift cylinder Beam Shank Protector Point Arm Pin Bushing Pin

Ripping depth Max. ripping depth Max. raise

I I

Giant ripper 1252 1 3-stage selection oossible 1300 870

10-112-l 0

123456789

, / / I

J 198F1113

1. 2. 3. 4. 5. 6. 7. 8. 9.

Plug Spring Spring retainer Valve body Spool Spring retainer Spring Push pin Solenoid assembly

A: To pin-puller cylinder head B: From power train pump C: To pin-puller cylinder bottom D. To steering case

1 o-1 12-2 0

OUTLINE l

The pin-puller solenoid valve is in the circuit between the pin-puller cylinder and the power train pump passing through the steering control valve. When the pin-puller switch in the operator’s compartment is operated, it switches the oil from the power train pump and acts on the pin-puller cylinder to operate the shank mounting pin for the ripper shank. Solenoid assembly (9) is deactivated when pushed in and excited when pulled out.

OPERATION 1. Pin-puller switch at PUSH IN position When the pin puller switch is turned to the PUSH IN position, no current flows to solenoid (9) and it is deactivated. When this happens, spool (5) opens ports A and B and ports C and D, and the oil from the power train pump flows from port A to port B and enters the bottom of pin-puller cylinder (IO). The oil entering the bottom end of the cylinder increases the hydraulic pressure in the circuit and extends the cylinder. Shank mounting pin (11) is pushed into shank (13).

From power

train pump

Switch at PUSH IN position

198FO2028

2. Pin-puller switch at PULL OUT position When the pin-puller switch is turned to the PULL OUT position, current flows to solenoid (9) and it is excited. When this happens, the solenoid pushes out push pin (8), and spool (5) moves to the left in the direction of the arrow. Ports A and B and ports C and D close, and ports A and C and ports B and D open. The oil from the power train pump flows from port A to port C and enters the head of pin-puller cylinder (IO). The oil entering the head end of the cylinder increases the hydraulic pressure in the circuit and retracts the cylinder. Shank mounting pin (I 1) is pulled out of shank (13).

From power train pump

10. 11. 12. 13.

Pin-puller cylinder Shank mounting pin Beam Shank

Switch at PULL OUT position

198FO2029

1 o-1 12-3 0

CAB ELECTRICAL

CIRCUIT DIAGRAM

Serial No. : lOOOl-10127

R.H. door wiper

Front wiper

Rear wiper

Cigarette

Caution

lighter

lamp

Lock-up indication lamp

connection

Front and Rear window washer

Car

stereo

oc&o r

R.H. and L.H. window washer

198FO2034-2

10-118-4 @

Serial No. : 10128 and up

H /xd’bor

wiper

( ./ ! P.

I amp

Alarm L/C L/C

indi indi

cat cat

wiDer

ont

wiper

ear

IIll

R. H door

wiper

CN399

( 1 i

lamp

rette ter

0281330~ 02BOQQ1

(12V for

LR LB LA

power radio)

83 0 0

source Car

Front. wind

rear washe

iI 2

CNMI

stereo

Converter

10-118-5 8

ELECTRICAL CIRCUIT DIAGRAM

AIR CONDITIONER

Serial No. : 10001 - 10127

Control panel

Air-conditioner

Starting switch

switch

Pressure switch

CN 108

CN351

CN12 CN381

Air conditioner compressor

Floor frame

Thermostat Blower motor

Air-conditioner

Blower resistor

relay

17MF02080

Serial No. : 10128 and up

Control Panel Blower

motor

switch

Air-conditioner

switch

S tart

ina

switch

Pressure

switch

conditioner ComIpressor

I OOOQQQO~

Floor

frame

1,“IP,P,P,!::

1Ch365

Air

conditioner

unit

8°K

L-Y

Blower

Air

conditioner

relay

motor

Blower

resistor

Thermostat

SAD01517

10-118-7 @

EVMS

(ELECTRONIC

VEHICLE MONITORING

Monitor

SYSTEM)

panel

Sensor

signal

Buzzer signal

Buzzer

Caution

lamp

Battery F19702046

OUTLINE The vehicle monitoring system monitors varil ous conditions of the vehicle by means of sensors provided throughout the vehicle. It proand incesses the information immediately, forms the operator of the condition by making a display on the panel. There are two major kinds of panel display. 1. The monitor assembly, which gives a warning when any fault is monitored on the vehicle. 2. The gauge assembly and service meters, which constantly indicate the condition of the vehicle. (Engine water temperature, torque converter oil temperature and fuel level.)

D275A-2

The vehicle monitoring system consists of a monitor panel, sensors, warning lamps, warning buzzers, and the power source. The monitor panel, and sensors are connected by wiring harnesses. The power is supplied from the battery to the monitor panel. As soon as any trouble occurs, the monitor and warning lamps start flashing and the warning buzzer sounds to protect the vehicle.

10-119

9 10

F19802003

1. Engine oil level 2. Radiator water level 3. Fuel level 4. Torque converter oil temperature 5. Engine water temperature 6. Battery charge 7. Engine oil pressure

8. Radiator water level 9. Engine water temperature 10. Torque converter oil temperature 11. Hydraulic oil temperature 12. Preheat 13. Service meter indicator 14. Service meter

OUTLINE l The monitor panel consists of the monitor portion that gives out warning when any abnormality occurs in the machine, and the gauge portion and service meter that always indicate the condition of the machine. The monitor and gauge portions each have microcomputers that process the signals from each sensor and display the results. A liquid crystal display is used. For details of the items displayed on the monitor and gauge portion, see the table on the next page.

2. CHECK items 1) After lighting up as explained in Section 1, if there is any abnormality in any CHECK item, that item flashes. 2) The CHECK items go out when the engine is started. (The rise in the engine oil pressure is used to judge if the engine is running or not, or if the voltage from the alternator is more than 1OV.)

OPERATION 1. Power switched on (starting switch ON) 1) All items on the gauge and monitor light up for 3 seconds. 2) The warning lamps light up for 2 seconds and the alarm buzzer sounds for 1 second.

1 o-1 20

CAUTION The caution items are checked from the time the engine is started until the time the engine is stopped. If there is any abnormality, the item flashes, and the warning lamp also flashes. If any items in CAUTION 2 flashes, the alarm buzzer also sounds. The monitor and warning lamps flash in an ON-OFF cycle of approx. 0.8 sec. The flashing cycle of the monitor may change slightly if the ambient temperature is low (approx. -10°C or below), but this is not an abnormality.

D275A-2

Monitor

panel indications

Classification 0 displav

rmbol

4 P

Method of indication

Radiator water level

Below LOW level

Engine oil level

Below LOW level

Indicates when the starting switch is turned ON with the engine stopped. If normal, the lamps do not light up. If abnormal, the lamps flash.

Engine oil pressure

When sensor is abnormal or wiring harness is disconnected

If normal, the lamps do not light up. If abnormal, the lamps light up.

3attet-y charge level

Insufficient charge

Indicates when the starting switch is turned ON while the engine is running. If normal, the lamp does not light. If abnormal, the lamp flashes and the warning lamp flashes at the same time.

Engine oil pressure

Below 0.5 kg/cm2

3adiator water level

Below LOW level

!ngine water temperature

When the engine water temperature gauge indicates the red ranqe (108” C or hiaher)

Torque converter

When the torque converter oil temperature gauge indicates the red range (over 130°C)

iydraulic

Range of indication

Indication items

oil temperature

Over 108°C When the preheat switch of seat switch is at ON, the lamp lights .rp (80 sec.) and changes to light going out to indicate that the preheating s completed.

When preheating

‘reheating

Engine water temperature

Indicates when the starting switch s turned ON while the engine is running. If normal, the lamp does not light up. If abnormal, the lamp and the warning ‘amp flash and the warning buzzer sounds.

102°C Green White

94°C 83°C 70°C

Lights up in the applicable

range

Lights up in the applicable

range

Red Torque converter

oil temperature

Green

Green Fuel level

Red

D275A-2

FULL 617 517 417 3/7 Z/7 EMPTY

Service meter

Indicates between 9999 hours.

zero and

Service meter indicator

When the service meter is working

All light up below the applicable

Operates while the alternator charging Clock time: 1 :l

level

Flashes while the service meter is working

10-121

SUPPLEMENTARY l

CONTROLLER

Tne supplementary controller acts as a power source box to supply electrical power to the panel assembly, switch panel, lock-up controller, etc. The variations in voltage of the power supply for the machine (battery, alternator) is large, so this supplementary controller transforms the power to a stable voltage before supplying it to the panel. Even if there is over-voltage caused by a failure in the alternator or regulator, it is cut here to protect the monitor panel.

CN 162 (3 pin)

CN464

(4 pin)

197FO2076

SENSOR The signal from the sensor is input directly to the machine monitor panel. One end of contact type sensors is always connected to the chassis ground. When the contacts of all the sensors except the engine oil pressure sensor close, and the signal wire is connected to the chassis ground, the panel judges it to be the normal signal. When the contact of the engine oil pressure sensor is open, and the signal wire is separated from the chassis ground, the panel judges it to be the normal signal.

Engine oil level Radiator

water

Hydraulic

oil temperature

level

Engine oil pressure Engine water Torque

temperature

converter

Fuel level

10-122

oil temperature

When normal

When abnormal

Contact

OFF

Contact

OFF

Sensor

Type of sensor

method

Contact

OFF

Contact

OFF

Resistance

D275A-1

Engine oil level sensor

A Structure of circuit

197FO2077

1. 2. 3. 4.

Radiator

Connector Bracket Float Switch

water

FUNCTION The sensor is installed to the L.H. side face of the oil pan. When the oil goes below the set level, the float goes down and turns the switch OFF. The monitor then flashes to warn of the abnormality.

level sensor

m I

Structure of circuit

1. Float 2. Sensor 3. Connector

D275A-2

561FO3177

FUNCTION The sensor is installed to the top of the radiator. When the coolant goes below the set level, the float goes down and turns the switch OFF. The monitor then flashes to warn of the abnormality.

lo-123

Hydraulic

oil temperature

sensor

Structure of circuit 198FO2047

1. 2. 3. 4.

FUNCTION The hydraulic oil temperature sensor is installed to the hydraulic pump inlet tube. It detects the temperature at switch (I), and when the temperature goes above the set temperature, the switch is turned OFF. The display appears on the monitor panel, the warning lamp flashes, and the alarm buzzer sounds.

Switch Case Wire Connector

Engine oil pressure sensor

cl 69

@ Structure of circuit

202FO5175

1. 2. 3. 4. 5. 6.

Plug Contact ring Contact Diaphragm Spring Terminal

1O-l 24

FUNCTION This sensor is installed to the engine cylinder block. The diaphragm detects the oil pressure, and when it drops below the standard pressure, the switch is turned ON, and the lamp lights up to warn of the abnormality.

D275A-1

Engine water temperature sensor Torque converter oil temperature sensor

w Structure

of circuit 198FO2046

1. Connector 2. Plug 3. Thermistor

D275A-2

FUNCTION These sensors are installed to the thermostat housing and torque converter outlet port tube. Any change in temperature is taken as a change in resistance of the thermistor. A signal is sent to the monitor panel and the temperature is displayed. When the panel display reaches a set point, the lamp flashes and the buzzer sounds to warn of the abnormality.

10-125

Fuel level sensor

Structure

of circuit

A-A 198FO2089

1. 2. 3. 4. 5. 6. 7.

Connector Float Arm Body Spring Contact Spacer

1 o-1 26

FUNCTION The fuel level sensor is installed to the side face of the fuel tank. The float moves up and down according to the fuel level. This movement of the float is transmitted by the arm and actuates a variable resistance. This sends a signal to the monitor panel to indicate the remaining fuel level. When the display on the monitor panel reaches a certain level, a warning lamp flashes.

D275A-2

PANEL SWITCH

OUTLINE l

The panel switch incorporates soft touch sheet switches for the headlights, rear lamps, working lamps, torque converter lock-up, APS, and the engine starting switch. When a switch is depressed, the red lamp will come on; when depressed once again, the lamp will go off. When the starting switch is turned off while any one of the sheet switches is ON, all the sheet switches will go OFF. They will not come on again when the starting switch is turned on (to prevent the bulbs from breaking).

197F127

RELAY BOX OUTLINE l

The relay box houses various relays which energize the lamps, torque converter lock-up and APS. The lamp come on or go off through the operation of the corresponding relay when the panel switch is operated. The relay box also houses the APS controller, fuses for protecting various electrical equipment, and the safety relay that protects the panel switch and relays from over-voltage from the power source (battery and alternator).

198FO2055

D275A-2

lo-127

RELAY BOX CIRCUIT Serial No.: 10001-10127

CN 362

CN361

197FO2085-1

lo-128 @

P ‘1.

” 0. 6 I. 26

0. 76

0. 5

0.75 1.25

_ _

017M02

I-

-0

‘t

‘-++?

2. 0

1.25

0. 75

017M02

An over-voltage protection circuit is built into the controller for the monitor power source. The output of this controller turns the safety relay inside the relay box ON, and supplies electrical power to the relay coil and panel switches. In other words, if any over voltage (approx. 34V) should occur in the power source circuit due to an abnormality in the battery or alternator, the output of the controller is cut and the safety relay is turned OFF to protect the relay coil and panel switches. At the same time, power source to the monitor panel is cut. (When this happens, the monitor panel goes out and the panel switches cannot be operated.) When the engine is started, the battery voltage drops, so the circuit does not pass through the controller. A circuit is formed directly from starting switch C to turn the safety relay ON.

Safety function

circuit drawing

Monitor panel power source

Relay box

I-T

I I

--1 Pane'switch

Relay power source Lock-up

______

I I

Safety relay

24” output

Supplementary controller (monitor power source)

I 1GND

I+

;;E&

e:lp I km

Alternator

197fO2086

D275A-2

1O-l 29

OPERATION .

OF LAMP SYSTEM

The lamps are lighted up by operating the panel switch. A signal is then sent to the relay box, and the relay inside the relay box is actuated to supply electricity to the lamp. Panel switch

Example of head lamp system When the head lamp switch on the panel is l pressed, the contacts of the head lamp switch close, and are connected to the ground. Electricity flows from the battery through the safety relay and fuse to the head lamp relay coil to close the head lamp relay contacts. When this happens, the electricity from the battery passes through the fuse, enters the head lamp relay, and flows to the head lamp to light up the head lamp. At the same time, electricity also passes through diode D,, and flows to the monitor night lighting night lighting to light up and air conditioner flows in the these lamps also. The electricity same way when the rear lamp switch and working lamp switch on the panel are pressed. The lamps, then lights up the respective electricity night lighting. monitors, and air conditioner

Monitor panel (night lighting)

\..._,,*’

F19702047

Head lamp system circuit diagram Relay box

--1

Safety relay

r---

Panel switch

Head lamp relay (L.H. and R.H.)

Head lamp

The power for the monitor night lighting is supplied from R.H. head lamp relay

I I I

_ -

Monitor illumination (3

Rear lamp -1

ncr

Working lamp -1

L 10-130

D4 +.am

Air conditioner illumination

Diode

I __

__I

747 197FO2088

D275A-2

APS CONTROL SYSTEM Serial No. : 10001 - 10167

Engine From fuel injection pump Air intake manifold

Water temperature sensor

’ I I I

Monitor panel

1 Water manifold

y Glow plug

Relay F19702048

APS SYSTEM

DIAGRAM

Fuel motor

1 Glow plug 2

Nozzle

Alternator CzGT

-__

nl7 J 197FO2090

1O-l 32 @

FUNCTION

APS start Flowoftime

APS stop

---------

Starting motor running

Glow plug preheating Starting switch Preheat switch (panel switch)

START (hand)

ON (hand)

OFF

Nozzle

OFF

I OFF

OFF

ON OFF

OFF (hand)

Min. 20°C

Light up

Preheat relay

Glow plug

Max. 20°C

Monitor panel display

Preheat back-up relav

ON (hand)

APS water temp. sensor

Heater relay

_____-----------

Engine start Heat up the glow plug

OFF ON

OFF 197F134

The APS functions to heat the air intake by burning the fuel in the intake manifold.

Z Z

The APS will operate in the following order When the engine cooling water temperature goes below 2o”C, the APS water temperature sensor contacts will close, thereby causing the signal line to connect to the machine body and causing the preheating relay to energize. Under the above condition, when the engine heat switch on the panel switch is depressed or when the starting switch is turned to HEAT, the large capacity heater relay to come ON, causing the current to flow to the glow plug to heat up the glow plug. The impressed voltage is lowered by a resistor to 18V to meat the rated voltage of the glow plug. The bimetal timer will operate while the glow plug is heating and the preheat (APS) pilot lamp will also light up. When the glow plug preheating time is up, the bimetal timer will come OFF and the pilot lamp will go OFF. This indicates that the glow plug is heated enough to operate the APS.

After the APS pilot lamp goes off, the APS controller is activated by turning the starting switch to START. The fuel injection nozzle in the intake manifold starts injecting fuel intermittently (IO times/set) through ON operation. After the engine is started, the fuel injection nozzle is operated by the alternator signal (so that the nozzle works only when the engine is running). When the engine water temperature rises above 2o”C, the APS water temperature sensor contacts open and the heater relay goes off, causing the glow plug to stop heating and the fuel injection nozzle to stop injection fuel. The preheat backup relay make use of the START signal to short both terminals of the resistor to supplement the voltage drop of the battery when the engine is started.

10-132-l 6%

Serial No. : 10168 and up

Panel

switch

Engine From fuel i,on Pump inject

1I Air

intake

manifold

Nozzle

:<*

APS water sensor

,’

II II II I

1 _____________-_/ ___________---------------_’ ~-__________________----____________---______~’

I Glow i______

Plus

II II fI I

Water aI / i _____i_______

temperature

; -1

manifold _j

I ;

I SAD01521

DIAGRAM

APS SYSTEM

CN142

Controller Power Glow

Glow

Nozzle

CN143 GND Water Starting

Water

temp. sensor

illmination

lam0

mater lamp

Preheat

Monitor

illmination

lamp

Preheating

lamo

Spare

SAD01 544

lo- 132-2 @

APS ACTUATION

CHART

APS start Flow of time ___________________ -l-+1Glow plug preheating

Starting

switch

APS stops completely I ________________________________________________

Starting motor turns

START

Preheating

switch

OFF

zntLrtemperature

IEngine starts, intake air heated

OFF (manual)

Specified

water

temperature

Specified water temperature or above

(20°C) or below

I Glow plug

OFF

APS fuel injection nozzle

abnormal

OFF

ON (12 set

OFF

Flashes (2 times/

3 set)

switch

is turned

OFF

The APS burns fuel inside the intake fold to heat the intake air.

The APS acts in the following

OFF

I ON

OFF

Lamp display When

mani-

order.

1. When the temperature of the engine cooling water is below the specified water temperature, the contacts of the APS water temperature sensor close and the water temperature sensor ON signal is input to the controller. 2.

Under the above conditions, if the preheating switch is turned ON, the controller sends electricity to the glow plug to heat it. When the glow plug is being heated, the preheating pilot lamp lights up.

After the preheating time for the glow plug has passed, the lamp goes out to show that the glow plug has been heated sufficiently to actuate the APS.

After the preheating lamp goes out, if the starting switch is turned to the START position, the APS fuel injection nozzle inside the intake manifold is switched ON/OFF (IO times/ set) to spray fuel.

When the engine cooling water temperature goes above the specified temperature, the APS water temperature sensor contacts open, and the action of the glow plug and APS fuel injection nozzle is stopped. When this happens, the preheating lamp flashes at 1 Hz to show that the preheating has been completed.

The preheating

If the glow plug or APS fuel injection nozzle system are short circuited with the ground, the lamp will light up until the short circuit is canceled. If the lamp does not go out when the preheating is completed (after 12 secor the lamp goes out onds have passed), and then lights up again, stop the engine and check for any short circuit with the ground.

If the preheating switch is turned ON when the engine cooling water temperature is above the specified temperature, the lamp lights up for 12 seconds, and then flashes. In this case, the glow plug is not actuated.

OFF.

lo- 132-3 @

TORQUE

CONVERTER

LOCK-UP CONTROL SYSTEM

Panel switch

,c _____

______\

/’ /’ /’ A’

/’

Transmission

T/C output shaft speed sensor (4 pulses/rev.)

Steering clutch

F19702049

TORQUE

CONVERTER

LOCK-UP

CONTROL

CIRCUIT

Lock-up display lamp

Panel switch ---__

.._I_

1 Lock-up controller

L/U valve source L/U valve signal

3 T/C speed (+) 3 T/C speed (-1

,3 T/M oil press. I

sen*or

qGiF-& Battery 24V

D275A-2

Battery relay

Lock-up solenoid

Torque converter speed sensor

Transmission oil pressure sensor

F19702050

10-133

OUTLINE l The torque converter lock-up control system uses a controller and the signals from two sensors to automatically locks up the torque converter according to the load on the machine. When the torque converter is locked up, the display lamp at the front of the operator’s compattment lights up. FUNCTION When the lock-up switch on the panel switch is pressed, the switch contact is closed and it is connected to the ground. Electricity from the battery passes through the fuse and flows to the lock-up relay coil in the relay box, and closes the lock-up relay contacts. When this happens, the electricity from the battery passes through the fuse and enters the lock-up relay, flows to the lock-up controller, and becomes the power source. l The lock-up controller receives signals from the transmission oil pressure sensor and torque converter speed sensor. It connects and cuts the lock-up solenoid and display lamp from the ground to switch the lock-up ON/OFF. The lock-up is switched ON-OFF if the signals from the two sensor fulfill the following conditions. t Lock-up ON (solenoid excited) When both of the following two conditions are satisfied (AND circuit) Torque converter output shaft speed: Above 1170 rpm Transmission oil pressure: Above 19.5 kg/cm’ * Lock-up OFF (solenoid deactivated) When either of the following two conditions are satisfied (OR circuit) Torque converter output shaft speed: Below 11 IO rpm Transmission oil pressure: Below 15 kg/cm2 l

1o-1 34

D275A2

SENSOR Torque converter

speed sensor

@.I^;) Structure

1. Connector 2. Flange 3. Sensor

Transmission

of circuit

561FO3114

FUNCTION The torque converter speed sensor is installed to the speed sensor gear of the torque converter output shaft. The rotation of the gear teeth generates a pulse voltage and sends a signal to the controller.

oil pressure sensor

Structure of circuit

17MF02082

1. 2. 3. 4.

Switch Tube Wire Connector

D275A-2

FUNCTION The transmission oil pressure sensor is installed to the transmission control valve. If the oil pressure is above the set pressure it is ON, and if it is below the set pressure it is OFF, and a signal is sent to the controller.

1o-1 35

MACHINE MONITOR

SYSTEM

(with SSC system)

Mode selection

Monitor

panel

display

Panel

Sensor

signal

I:_;

Sensors

Lamp sisnal

I!5 Power

source 1

I--I:

Buzzer

sianal

Buzzer

(central

Caution warnina

Battery

The machine monitor system uses sensors installed at various parts of the machine to observe the machine condition. It processes this information swiftly and displays it on the panel to keep the operator informed of the machine condition. The information displayed on the panel can be broadly divided into the following categories. 1. The monitor group, which informs the operator when there is any abnormality in the machine 2. The gauge group (coolant temperature, torque converter oil temperature, fuel level), which always displays the condition of the machine.

D275A-2

lamp)

SWD03775

The machine monitor system consists of the monitor panel, sensors, auxiliary controller, warning lamp, alarm buzzer and power source. The monitor panel, auxiliary controller, and sensors are connected with wiring harnesses, and the power supply for the monitor panel is taken from the battery through the auxiliary controller. If any abnormality occurs in the machine (detected by the sensors), the monitor and warning lamp flash and the buzzer sounds to protect the machine.

1o-137 a

MONITOR

PANEL

Mode &itches

1. Engine oil level 2. Radiator water level 3. Fuel level 4. Torque converter oil temperature 5. Engine cooling water temperature

6. Battery charge 7. Electronic system 8. Engine oil pressure 9. Radiator water level water 10. Engine cooling temperature

OUTLINE . The monitor panel consists of the monitor portion, which gives out warning when any abnormality occurs in the machine, and the gauge portion and service meter, which always indicate the condition of the machine. The monitor and gauge portions each have microcomputers that process the signals from each sensor and display the results. A liquid crystal display is used. For details of the items displayed on the monitor and gauge portions, see the table on the next page. OPERATION 1. Power switched on (starting switch ON) 1) All items on the gauge and monitor light up for 3 seconds. 2) The warning lamps light up for 2 seconds and the alarm buzzer sounds for 1 second. 2. CHECK items 1) After lighting up as explained in Section 1, if there is any abnormality in any CHECK item, that item flashes.

1 O-138

SWD03776

Monitor

* *

11. Torque converter oil temperature 12. Hydraulic oil temperature 13. Engine preheating 14. Service meter indicator 15. Service meter

The CHECK items go out when the engine is started. (To judge if the engine is running or not, the system checks if the engine oil pressure has risen or if the voltage from the alternator is more than IOV.)

CAUTION The caution items are checked from the time the engine is started until the time the engine is stopped. If there is any abnormality, the item flashes, and the warning lamp also flashes. If any item in CAUTION 2 flashes, the alarm buzzer also sounds. The monitor and warning lamps flash in an ON-OFF cycle of approx. 0.8 sec. The flashing cycle of the monitor may change slightly if the ambient temperature is low (approx. -1O’C or below), but this is not an abnormality.

D275A-2

MONITOR PANEL DISPLAY Display categoq

Display

Symbol

Display

item

Radiator

water

Engine

level

range

Below

low level

oil level

Below

low level

Engine

oil pressure

Below

specified

Battery

charge

When

charge

Display

Displays when engine is stopped and starting switch is ON Display when normal: OFF Display when abnormal: Flashes

SAD01479

CHECK

method

SAD01480

Display when normal: OFF Display when abnormal: Flashes

pressure

SAD01481

is defectivr

> Displays when starting

SAP00522

CAUTION SSC controller system

electronic

When system

is abnorma I

switch is ON and engine is running Display when normal: OFF Display when abnormal: Flashes CAUTION lamp flashes at same time

SWD03777

Engine

oil pressure

Below 49.03 kPa IO.5 kg/cm2 1

SAii1481

Radiator

water

level

Below

low level IIisplays

SAD01479

Engine water

CAUTION :

when starting

<switch is ON and engine is temperaturc

SAD01482

unning

When at highest level (108°C or above) on engine water temperature

ilisplay when normal: OFF Ilisplay when abnormal:

gauge

(CAUTION

I=lashes lamp flashes and at

‘alarm buzzer sounds

Torque converter temperature

oil

SAD01483

When at highest level (130°C or above) on torque converter temperature

!same time

gauge

iydraulic

oil temperature

108°C or above

SAD01484

Pilot

‘reheating SWD03805

10-140 0

VVhen preheating

I During cold weather, when sheet switch (preheating switch) on switch panel is ON, it lights up Ifor approx. 12 seconds. After 1this, it goes out to inform opera1tor that preheating is completed.

D275A-2

Display category

Display

Symbol

Display

item

range

Display

method

108t2% 102 i-;-c 98%

Engine

water

temperaturN

94% 83%

SAD01482

70%

One place lights applicable level

Torque converter temperature

Gauges

up to show

oil

SAD01483

FULL 6/7

5/?

Fuel level

4/7 3/7

SAD01486

0 From 0 to 99999

Actuated when alternator is charged. Advances by 1 hour for every hour.

Service

Lights up when service meter is running

fizq

Service meter

ap-

2/7 EMPTY

Red

Hourmeter

All lamps light up below plicable level

SKD00631

Service

meter

indicator

meter

SKD00632

D275A-2

10-141 a

MODE SELECTION SYSTEM * SSC stands for Shoe Slip Control system.

The following

explanation

uses the abbreviation

REVERSE limit switch

leve ‘r

Ripper

SSC.

Rinner PPC valve oil Pressure switch Back-up buzzer

Accelerati sensor REVERSE speed

ranse

signal

FORWARD speed

ranse

signal

SSC controller

Fuel

control

1st

lever

Manual signal

throttle

Torrue sianal

converter Pulse (20 ouIse/rev)

Decelerator nedal

-i-

; : o_

Auto lock-un control

To floor, frame

2 z z

: * G Iz, -0 7; :3 25 ELPC _

control’er

Engine 1

ranae

signal

Torque converter outaut shaft speed sensor signal (20 Pulse/rev)

g z 0

speed

sensor

sianal

Fuel

injection<

, eyb;;; i;yete& be;bbact’)

)

1 (&&

Engine actuator

Lock-un

actuation

Transmission

oil

signal Pressure

I sensor

signal SWD03778

10-142 a

D275A-2

The mode selection system consists of the mode selection panel (with built-in microcomputer) which selects the operating mode, the shoe slip controller (with built-in microcomputer) which governs the engine control, the ELPC controller which receives the command from the shoe slip controller and controls the fuel injection pump, the lockup controller which switches the lock-up of the torque converter ON/OFF according to the torque converter dividing pulse output by the shoe slip controller, and various sensors. The mode selection system automatically carries out engine control to match the operating mode selected by the operator, and acts to reduce fuel consumption, extend the life of the track shoes, and reduce the frequency of operation of the deceleration. The engine control modes consist of the economy mode control used when dozing, the SSC control used when ripping, and the reverse slow mode control, which can be used for either operation. The lock-up control mode is the same as the conventional lock-up function. It cannot be selected in combination with the above modes.

D275A-2

10-143 0

Operation of mode selection system . It is possible to select the five modes optimum Open tion

conditions

Lode ;witch

individually for the type of work.

Mode

actuation

P,3;OFF

Torque converter output shah speed

OFF

1,170rpm or above

TraIE-

When transmission RI, R2, R3

is a

0 When the following conditions are fulfilled 1. When transmission is at Fl 2. After ripper DOWN, ripper TILT lever is operated and limit switch is turned ON Q Q .-

features

of mode

WHen torque converter approaches stall range or when gear is shifted, lock-up is turned OFF; when there is light load, lock-up is turned ON. 2. Possible to use at all speed ranges 3. Impossible to select combined operation with other mode 4. Suitable for dozing operations where there is comparatively little change in load. 1.

When transmission is al Fl with economy mode switch (1) or (2) ON

.-i?

to carry out work under the

1.5MPa 1.9MPa 19.5kgfcmZ}{15kg/cmzl or above or below

mi$o” pressure

switche: according to the

Actuation,

conditions

. Automatically

or in combination

When economy mode ((1) or (2)) and shoe slip control are set in combination, economy control is carried out when the transmission is shifted to Fl, and slip control is carried out when the ripper lever is operated and the switch is turned ON. The engine output can be controlled to 2 levels without operating the engine deceleration. Mode (1): 90% (at 2.4 km/h) Mode (2): 70% (at 2.4 km/h) At neutral, the engine speed is reduced to partial speed. 1. The engine output can be controlled to partial without operating the engine deceleration. Engine speed when in traveling reverse: 1,400 - 1,850rpm 2. Set speed when traveling in reverse RI, R2, R3: 71 - 94% of full throttle To prevent the machine from starting suddenly when it moves off, modulation is carried out. The SSC controller controls the engine output according to the drawbar pull characteristics (see Rockbed selection below) selected by the operator from the drawbar pull characteristics (set to 5 levels), and prevents the occurrence of slippage. When this happens, if the ripper DOWN signal is input, the SSC controller reduces the drawbar pull characteristics by 40% and controls the engine output. The SSC controller takes the drawbar pull immediately before slippage occurs when the shoe slip ratio is 25% or more as the maximum and carries out control of the engine output. When this happens, if the ripper TILT or ripper UP signal are input, the SSC controller increases the drawbar pull characteristic by approx. 30 - 60% and controls the engine output. At neutral, the engine speed is reduced to partial speed.

Interconnected with 1. When the SSC control is turned ON, selection shoe slip control and lights up. is turned ON to the 2. The selection is made 1 ti 3 ti 5 according load and condition 01 the bedrock.

mode

131

Ir When the above modes are set, it is possible to operate the fuel control lever and decelerator pedal. In such cases, the engine output control is carried out according to the minimum value command from the controller command, throttle command, and deceleration command.

10-144 0

D275A-2

MODE SELECTION PANEL

1. 2. 3. 4. 5. 6.

Lock-up mode switch Economy mode switch Reverse slow mode switch SSC control mode switch Rockbed selection mode switch Rockbed selection mode switch

(hard) (soft)

3 SHOE SLIP

Outline l The mode selection panel has 6 mode seThe selection mode lection switches. changes each time the switches are pressed. The LED lights up to display the existing condition.

D275A-2

10-145 a

INITIAL SET SWITCH

1. 2. 3. 4.

I98FO2043-

Outline The initial set switch is used to set the mode setting to a constant mode pattern. If the initial set switch is operated and the starting switch is turned ON, all the switches on the mode selection panel will be automatically set to one of the mode patterns shown in the chart on the right. Even after the mode pattern is set, it is possible to select the mode freely. The normal mode pattern in the chart on the right is the pattern set when the initial set switch is OFF (the normal condition when the machine is shipped from the factory). It is the mode pattern suited to digging bedrock and dozing operations. The initial set mode in the chart on the right is the pattern set when the initial set switch is turned ON (connector CNSOI-(11) on the mode selection panel is connected to the chassis ground). This mode pattern is suitable for specialized operations with blasted rock.

ELPC controller SSC controller Initial set switch Monitor auxiliary

controller

Normal

mode pattern

Item

Lock-up

(when

switch

is OFF)

Actuation

mode

Economy Reverse

2 3

mode slow

SSC control F&ked

selection

Initial

mode

pattern

(when

Item

switch

is ON)

Actuation

The condition inside the n in the actuation column in the chart on the right is the mode set when the starting switch is turned ON. Reverse

slow

SSC control Rmo;$ked selection

lo-146 0

OFF

OFF HW 1~2++4tt5

D275A-2

SSC CONTROLLER

‘; SED01409

1. Self-diagnostic Function 1. The SSC controller uses the input signal from the acceleration sensor to calculate the travel speed of the machine in relation to the ground. In addition, it inputs the torque converter speed sensor signal and calculates the shoe speed. From these data, it detects the shoe slip ratio. 2. Next, it inputs the engine speed sensor signal and torque converter speed sensor signal, and calculates the drawbar pull. 3. It uses the results of the calculations in Steps 1 and 2 above together with the mode selection signal from the monitor panel and the transmission oil pressure sensor signal to calculate the optimum engine speed. It then sends a signal to the ELPC controller as the SSC control command.

D275A-2

display

LED

When the mode selection panel lock-up mode signal is input, it sends the torque converter output shaft speed pulse (20 pulse/ rev) as it is to the lock-up controller. The SSC controller has a self-diagnostic function, and if there is any abnormality in the input or output system, the 2 LEDs flash to display the problem.

10-147 0

SENSORS

ENGINE SPEED SENSOR

Structure

circuit

SEW00289

1. Magnet 2. Terminal 3. Case 4. Boot 5. Connector

TORQUE CONVERTER SPEED SENSOR

@*g)

D D

Structure

of circuit

SBDo1545

I. Connector 2. Flange 3. Sensor

lo-148 0

D275A-2

Transmission Transmission

F oil pressure sensor 1st oil pressure sensor

Structure

SW003806

circuit

1. Switch 2. Tube 3. Wire 4. Connector

Work equipment control Backup alarm switch Neutral safety switch

lever (ripper)

limit switch

SJD02655

1. Plunger 2. Microswitch 3. Plug 4. Ball 5. Bearing

D275A-2

6. 7. 8. 9. IO.

Cap Roller Stopper Diaphragm Connector

10-149 0

ACCELERATION

SENSOR

Acceleration

-O-

Deceleration -

1. 2. 3. 4.

Amp

Plate Sensor portion Wire Connector

SWD03781

Outline The acceleration sensor is installed under the front of the operator’s cab. With the acceleration sensor, the position of the ball inside the sensor changes according to the acceleration. Inside the sensor, there is a coil that detects the position of the ball. This is amplified by the amp and is sent as a voltage change to the SSC controller. The input and output characteristics of the sensor are shown in the diagram on the rig ht. l

Acceleration

(G) SWD03782

10-150 0

D275A-2

ENGINE CONTROL SYSTEM

17MF02083

1. Manual potentiometer 2. Deceleration pedal 3. Mode selection panel, monitor panel 4. Panel switch 5. ELPC controller 6. Shoe slip controller 7. Fuel control lever 8. Relay box 9. Torque converter lock-up controller 10. Battery relay 11. Battery 12. ELPC actuator 13. Fuel injection pump

D275A-2

Outline . Engine control is carried out for the following two systems. 1. When the fuel control lever and decelerator pedal are operated, they control the fuel injection pump through the linkage and ELPC actuator. 2. When mode selection system is actuated The necessary information for the shoe slip controller enters, the processed manual command is sent to the ELPC controller, drives the ELPC actuator and controls the fuel injection pump.

10-151 a

ELPC CONTROLLER

CNSM

I SED01418

No. 1Input/Output 1 I.1

Input

2.1

output

Signal

Self-diagnostic

No. 1Input/Output 1

display

Signal

1 Power source (+)

12.

Input

GND

I-

13.

Proportional solenoid (+I

14. ( output

1 Proportional solenoid H

I -

15.1

Input

Feedback signal

16.

output

Feedback power source (+I

17.

output

Manual power source (+I

18.

output

Input

Manual command

19.

output output

Input

Shoe slip command

20.

10.

21.

11.1

I -

LED

Feedback power source (-) Manual power source (-1 Accelerationsensor power source (-1 Alarm signal

D275A-2

Outline The ELPC controller receives the manual signals shown in the diagram on the right, carries out internal processing, and sends a signal to the ELPC actuator. l

Control function of controller 1. Engine speed set function using manual potentiometer An output signal is sent according to the angle of the manual potentiometer so that the ELPC actuator output lever rotation angle matches manual command voltage 0. Rotation angle @I gives feedback to the controller according to the ELPC feedback potentiometer signal, and always displays the actuation of the ELPC actuator.

(Input sianail Starting (Dower

(Outnut

snitch source)

signal)

flanuai Potentiometer (desceleration sienall

L________________J ELPC feedback botentioneter tvotentioaeter

c sionalf

I SV002540

ELPC Valve output lever rotation anale

Engine speed control according to shoe slip control command (throttle signal) The ripper controller indirectly controls the engine speed according to the shoe slip command because of the mode selection system control. The ELPC controller receives the signal from the manual potentiometer and the shoe slip command (throttle signal) from the shoe slip controller, and controls the engine according to the low engine speed signal (high voltage) (it sends a signal to the ELPC actuator).

ELPC controller output characteristice

(Example) When the transmission is at neutral, even if the fuel control lever is set to the FULL position, if the economy mode has been selected, the engine speed is automatically reduced to partial speed. For details, see SHOE SLIP CONTROL.

output

characteristic SVD02541

ELPC Valve output lever rotation anofe

ELPC controller output characteristice

Ful I 3 % _ VI ~ ld,ina -~----------_-~----._ 8

stop 1

1. 1

I I I

1. 6

2. 5

ssc command voltage SVD02542

D275A-2

10-153 0

ELPC ACTUATOR

SVD02543

1. Feedback potentiometer 2. Manual potentiometer 3. Proportional solenoid 4. Output shaft 5. Input shaft 6. Output control spring 7. Load piston 8. Output control spool 9. Input lever

10-154 0

10. Input spool 11. Pilot spool 12. Spring 13. Stopper 14. Output spool (piston) 15. Joint 16. Output lever

D275A-2

‘9

A-A

D-D

E-E SVD02544

Outline (1) When the fuel control dial is operated, the potentiometer resistance changes. This signal is sent to the ELPC controller through ripper controller and the processed current command from the controller is input to proportional solenoid (3). The proportional solenoid generates a propulsion force which is in proportion to the current command, moves spool (81, and sets the oil pressure at port PI. Input spool (IO) and pilot spool (11) move to a position where this oil pressure PI and spring (12) are in balance. Output spool (14) follows this and moves in the same direction to con-

D275A-2

trol the fuel injection pump through output lever (16) and the link. In addition, a signal is sent to the ELPC controller from feedback potentiometer (1) according to the rotation of output shaft (41, and the actuation of the ELPC actuator is observed. (2) When mode selection is selected, if the throttle signal from the shoe slip controller is a low-speed command, proportional solenoid (3) is driven according to the throttle signal, regardless of the position of input lever (91, and controls input spool (IO), output spool (141, and the fuel injection pump.

10-155 0

MANUAL

POTENTIOMETER

1. 2. 3. 4. 5.

Shaft Potentiometer Tube Wire Connector

t--==== I Structure

circuit SBD02367

Function The manual potentiometer is installed to the opposite side of the ELPC actuator input lever. The decelerator pedal and ELPC actuator input lever are connected by a link. l

When the decelerator pedal is moved, shaft (I) of the manual potentiometer is rotated through the link, ELPC actuator input lever, and input shaft, and the resistance changes. A constant voltage is applied between pins 1 - 3 of the potentiometer, and a voltage signal corresponding to the position of the fuel control lever is sent to the ELPC controller from the No. 2 pin.

FEEDBACK POTENTIOMETER I. 2. 3. 4.

Structure

Potentiometer Wire Tube Connector

circuit

SVDO2545

Function The feedback potentiometer is installed to the opposite side of the ELPC actuator output lever. The fuel injection pump governor lever and ELPC actuator output lever are connetted by a link. l

lo-156 a

When the ELPC actuator output lever (fuel injection pump governor lever) is rotated by the command from the ELPC controller, the rotating body of the feedback potentiometer is rotated through the output lever and output shaft, and the resistance changes. A constant voltage is applied between pins 1 - 3 of the potentiometer, and a voltage signal corresponding to the position of the output lever is sent through the amplifier to the ELPC controller from the No. 2 pin.

D275A-2

PROPORTIONAL

SOLENOID

The proportional solenoid generates a propulsion force according to the command current from the ELPC controller as shown in the diagram on the right. The propulsion force generated by the proportional solenoid acts on pressure control spool (8) and produces the oil pressure shown in the diagram on the right. Therefore, by controlling the command current, the propulsion force can be changed and the oil pressure controlled.

Operation 1. When proportional solenoid is continuous If electric current flows from the ELPC controller to proportional solenoid (31, the proportional solenoid generates a propulsion force proportional to the current. When this happens, the propulsion force of the proportional solenoid and the sum of the propulsion force from the oil pressure at port PI applied to load piston (7) and the reaction force of pressure control spring (6) are balanced and the pressure is adjusted. At this point, the oil pressure at port PI is determined by the balance of the force pushing input spool (IO) to the left and the reaction force of spring (121, so the stroke of input spool (IO) is controlled.

MPa (ka/cm*l

--)

Current (A)

SVD02546

When proportional solenoid is not continuous (when there is disconnection in command circuit) If no current flows to the proportional solenoid, and pressure control spool (8) is pushed back by the reaction of pressure control spring (61, so no oil pressure is generated at port PI. However, when the fuel control lever is operated, if it is operated to the FULL position, input spool (IO) and pilot spool (11) move to the right to follow the movement of input lever (9) because of the reaction force of spring (12). As a result of this, output spool (14) and. joint (15) also move to the right. When the fuel control lever is at the SLOW or STOP position, input lever (9) directly pushes input spool (IO) and pilot spool (II) to the left. As a result of this, output spool (14) and joint (15) also move to the left.

D275A-2

SVD02547

SVD02548

10-157 0

OPERATION

OF ELPC ACTUATOR

Fuel control lever operated (Engine at low idling)

SLOW

FULL

5’

SW003794

When fuel control lever (17) is operated, shaft (18) of manual potentiometer (2) is rotated by the link and input shaft (5), and the resistance value changes. This signal is sent to the ELPC controller, and the processed current command from the controller enters proportional solenoid (3). The solenoid moves spool (8) in proportion to the current command and sets the oil pressure at port PI to the specified pressure. Pilot spool (11) and input spool (IO) of the ELPC valve move to the right in the direction of the arrow until oil pressure PI and spring (12) are balanced. When this happens, the circuit between orifice a of piston (14) and passage c closes, and the circuit between orifice b of pilot spool (1 I) and chamber B opens. The oil from the power train pump always enters chamber A. The circuit between orifice a and passage c is closed, so the oil pressure rises. The oil in chamber B passes through orifice b and flows to chamber C. It then flows from port T to the drain circuit, so the oil pressure in chamber B goes down. Therefore, piston (4) is pushed to the right by the oil pressure in chamber A, moves to the position where the circuit between orifice a and passage c opens (in other words, the point where the rod of joint (15) and the left end of pilot spool (11) contact), and stops.

lo-158 a

SWD03795

IO SWD03796

D275A-2

When piston (14) is pushed out to the right in the direction of the arrow, joint (151, which forms one unit with the piston, also moves to the right, so the throttle lever of the fuel injection pump is moved to the FULL position. If the fuel control lever is operated continuously, the above operation is repeated and the engine runs at full speed. In addition, the action of the oil pressirre in chamber A also reduces the operating effort of the fuel control lever. When the fuel control lever is stopped at a fixed point, piston (14) of the ELPC valve stops at a point where the circuit between orifice a of chamber A and passage c is open. At this point, the passage from orifice b (in other words, the passage to the drain circuit) is closed, and at the same time, oil from passage c enters chamber B, so the oil pressure rises. When this happens, the difference in pressure between chambers A and B (in other words, the pressure moving piston (14) to the left or right) disappears, so the piston is held in the same position. Therefore, the engine speed can be held constant to match the amount that the fuel control lever is operated.

D275A-2

SWD03797

10-159 0

Fuel control lever moved (Engine stopped)

stopped

slow

stop

SIOW

SWD03798

SW003799

When fuel control lever (17) is moved from the STOP position to the slow position, input lever (9) rotates and the reaction force of spring (12) moves ELPC valve input spool (IO) and pilot spool (11) to the right in the direction of the arrow, following input lever (9). However, the engine at this point is stopped, so no oil pressure acts on the ELPC valve. Pilot spool (11) uses the protruding portion at the left end to move piston (14) and joint (15) directly to the right. This moves throttle lever (18) of the fuel injection pump to the slow position.

lo-160 0

D275A-2

TORQUE CONVERTER

Mode selection

LOCK-UP CONTROL SYSTEM

c_________________

Panel

‘.

/’ ,’

,’

‘. ‘. ‘. ‘\

‘\

‘. ‘.

SSCcontroller

Transmission

Pressure oil

sianal

Torque _-_-___

output

converter shaft 30r

pu 1se/rev)

SWDO3800

TORQUE CONVERTER LOCK-UP CONTROL CIRCUIT DIAGRAM

Lock-up display

relay

D275A-2

solenoid

lamp

speed

sensor

Pressure

sensor

SWD0380

lo-161 a

Outline With the torque converter lock-up control system, the torque converter lock-up is operated automatically according to the load on the machine by the controller and signal from the two sensors. When the torque converter is locked up, the display lamp at the front of the operator’s seat lights up. When the starting switch is turned to the ON position, the contacts of the lock-up relay inside the relay box close and power is supplied to the lock-up controller. The torque converter speed sensor is connected to the SSC controller, and inputs a pulse signal corresponding to the torque converter speed to the SSC controller. The SSC controller sends the input pulse signal according to the signal from the mode selection panel (the signal for the lock-up ON/ OFF switch) to the lock-up controller, or stops the system. The lock-up controller receives the torque converter speed signal from the SSC controller and transmission oil pressure sensor, and connects or disconnects the connection of the lock-up solenoid and display lamp to the ground to turn the lock-up ON or OFF. The lock-up is turned ON or OFF when it fulfills the following conditions for the two sensors. When lock-up is ON When both of the following conditions are fulfilled (AND circuit): Torque converter output shaft speed: 1,170 rpm or more Transmission oil pressure: 1.9 MPa (19.5 kg/cm*} or more When lock-up is OFF When either of the following conditions are fulfilled (OR circuit): Torque converter output shaft speed: 1,110 rpm or less Transmission oil pressure: 1.5 MPa (I 5 kg/cm*) or less

lo-162 0

D275A-2

TESTING AND ADJUSTING

Standard value table for engine.. ............... 20- 2 Standard value table for chassis ................ 20- 3 Standard value table for electrical judgement.. .............................................. 20- 9 Table of tools for testing, adjusting and troubleshooting ............................... 20-I 1 Testing and adjusting belt tension.. ........... 20-13 Adjusting valve clearans ............................. 20-14 Measuring compression pressure .............. 20-15 Measuring blow-by ...................................... 20-16 Adjusting fuel injection timming ................ 20- 17 Measuring exhaust color.. ........................... 20- 18 Measuring engine oil pressure ................... 20-19 Measuring engine speed ............................. 20-19 Measuring boost pressure .......................... 20-20 Measuring exhaust temperature ................ 20-21 Adjusting of fuel control linkage ................ 20-22 Adjusting of fuel control linkage (with SSC system) ............................... 20-22-I Adjusting of gear shift lever linkage.. ....... .20-24 Adjusting of steering clutch linkage .......... 20-28

Adjusting of brake pedal linkage . . .. . .. .. . . . . . . . 20-30 Adjusting of work equipment control linkage . .. . . .. . . . .. . . . . . . . . .. . . . . . . .. .. .. . . . .. . . .. . . . . .. . . . . . 20-32 Adjusting clearance of idler . . .. . . . . . . .. . . .. . .. . . 20-35-I Measuring speed at torque converter stall . . . . 20-36 Measuring speed at torque converter stall + hydraulic pump relief . .. . . . .. .. . . .. . . . .. . . . . . . . 20-37 Measuring power train oil pressure .. . . . . . . . . 20-38 Testing and adjusting work equipment main relief pressure . . . . . .. .. . . . . . . .. .. . . . . . . . . . . . .. .. .. . . .. . 20-41 Bleeding air from hydraulic cylinder .. . . . .. . . 20-42 Measuring linkage inside cylinder .. .. . . .. . . . . . 20-43 Checking location of cause of hydraulic drift of blade and ripper . . .. . .. . . . . .. . . .. . . . .. . . . 20-44 Procedure for simple test of steering brake .. . . . . . .. . . .. .. . . .. . .. . . . . . . . . . . . .. . .. . . .. . . 20-45 performance Procedure for testing sensor . . . . . . . . .. . . .. .. . . .. . . 20-46 Testing and adjusting ELPC valve potentiometer (with SSC system) . . .. . . 20-48-I Troubleshooting . . . . . . . .. . . . . . . . . .. . .. . . . . .. . . . . .. .. .. . . . . . 20-49

The following precautions are necessary when using the STANDARD VALUE TABLE for testing and adjusting, or for troubleshooting. 1. The values in the table are for new machines, and obtained for reference to value for new machines and the values when shipping from the factory. Therfore, they should be used as target values for judging the progress of wear, or when repairing the machine. 2. The values for judging failures are based on standards when shipping the machine from the factory, and on the results of various tests. These values should be used as reference together with the repair condition and operating record of the machine to make judgements on failures. 3. The values in the table should not be used for judging claims. a

a a a

When carrying out testing, adjusting or troubleshooting, stop the machine on level ground, install the safety pins and block the tracks. When working in groups, use agreed signals and do not allow unauthorized persons near the machine. When checking the water level in the radiator, wait for the water to cool. Do not remove the radiator cap while the water is hot. Boiling water may spurt out. Be careful not to get caught in rotating parts.

D275A-2

20-l a

STANDARD

VALUE TABLE FOR ENGINE

Machine

Serial

model

D275A-2

numbers

10001 - 10167

Engine

Unit

Standard value

Permissible value

1,960 2 50 600 k 50 1,800 2 50

1,960 + 50 600 2 50 -

“C

Max. 650

Max.

At rated output

kPa {mmHgI

Min. 120 {Min. 9001

Min. 108 {Min. 810}

At sudden acceleration At high idling

Bosch index

Max. 6.0 Max. 1.0

Max. Max.

8.6 2.0

Intake valve Exhaust valve (at cold)

0.4 1.0

MPa {kg/cm*1

Min. 2.86 {Min. 29)

Min.

1.97

{Min.

20)

kPa ‘mmH20)

Max. 2.9 {Max. 3001

Max. 5.9 {Max. 6001

5 z

Item

Engine

Measurement

Exhaust temperature (turbocharger inlet port temperature) Boost pressure

Valve

gas color

clearance

Compression

Blowby

conditions

High idling Low idling Rated speed

speed

Exhaust

S6D170-1

pressure

Whole speed range (ambient temperature:

Oil temperature: 40 - 60°C Engine speed: 210 - 250 rpm (SAEBO oil) At rated output (Water temperature: (SAESO oil)

pressure

20°C)

Operating

range)

(Water temperature: Operating At high idling (SAESO)

range) 0.3 - 0.49 13.0 - 5.0) Min. 0.15 {Min. I.51 0.25 - 0.44 12.5 - 4.5) Min. 0.1 {Min. 1.0)

Min. 0.25 {Min. 2.5) Min. 0.7 {Min. 7.01 Min. 0.18 {Min. 1.8} Min. 0.07 {Min. 0.7)

“C

80 - 110

Max.

“(de@

38 + 1

38 * 1

Deflection when pressed with finger force of approx. 58.8 N 16 kg}

Deflection when pressed with finger force of approx. 98 N {IO kg}

13 -17

At low idling

(SAE30)

At high idling

(SAEIOW)

At low idling

(SAE 1 OW)

MPa {kg/cm*1

Oil pressure

Whole

Oil temperature Fuel injection Alternator

timing

belt tension

Air conditioner belt tension

compressor

700

speed

ranoe

(inside

oil Dan)

B:T.D.C.

120

mm Dimension A: 50 f 5

Fan belt tension (auto tension)

17MF02140

(

20-2 @

1: For reference

Machine

Serial

model

D275A-2

10168 and up

numbers

Engine

Measurement

Item

Engine

Exhaust temperature (turbocharger inlet port temperature) Boost pressure

Valve

gas color

clearance

Compression

Blowby

conditions

High idling Low idling Rated speed

speed

Exhaust

S6D170-2

pressure

Whole speed range (ambient temperature:

Fuel injection Alternator

belt tension

Air conditioner belt tension

compressor

1,960 -c 50 600 2 50 1,800 2 50

1,960 5 50 600 2 50 -

“C

Max.

650

Max. 700

Min. 120 {Min. 900)

Min. 108 {Min. 810}

At sudden acceleration At high idling

Bosch index

Max. Max.

Max. 8.0 Max. 2.0

Intake valve Exhaust valve (at cold)

0.4 1.0

MPa {kg/cm21

Min. 2.86 {Min. 29)

Min. 1.97 {Min. 20)

kPa [mmH201

Max. 2.9 {Max. 3001

Max. 5.9 {Max. 600)

0.3 - 0.49 (3.0 - 5.0) Min. 0.15 {Min. 1.5) 0.25 - 0.44 (2.5 - 4.51 Min. 0.1 {Min. l.O}

Min. 0.25 {Min. 2.5} Min. 0.7 {Min. 7.0} Min. 0.18 {Min. 1.8} Min. 0.07 {Min. 0.71

“C

80 - 110

Max.

“(de@

Oil temperature: 40 - 60°C Engine speed: 210 - 250 rpm (SAEBO oil) Operating

range)

(Water temperature: Operating At high idling (SAESO)

range)

At low idling

(SAE30)

At high idling

(SAEIOW)

At low idling

(SAEIOW)

Whole timing

Permissible value

kPa ImmHgI

MPa {kg/cm21

Oil pressure

Oil temoerature

Standard value

At rated output

At rated output (Water temperature: (SAE30 oil)

pressure

20°C)

Unit

speed

range

(inside

oil pan)

B.T.D.C.

6.0 1.0

120

Deflection when pressed with finger force of approx. 58.8 N (6 kg}

Deflection when pressed with finger force of approx. 98 N {IO kg}

13 -17

mm Fan belt tension (auto tension)

(

1: For reference

20-2-l 63

STANDARD VALUE TABLE FOR CHASSIS

Classi ficatio

Check item

Unit

Conditions Engine oil pressure: within operating range l Engine oil temperature: within operating range l Power train oil temperature: 70-80°C l Hydraulic oil temperature: 45-55X l No. of speed range : F3

Standard value

Permissible value

1,580 f 50

Min 1,510

1,375 f 50

Min 1,240

90 * 20

90 z!z20

60 f 20

60*20

25 * 5

25 Z!Y5

Torque converter stall speed

Torque converter stall + hydraulic relief speed

Engine: Fuel control lever

Center of lever knob

Engine:

rpm

low idling - full throttle low idling

- stop Decelerator

pedal

Center of pedal Engine: full throttle -

Engine stopped

Between each speed range

35 * 5

Center of lever knob

F-R

61 f6

Engine low idling

Full stroke

147.5 f 7.5

Center of lever knob

Until clutch is fully disenaaaed

55 f 5 Play: Max. 5

55 + 5 Play: Max. 5

Engine low idlina

Full stroke

Center of pedal

To point where brake pressure becomes 0 ka/cm*

Gear shift lever

Steering lever

Brake pedal

Engine low idling l Center of lever knob l Hydraulic oil temperature: 45 - 55°C l Engine low idling l Center of lever knob l Hydraulic oil temperature: 45 - 55°C

Low idling

100+5

lOOf

80 k 5

80 f 5

Blade control lever

Ripper control lever

Fuel control lever

Center of lever knob

Engine speed 850 f 50 rpm l Center of pedal

HOLD HOLD -

RAISE LOWER

70 f 7

HOLD HOLD -

LEFT TILT RIGHT TILT

55 f 6

55+6

HOLD HOLD -

RAISE LOWER

55 + 6

HOLD HOLD -

TILT IN TILT BACK

55 dz6

55 z!z6

Engine:

low idling - full throttle

12.5 f 2.5

Max. 18

Engine:

full throttle - low idling

11+3

Max. 16

Engine:

low idling - stop

17f3

Max. 27

10.5 f 2.5

Max. 17

4.8f1.8

Max. 7

Decelerator

pedal

Engine stopped

Center of lever knob

Gear shift lever

Engine:

full throttle - low idling

3fl

Max. 5

20-3

Classi, ficatior

Check item Engine low idling l Center of lever knob

Steering lever

I I

Conditions

Unit

Until clutch is fully disengaged Until machine turns when brake is aDDlied

Engine: low idling Engine stops or stalls with one brake l Center of pedal

Standard value

Permissible value

3.3 + 0.8

Max. 7

721

Max. 10

38 III 4

Max. 45

4.8 f 0.8

Max. 8

3.3 + 0.8

Max. 8

Brake pedal

Engine low idling l Center of lever knob l Hvdraulic oil temperature: 45 - 55°C l

Blade control lever

Engine low idling l Center of lever knob l Hydraulic oil temperature: 45 - 55°C

HOLD -

RAISE

HOLD I-I HOLD HOLD -

LOWER

HOLD HOLD -

RAISE LOWER

LEFT TILT RIGHT TILT

t I

I kq

Max. 6

3.3 + 0.8

Ripper control lever

Radiator shutter control lever

TILT IN TILT BACK

Close -+ Open Open -+ Close

3.13 f 0.8

Max. 6

15+3 6rt3

Torque converter relief pressure (inlet)

Low idling

Torque converter outlet pressure

Low idling

0.5 -

Full throttle

5.5 2 A::

5.5 + A:;

Low idling ~Full throttle

13 +:,

0.5 -

Full throttle

Lock-up clutch Torque converter lock-up pressure

Transmission ing pressure

reduc-

Transmission lubrication pressure

2.0

0.5 -

2.0

23 -

Full throttle

27 f 2

27 + 2

Min. 24

27 f 2

Min. 24

21.5 f 1.5

21.5f

Min. 0.1

2.0 f 0.5

25 * 2

Min. 22

Full throttle

27 + 2

Min. 24

Low idling

25 f 2

Min. 22

27 & 2

Min. 24

Oil temperature in power train: 70 - 80°C full throttle l Engine speed: Low idling Full throttle Low idling

Brake operating pressure

kg/cm2

&z-----l

I Ripper pin-puller

Blade tilting pressure Ripper lifting pressure

2.0

23 -

Steering clutch operating pressure

Blade lifting pressure

0.5 91;

91:

Transmission main relief pressure Transmission modulating pressure

2.0

Low idling

Stator clutch

20-4 0

Max.6

F HOLD HOLD -

3.3f0.8

Hydraulic oil temoerature: 45 i 55°C

Low Full throttle

1.5

(v z z

ficatic

Check item

Standard value

Permissible value

Low idling

8-13

Max. 26

Full throttle

3-5

Max. 6

Low idling

1 .o -

1.5

1.0 -

1.5

Full throttle

1.0 -

1.5

1 .o -

1.5

Low idling

8-13

Max. 17

Full throttle

3-4

Max. 6

Low idling

6-10

Max. 16

Full throttle

2.5 -

Conditions

Unit

Posture of work equipment

z z 1

Blade speed (lift)

197FO1547

Hydraulic oil temperature: 45 - 55°C no load l Blade: l From ground to maximum height l

z g-J

Posture of work equipment 5 I= t !Y Blade speed (tilt) 197FO1549

Hydraulic oil temperature: 45 - 55°C no load l Blade: l Left tilt - Right tilt

5 i=

z oc

3.5

Max. 5

Posture of work equipment Low

qipper speed (lift)

8-12

Max. 15

2.5 -

3.5

Max. 5

Low idling

1.5 -

2.5

1.5 -

2.5

Full throttle

1.5 -

2.5

1.5 -

2.5

Low idling

12-

Max. 21

Full throttle

4.5 -

5.5

Max. 6.5

197FO1549 ) Hydraulic oil tempera-

ture: 45 - 55°C 1 Shank set at bottom hole ) From ground to maximum height

E 19

work equrpmenr z

tipper speed (tilt)

197FO1550 1 Hydraulic oil tempera-

ture: 45 - 55°C 1Shank set at bottom hole 1 From tilt back tilt in

Low idling

8-12

Max. 15

Full throttle

3-4

Max. 6

2 3 F

20-5

Classificatior

Unit

Conditions

Check item

Permissible value

Standard value

Posture of work equipment Pitch dump

2.5 IO.6 degl4.3

Pitch back

3.0 IO.6 deg/3.5

legree /set

Pitch speed

Hydraulic oil temperature: Blade: no load pitch back l Pitch dump l Full throttle l

45 -

55°C

Posture of work equipment 7.1 80.6 deg14.3 s

Left tilt Negree lsec

Dual tilt speed

17MF02142

Dual tilt

Hydraulic oil temperature: 45 - 55°C no load l Blade: Right tilt l Left tilt l Full throttle

Right tilt

7.1 80.6 degf4.3

Semi U dozer

1,135 mm

Hydraulic oil temperature: 45 - 55°C l Lower the blade from the maximum height, and measure the time taken from the point when the blade touches the ground to the point where the idler is raised from the ground

U dozer

1,215

Engine low idling

Max. 6

Max. 12

Engine full throttle

Max. 1.5

Max. 2.0

Max. 1.0

Max. 1.5

Time lag (blade)

Hydraulic oil temperature: 45 - 55°C l Lower the ripper from the maximum height, and measure the time taken from the point when the ripper touches the ground to the point where the sprocket is raised from the ground l Engine full throttle

sec.

Time lag (ripper)

20-6

Classification

Check item Posture

Standard value

Permissible value

Max. 200/l 5

Max. 400/l 5

Max. 3015

Max. 10015

Max. 3015

Max. 8015

Max. 3015

Max. 80/5

Max. 80/I 5

Max. 160/l 5

Max. 3015

Max. 6015

of work equipment

!EtE&

Hydraulic drift (blade lift)

197FO1551

Hydraulic oil temperature: 45 - 55°C l Engine stopped l Center of blade cutting edge; from height of 800 mm to ground

Posture

Hydraulic (machine down)

Unit

Conditions

of work equipment

197FO1552

drift moves

Hydraulic oil temperature: 45 - 55°C l Engine stopped l Blade pushed down, movement at center of idler l

Posture

of wgrk

equipment

LEFT TILT

mmlmir

197FO1553

Hydraulic drift (blade tilt)

Hydraulic oil temperature: 45 - 55°C l Tilt blade to raise machine, engine stopped immediately to reach ground l Measure retraction of tilt cylinder l

Posture

RIGHT TILT

of work equipment

Hydraulic drift (ripper lift)

197FO1554

Hydraulic oil temperature: 45 Engine stopped l Ripper point: 500 mm above the ground l

55°C

Posture

Hydraulic (machine

drift moves

of work equipment

197FO1555

down)

Hydraulic oil temperature: 45 Engine stopped l Ripper pushed down movement at center of sprocket l

55°C

20-7

Classi ficatioi

Check

item

Conditions F

On level surface Engine at full throttle water temperal Engine Inside operating ture: range l Run up distance: IO-30m distance: l Measurement 20 m l

Travel

20-8

speed

1st

(3.8 f 0.2)

(3.8 f 0.2) 10.7 + 0.6 (6.7 f 0.3)

2nd

10.7 * 0.6 (6.7 + 0.3)

3rd

6.1 z!z 0.3 (11.8 * 0.6)

6.1 f 0.3 (11.8 f 0.6)

1st

14.7 IL 0.8 (4.9 + 0.2)

14.7 + 0.8 (4.9 * 0.2)

2nd

8.3 + 0.4 (8.7 + 0.4)

8.3 + 0.4 (8.7 f 0.4)

3rd

4.8 +I 0.3 (14.9 f 0.7)

4.8 f 0.3 (14.9 f 0.7)

1st

1.0 18.9+ (3.8 * 0.2)

1.0 18.9f (3.8 f 0.2)

2nd

10.4 do 0.6 (6.9 f 0.3)

10.4 I!Z 0.6 (6.9 * 0.3)

3rd

6.1 f 0.3 (11.7 f 0.6)

1st

14.7 * 0.7 (4.9 f 0.2)

14.7 IL 0.7 (4.9 f 0.2)

2nd

8.1 f 0.4 (8.9 f 0.4)

8.1 f 0.4 (8.9 k 0.4)

3rd

4.8 + 0.3 (15.1 f 0.8)

4.8 f 0.3 (15.1 + 0.8)

sec. (km/h)

STANDARD VALUE TABLE FOR ELECTRICAL JUDGEMENT

SYS ten

Component

Coolant

level sensor

tonnector

CN405 (Male)

‘esting lethod

Judgement

1) When using the short connector, the followin results show that the sensor is defective

1) Engine started

1) The following is normal

1) Starting switch OFF

Coolant

results show that the sensor

Max. 1 Q

level normal

I Coolant level abnormal Coolant temperature sensor (Coolant temperature

The following is normal CN402 (Male)

gauge)

Ambient temoerature

Engine oil pressure sensor

1 Min IMP

20°C I 10°C

CN453 (Male)

When normal Approx.

29kQ I

Approx.

52kQ I

Approx.

80kS

1) Starting switch OFF 2) Disconnect CN402 (coolant temperature gauge) 3) Disconnect CN453 (T/C oil temperature gauge)

1) When CN403 is connected to chassis ground, the following results show that the sensor is defective

1) Engine started

1) The following is normal

1) Engine started

CN403

results show that the sensor

Engine oil pressure 0.7 ka/cm2

over

Engine oil pressure 0.7 ka/cm*

under

Min. IMQ Max. 1 Q

The following results show that the sensor normal (Normal temperature 25°C)

Fuel level sensor (fuel gauge)

results show that the sensor

35°C Torque converter oil temperature sensor (Torque converter oil temperature gauge)

Measurement conditions

table

CN423 (Male)

CN423 (Male) @ Full

Approx.

109 or less

Empty

Approx.

859

I is

1) Starting switch OFF 2) Disconnect CN423

20-9

systern

Component

Connector

No. ~e~h~~

Judgement

Measurement conditions

table

I I SF 52

Hydraulic oil temperature sensor

CN452 (Male)

;

CN404 (Male)

1) Engine started

1) The following is normal

1) Starting switch OFF

results show that the sensor

1) When CN404 (female) is contacted to chassis ground, the following results show that the

Engine oil level sensor

1) When CN452 (female) is connected to chassis ground, the following results show that the sensor is defective

I I & g 9

1) The following is normal

results show that the sensor

.E ; :

r”

20-10

Engine oil level normal

Max. 1 R

Engine oil level abnormal

Min IMR

1) Starting switch ON,

1) Starting switch OFF

TABLE OF TOOLS FOR TESTING, TROUBLESHOOTING Test measurement

item

Symbol

ADJUSTING

Part No.

Part

Name

AND

Remarks

I Digital

display: L: 60 - 2,OOOrpm H : 60 - 19,999rpm

-50 -

1,200”C

speed

799-203-8001

Multi-tachometer

Water temperature, oil temperature, exhaust temperature

799-101-6000

Digital

799-101-5001

Hydraulic

790-261-1201

Digital

799-401-2320

Hydraulic

gauge

1.0 MPa {IO kg/cm21

799-401-2310

Pressure

gauge

199.9 kPa I1500

795-502-1210

Compression

795-502-1350

Engine

gauge

Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa 125, 60, 400, 600 kg/cm2}

tester

Oil pressure

temperature

hydraulic

Pressure

tester

2 -

Boost pressure

Compression

Blowby

pressure

1 799-201-1504

Blowby

799-201-1590

Gauge

Commercially available

Feeler

1 799-201-9000

Handy

smoke

Commercially available

Smoke

meter

Commercially available

Push-pull

drift

Commercially available

speed

Commercially available

Stopwatch

799-601-7100

T-adapter

799-601-7070

Adapter

pressure

i z

Valve clearance

z z Exhaust

Operating Stroke, Work

color

hydraulic equipment

Troubleshooting harness, sensor

of wiring

Troubleshooting aqe, resistance

of value

Measuring wear sprocket tooth

timing

volt-

0 - 9.8 kPa (0 - 1000 mmH,OI Intake valve: 0.4 mm; exhaust valve: 1.0 mm

gauge I

checker

force

Fuel injection

cheker

mmHg1

0 - 6.9 MPa (0 - 70 kg/cm21 Kit Part No.: 795-502-1205

gauge

gauge: 68.6 MPa {700 kg/cm21

scale

j Discoloration: 0 - 70 % (with standard color) (Discoloration x l/IO = Bosch index) -

I -

kit

Commercially available

791-627-1130

Wear

795-471-1200

Gauge

For those owning 799-601-2500 799-601-7000 is possible SWP14

gauge assembly

Dial gauge available

is commercially

20-11 @

TESTING AND ADJUSTING Serial

No . : 10001

BELT TENSION

- 10167

1. Testing fan belt tension is installed, so check 0 An auto-tensioner that the dimension of the tension spring = 50 k 5 mm when the belt is reb$FdA

1. Adjustment nut 2. Washer 3. Tension spring 4. Adjustment bolt 5. Tension pulley A. Protrusion of adjustment

bolt

4 ?

6162F291

0”

0’

2. Testing and adjusting alternator belt tension Testing of the belt when it l Check the deflection is pressed at approx. 58.8N (6 kg) at a midpoint between the alternator and accessory drive pulley. Deflection: 15 mm * Adjusting 1. Loosen alternator assembly mounting bolt (1) and belt tension adjustment bolt (2). 2. Using a pipe, move the alternator to adjust Tighten the adjustment the belt tension. the alternator bolt first, then tighten mounting bolt.

Alternator

belt

569F102

20-l 3 @

Serial

No . : 10168

and

1. Testing and adjusting alternator belt tension Testing . Check the deflection of the belt when it is pressed at approx. 58.8 N (approx. 6 kg} at a midpoint between the alternator and accessory drive pulley. * Deflection: 15 mm

Adjusting 1) Loosen alternator assembly mounting bolt (I) and belt tension adjustment locknut (2). 21 Turn adjustment nut (3) to adjust the tension of the belt to the standard value. the belt tension, tighten 3) After adjusting locknut (2), then tighten alternator assembly mounting bolt (1).

20-13-l @

ADJUSTING

VALVE CLEARANCE

Adjust the clearance between the rocker lever and crosshead as follows:

1. Remove the cylinder head cover. 2. Rotate the crankshaft in the normal direction to align the 1.6 TOP line on vibration damper (1) with pointer (2) to set the No. 1 cylinder at compression top dead center. When rotating, check the movement of the valves. 3. When No. 1 cylinder is at compression top dead center, adjust the valves marked 0. When No. 6 cylinder is at compression top dead center, adjust the valves marked 0.

Valve

arrangement

TDD00723

4. To adjust the clearance, insert feeler gauge G between rocker arm (3) and crosshead (4), and adjust with adjustment screw (5) until the clearance is a sliding fit. Then tighten locknut (6) to hole the adjustment screw in position. m *

Locknut:

68.8 z 9.8 Nm {S t 1.0 kgm)

After tightening clearance again.

the

locknut,

check

the

5. Next, rotate crankshaft one turn in the normal direction and adjust the valve clearance of the remaining valves marked 0. * After adjusting No. 1 cylinder at compression top dead center, it is also possible to turn the crankshaft 120” each time and adjust the clearance of the valves of each cylinder according to the firing order. Firing order: l-5-3-6-2-4

k TWD01232

20-14 a

Be careful not to touch any hot places when installing or removing the measuring tools.

of the cooling water Raise the temperature the operating range before measuring.

1. Adjust the valve clearance. For details, see ADJUSTING ANCE.

VALVE

CLEAR-

2. Remove the nozzle holder assembly of the cylinder to be measured. j, Be careful not to let dirt or dust get inside. 3. Install tool E2 in the mount of the nozzle holder assembly, then connect tool El to tool E2. Sr Coat the tip of tool E2 with a small amount of oil. 4. Set tool chometer.

8 Z 6

A to

the

pick-up

port

of the

ta-

5. Place the fuel control lever in the NO INJECCrank the engine with the TION position. starting motor and measure the compression pressure. If the fuel control lever is not placed at A the fuel will NO INJECTION position, spurt out. compression the measuring A When be careful not to touch any pressure, *

hot parts or rotating parts. pressure at the Measure the compression point where the pressure gauge indicator remains steady. pressthe compression When measuring ure, measure the engine speed to confirm that it is within the specified range. pressthe compression After measuring ure, install the nozzle holder assembly.

20-15

Raise the coolant temperature ting range before measuring.

to the opera-

1. Install tool Fl to the tip of engine hose (I), then connect it to tool F2.

breather

2. Run the engine at rated output, and measure the blow-by pressure.

Adapter

measuring, be careful not to A When touch anv hot Darts or rotatina Darts.

Nozzle

* The blow-by should be measured with the 0 0

engine running at rated output. When measuring in the field, a similar value can be obtained at stall speed. If it is impossible to check at rated output or stall speed, measure at high idling. In this case, the blow-by value will be about 80% of the value at rated output. Blow-by varies greatly according to the condition of the engine. Therefore, if the blow-by value is considered abnormal, check for problems connected with defective blow-by, such as excessive oil consumption, defective exhaust gas color, and prematurely dirty or deteriorated oil.

17MF02143

17MF02144

20-16

ADJUSTING

FUEL INJECTION TIMING

Serial No . : 10001 - 10167 1. Rotate

the crankshaft in the opposite direction in 40 to 50” from No. 1 cylinder at compression top dead center.

2. Rotate the crankshaft in the normal direction, and align pointer (2) correctly with the 38” I.J line on vibration damper (1). 3. Disconnect fuel injection pipe (3) of No. 1 cylinder. 4. Remove delivery valve holder (4), take out spring (5) and delivery valve (6), then install delivery valve holder (4) again. 5. Place the fuel control lever at the FULL position. * When the coupling is rotated, the injection time is changed as follows. cylinder block to ADTurn TOWARDS VANCE timing. Turn AWAY from cylinder block to RETARD timing.

E: : 6

6. Loosen the bolt in the oblong hole of the laminated coupling and operate the priming pump while moving the coupling. Stop at the point where the fuel stops flowing from the delivery valve holder. 7. Remove delivery valve holder (4), assemble delivery valve (6) and spring (5), then install delivery valve holder (4) again. m

Coupling mounting bolt: 88.3 + 4.9 Nm I9.0 d 0.5 kgm}

QGE

Delivery valve holder: 112.8 + 4.9 ill.5

f 0.5 kgm}

8. Connect fuel injection pipe (3). m

Sleevew

nut: 21.6 2 2.0 12.2 f 0.2 kgm1

Oblong hole

6162F663

Serial 1. 2. 3.

No. : 10168 and up

Remove the tube between the air cleaner Komaclone and the muffler. Remove the injection pump coupling cover. Remove the head cover, disconnect spill tube (I) and delivery tube (2) of the No. 1 piston, then remove No. 1 nozzle holder assembly (3). Align No. 1 cylinder with the compression top dead center line (1:6). When doing this, check that the fuel in* jection timing line on the fuel injection pump is near the line on the fuel injection pump body. Set dial gauge Q to the nozzle holder hole where the nozzle holder assembly has been (See the diagram.) removed. Set the scale on dial gauge Q to 0 when the piston is at the top dead center. Rotate the crankshaft in the normal di* rection and in the reverse direction in turn to align the top dead center. Ir Record the value indicated by the short indicator on the dial gauge. Rotate the crankshaft approx. 45” in the reverse direction from the No.1 cylinder TOP position. again slowly in the Rotate the crankshaft normal direction and set to specified dimension “c”. * Specified dimension c: 6.51 d 0.2 mm * Always rotate the crankshaft in the normal direction to align the position. * Continue to rotate in the normal direction, and when the No.1 cylinder reaches the TOP (top dead center) position (the indicator on the dial gauge starts to rotate in reverse), check that the dial gauge reading is 0 r 0.2 mm. If it is not within 0 f 0.2 mm, carry out from Step 6 again. _..~ Check that fuel injection timing line “a” on the fuel injection pump is aligned with line

“b” on the coupling.

20-17-l @

BED00346

10. If the lines are not aligned, loosen bolt (4) in the oblong hole, move the coupling to align the lines, then tighten the bolt.

20-17-2 8

MEASURING

EXHAUST COLOR

0 When measuring in the field where there is no air or electric power supply, use tool Hl; when recording formal data, use tool HZ. * Raise the coolant temperature to the operating range before measuring. Be careful not to touch any hot parts when A removing or installing the measuring tools.

Measuring

with HI.

1) Install filter paper to tool Hl. 2) Insert the exhaust gas suction port into the exhaust pipe, accelerate the engine suddenly, and operate the handle of tool HI at the same time to collect the exhaust gas on the filter paper. 3) Remove the filter paper and compare it with the scale supplied to judge the condition.

Measuring with H2. 1) Insert probe 0 into the outlet port of the exhaust pipe (I), and tighten the clip to secure it to the exhaust pipe. 2) Connect the air hose and the socket of the probe hose accelerator switch to tool H2. * Keep the pressure of the air supply below 1.47 MPa {I5 kgm2} 3) Connect the power cord to the AC socket. * When connecting the cord, check that the power switch of’tool H2 is OFF. 4) Loosen the cap nut of the suction pump, and fit the filter paper. * Fit the filter paper securely so that the exhaust gas cannot leak. 5) Turn the power switch of tool H2 ON. 6) Accelerate the engine suddenly, and depress the accelerator pedal of tool H2 at the same time to collect the exhaust gas color on the filter. 7) Place the filter paper used to catch the exhaust gas color on top of at least IO sheets of unused filter paper inside the filter paper holder, and read the value shown.

17MF02147

// 17MF027 48

20-18 8

MEASURING

ENGINE OIL PRESSURE

the coolant temperature *Raise ting range before measuring.

to the opera-

1. Remove pressure measurement plug (1) (PT l/8), then install oil pressure gauge C (IO kg/ cm2). 2. Start the engine, and measure the oil pressure at low idling and high idling.

FO2150

MEASURING

ENGINE SPEED

Be careful not to touch any hot parts A when removing or installing the measuring tools. *

Measure the engine speed under the following conditions: 1) Coolant temperature: Within operating range 70 - 90” C 2) Power train oil temperature: 45 - 55” C 3) Hydraulic temperature:

1. Remove cap (1) from the speed pick-up port, then install the adapter of tachometer A. 2. Connect tachometer A to the adapter with the cable. measuring the engine speed, be A When careful not to touch the rotating parts or hot parts. 3. Start the engine and measure the engine speed at high idling and low idling. Sr When measuring items other than above (torque converter stall, torque converter stall + hydraulic pump relief), see the measurement procedure for each item.

20-19

MEASURING

BOOST PRESSURE

Be careful not to touch any hot parts A when removing or installing the measuring

tools. 1. Remove boost pressure measurement plug (1) (PT1/8), then install the coupler inside oil pressure gauge kit C. 2. Connect the oil pressure measurement hose to the coupler and pressure gauge N (14.7 kPa {I,500 mmHg)).

When measuring the pressure, be careful not to touch the rotating parts or hot parts. Note: Operate the engine speed at midrange or above, and use the self-seal portion of the gauge to bleed the oil inside the hose. 0 Insert the gauge about half way, repeat the action to open the self-seal portion, and bleed the oil. Sr If there is oil inside the hose, the gauge will no work, so always bleed the oil. 3. Run the engine at the rated speed and read the gauge indicator.

20-20 8

17MF02153

MEASURING

EXHAUST TEMPERATURE

temperature sensor is installed to the A The exhaust manifold, so if the machine is being operated, wait for the manifold temperature to drop before installing the sensor. Raise the coolant temperature to the operating range before measuring. Remove

the adiabatic plates. (Serial No.:10168 and up) Remove plug (1) from the exhaust manifold, and install temperature sensor (2). l Temperature sensor: 6215-11-8180 (cable length 610 mm) or 6215-11-8170 (cable length 490 mm)

Connect to digital temperature the wiring harness.

s: : 6

17MF02154

gauge B with

Measurement procedure 1. When measuring with the torque converter stalled * The conditions are only for torque converter stall, so when measuring the exhaust temperature, the core of the sensor will heat up and the torque converter will overheat before a stable value is obtained. 1) Raise the exhaust temperature by using full stall (torque converter stall + hydraulic pump relief) (standard value: Approx. 650°C). 2) In the above conditon, cancel the hydraulic rleief, and carry out only torque ocnverter stall. (If the temperature starts to go down, or goes up without going down, repeat step 1) to raise the set temperature.) when the 3) Note the stable temperature temperature starts to go down. 2.

: /

When measuring the maximum value for the exhaust temperature Carry out actual work and measure the maximum value during operation. * Use the peak mode (it can store the maximum value in memory) of the temperature gauge function. Note: The exhaust temperature varies greatly according to the ambient temperature (temperature of the engine intake air), so if any abnormal value is obtained, carry out temperature compensation. * Compensation = Measured value + 2 (converted ambient temperature - ambient temperature) * For the D275A-2, the converted ambient temperature is taken as 20” C.

X-type

connector

(2Pinl Temperature

sensor

BLD00675

Temperature

Stable

Exhaust temperature at torque converter stall

Full

When measured only with torque converter

stall

Torque converter overheat

+ Torque verter

constall

reading

-Time

_ BKD00676

20-2 1 @

ADJUSTMENT

OF FUEL CONTROL LINKAGE

1) Make the length between the pins of rod (1) 637 mm, and interconnect lever (2) and friction clutch (3). 2) Fix fuel control lever (2) at a position where clearance A between friction clutch (3) and idling set spring box (4) is 0 mm. 3) With the friction clutch in the condition in Step I), set lever (5) installed to the engine fuel injection pump to the idling POsition. 4) In this condition, set rods (6), (7), (8) and (9) to the standard length, and interconnect them. * Standard length of rod (6): 887 mm (7): 986 mm (8): 559 mm (9): 845 mm * To adjust for the parts tolerance and assembly tolerance, turn the turnbuckle attached to rod (7), and adjust the length to interconnect rod (7).

F17M02010

With decelerator pedal linkage rod (IO) not interconnected, pull fuel control lever (2) towards the rear of the machine. Check that lever (5) of the engine fuel injection pump contacts the FULL stopper. 6) Keep the lever in this position, and turn FULL stopper (11) until it contacts the fuel control lever. Then turn the stopper back two turns, and lock it in position. pedal linkage rod (IO) 7) With decelerator not interconnected, push fuel control lever (2) towards the front of the machine. Check that lever (5) of the engine fuel injection pump contacts the STOP stopper. 8) With the lever in this position, turn stop adjustment bolt (12) attached to idling set spring box (4), and adjust clearance B to 0 mm. Then turn the bolt back one turn, and lock it in position. 9) Set fuel control lever (2) at the full throttle position, and set so that clearance C at the decelerator pedal is 0 mm, and clearance D at the end of decelerator pedal linkage rod (10) is also 0 mm. 10) Start the engine, set the throttle lever to 850 _+ 50 rpm, then adjust with the turnbuckle of rod (10) so that clearance C is 0 mm. 11) Run the engine at high idling, and adjust with rod (IO) so that clearance D is 0 mm. Run the engine at high idling, and adjust with adjustment bolt (13) so that clearance E is 0 mm, then lock in position with the nut. 5)

E 6

Clearance

E-t_

154F21114

F17M02011

20-23

ADJUSTING

FUEL CONTROL

LINKAGE

(WITH SHOE SLIP CONTROL)

Set the distance between the pins of rod (1) to 630 mm, then connect throttle lever (2).

Set the throttle lever to the idling position. * Move the throttle lever towards the idling position. The point where idling stopper clearance A is 0 mm is the idling position.

Connect rods (3), (41, and (5) so that the distance between the pins is as shown below. j, Rod length (3): 887 mm Rod length (4): 300 mm Rod length (5): 986 mm

TWD01234

17MF02158

20-23- 1 0

D275A-2

Move throttle lever (16) 90 mm towards the FULL position and bring it into contact with FULL stopper (15). (There is no need to lock it)

TWD01236

insert rotation adjustment dowel pin (0420510830) into the ELPC valve input lever portion, fix the input lever in position, and connect rods (12) and (13). Rod length (12): 232 mm Rod length (13): 93 mm

Dowel Pin for

rotation /adjustment

Solenoid

Input lever

TWD01237

Governor

12 TWD01238

Set the distance between the pins of rod (11) to 854 mm, then connect engine governor lever (17) and the center hole of lever (IO) (length of lever: 90 mm). Adjust rod (12) so that engine (17) contacts the FULL stopper.

D275A-2

governor

,lOOmm Full position

lever

20-23-2 a

8) With the throttle lever at the FULL position, keep the rotation adjustment dowel pin inserted, start the engine, measure the engine speed, and adjust rod (12) so that the engine reaches full

speed. li Engine full speed: 1960 f 50 rpm *

Check that loose spring (18) deflects at least 1 mm. * Check that governor lever (17) is in contact with the governor FULL stopper. dowel pin, re9) Remove the rotation adjustment turn the throttle lever to the low idling position, and adjust with rod (13) or (5) so that the speed is the low idling speed. * Low idling speed: 600 f 50 rpm IO) Move the throttle lever gradually to the FULL position, and fix FULL stopper (15) in the guide portion at the point where the engine speed reaches the full speed measured in Step 8. 11) Stop the engine, turn the starting switch OFF, then remove the engine speed sensor connector. 12) Start the engine, set the throttle lever to the FULL position, turn the SSC switch ON, run for approx. 10 seconds, then check that the engine speed is 660 - 930 rpm. If the engine speed is not within the above range, adjust again as follows. When less than 660 rpm i) Set the position of the hole in lever (IO) to 80 mm, and connect rod (II). ii) Carry out the adjustment again from Step 6 to Step 10. When more than 930 rpm i) Set the position of the hole in lever (IO) to 100 mm, and connect rod (II). ii) Carry out the adjustment again from Step 6 to Step 10. l

20-23-3 0

TWD01240

D275A-2

13) Connect the engine speed sensor connector. 14) After adjusting the speed, turn FULL stopper (15) of throttle lever (16) back one turn and fix it in position. * Leave room to spare at the full end. 15) Remove connector CNSOG at the turn frame left end, start the engine, move the throttle lever gradually to the STOP position, and stop the engine. Check that the governor lever is in contact with the STOP stopper, push the stopper bolt in to bring it into contact, then turn it back one turn and fix it in position. 16) Start the engine, set the throttle lever to 850 ? 50 rpm, then adjust with the turnbuckle of rod (4) so that clearance B is 0 mm. 17) Run the engine at full speed and adjust rod (4) so that clearance C is 0 mm. 18) Run the engine at full speed and adjust with adjustment bolt (22) so that clearance D is 0 mm, then lock with the nut.

TWD01236

Stopperbolt Tiahten until it contacts stopper bolt. then loosen 1 turn and Locknut

TWD01242

TWDO I243

D275A-2

20-23-4 a

ADJUSTMENT

OF GEAR SHIFT LEVER LINKAGE

3 llMF02184

20-24

Sr Tighten the locknuts of the rods and cables securely, and bend the cotter pins securely. w

Locknut (14), (15): 7.25 f1.75

kgm

Speed selector lever (1) and direction selector lever (2) are installed to the transmission control valve. The speed position and direction position of each lever are determined by the detent inside the valve.

1) Set lever (1) in the N position, and connect gear shift push-pull cable (3) to bracket (4) and lever (1). 2) In this position, adjust the mounting height of the switch so that neutral safety switch (5) is pushed in 1.5 mm. * Movelever(l)@+@+@+@ @ + 0. Check that the push-pull cable moves the correct distance. 3) Set lever (2) in the REVERSE position, and connect direction selector push-pull cable (6) to bracket (4) and lever (2). In this condition, adjust the mounting height of the switch so that backup alarm switch (7) is pushed in 1.5 mm.

17MF02160

1.5 mm

17MF02161

20-25

4) S.et gearshift lever (8) to the N position (N position of change guide (9)), and put safety lock lever (IO) in the LOCK position. * If the LOCK position of the safety lever does not match the position of the change guide, adjust the length of rod (11). * Standard length of rod (11): 115 mm 5) Secure push-pull cables (3) and (6) to bracket (17). 6) Adjust so that the amount of protrusion of push-pull cables (3) and (6) is as follows. * Speed (3): 157 mm Directional (6): 130 mm 7) Turn the turnbuckle and connect push-pull cables (3) and (6) to rods (12) and (13) (with the turnbuckle screwed in approx. 5 mm). j, Position of speed lever (8): FORWARD and 2nd position. * After adjusting all the parts of the linkage, check that gear shift lever (8) moves the correct distance for all eight positions. (FORWARD: @-+@-0-0; REVERSE: @I-@-Q-Q. * Check that when the gear shift lever is put in the N position for FORWARD and REVERSE, it cannot move @ + @ + @ when the safety lock lever is in the lock position.

17MF02162

17MF02163A

20-26 Co

ADJUSTMENT

OF STEERING CLUTCH LINKAGE

45 nlm 147.5+10

1 a

9 1 c! _

197F417

20-28

Tighten the lock nuts of the rods and cables securely, and bend the cotter pins securely.

1. Adjust the length of stopper bumper (2) so that steering lever (1) is 45 mm from the front face of the guide box. 2. Keep the protrusion of push-pull cable (3) above the floor frame at 157 mm, and interconnect rod (4) and cable (3). 3. Push steering levers (5), (6) installed to the steering brake valve towards the rear of the machine at 1 - 2 kg. With the rods in contact with the spool inside the valve, interconnect push-pull cable (3) and rod (7). * Standard length of rod (7): 146 mm 4. After interconnecting all the parts of the linkage, if the play of steering lever (1) is more than 5 mm, screw in yoke (8) at the rear of push-pull cable (3) to adjust the length and remove the play.

8 z 6

5. After adjusting all parts of the linkage, pull the steering lever fully and check that it travels 147.5 rtr 7.5 mm. Check also that there is a clearance between the steering lever and the guide box. * The distance the steering lever travels is determined by the contact with the stopper of the spool inside the steering valve. When the steering lever is pulled fully, check that the lever on top of the valve always moves the full stroke (Full stroke = 32 mm).

20-29

ADJUSTMENT

OF BRAKE PEDAL LINKAGE

197F417A

20-30

Tighten the lock nuts of the rods and cables securely, and bend the cotter pins securely.

1. With brake pedal (1) depressed, pull up parking lever (2) and lock the brake pedal. Adjust the length of rod (3) so that the brake pedal moves a distance A = 95 f 5 mm. 2. Push lever (4) towards the rear of the machine at 1 - 2 kg. When it contacts the spool inside the brake valve lightly, interconnect rods (5), (6). * When doing this, adjust the length of rod (6) so that there is no play of the connecting pin at applied side. 3. After adiustino all the parts of the linkage, depress brake pedal (1) fully and check that the distance the brake pedal travels is A = 100 f 5 mm. Check also that brake valve lever (4) travels a distance of 20 - 22 mm. * The distance the brake pedal travels is determined by the contact with the stopper of spring box rod (7) installed to the bottom of the pedal. If the travel of the brake pedal is not adjusted to the specified range, the linkage and brake valve may be acting the stopper. This means that there is excessive load on these parts and the necessary braking force cannot be obtained. This may also cause failures in the brake system.

197F419

4. After connecting and adjusting all linkages, depress the brake pedal, pull parking lever (2) up and lock the pedal. In this condition, check that the left and right brake oil pressures are “0”. For details of the place and method of measuring the oil pressure, see MEASURING OIL PRESSURE.

20-3 1

ADJUSTMENT 1.

ADJUSTMENT

OF WORK EQUIPMENT CONTROL LINKAGE OF BLADE CONTROL LINKAGE

197F420

20-32

1. Set blade control lever (1) at HOLD position, and set blade lock lever (2) at LOCK position to hold blade lever in position. 2. In this position, and (6). jr

interconnect

rods (3), (4), (5)

Standard

length of rod(3): 171 mm (4): 190 mm (5): 485 mm (6): 556 mm To adjust length of each rod, turn the turnbuckle attached to rods (5) and (6). Do not move levers (7), (8) connected to the control valve to interconnect rods (5), (6).

3. After interconnecting all parts of the linkage, move lock lever (2) between the LOCK and FREE positions in turn, and check that rods (5), (6) do not move. * If rods (5), (6) move, this means that the HOLD position of the blade lever does not match the HOLD position of levers (7), (8) on the valve. When the lock lever is at the LOCK position, levers (7), (8) on the valve are always pulled.

f: 5 E;

4. After adjusting all parts of the linkage, move the blade control lever to RAISE, LOWER, FLOAT, LEFT TILT, and RIGHT TILT. Check that the movement of levers (7), (8) on the valve are distances L, to L,. * Travel of lever (L,): 23.4 mm (LJ: 23.4 mm (LJ: 14.6 mm (LJ: 15.6 mm (L,): 15.6 mm

197F421

20-33

ADJUSTMENT

OF RIPPER CONTROL LINKAGE

II 197F422

20-34

1. Set ripper control lever (1) at HOLD position, and set ripper lock lever (2) at LOCK position to hold ripper lever in position. 2. In this position, interconnect rods (3), (4), (5) and (6). * Standard length of rod (3): 200 mm (4): 190 mm (5): 557 mm (6): 538 mm * To adjust length of each rod, turn the turnbuckle attached to rods (5), (6). Do not move levers (7), (8) connected to the control valve to interconnect (5), (6). 3. After interconnecting all parts of the linkage, move lock lever (2) between the LOCK and FREE positions in turn, and check that rods (5), (6) do not move. * If rods (5), (6) move, this means that the HOLD position of the ripper lever does not match the HOLD position of levers (7), (8) on the valve. When the lock lever is at the LOCK position, levers (7), (8) on the valve are always pulled. 4. After adjusting all parts of the linkage, move the ripper control lever to RIPPER RAISE, RIPPER LOWER, RIPPER TILT, and RIPPER TILT BACK. Check that the movement of levers (7), (8) on the valve are distances L, to L4. * Travel of lever (L,): 15.6 mm (LJ: 15.6 mm (LJ: 15.6 mm (LJ: 15.6 mm * For machines with a giant ripper, check that connector CN263 of pin puller switch (9) is connected.

20-35

ADJUSTING

CLEARANCE OF IDLER

If idler side guide (1) and guide plate (2) are worn, and there is play to the side, or the idler is at an angle, adjust as follows.

1. Adjustment in side direction 1) Drive the machine for 1 - 2 m on flat ground, then measure clearance A (left, right, inside, outside: 4 places).

2) If clearance

A is more than 3 mm, remove bolt (3) and (4), then take out shim (5), and adjust as follows. Clearance of one side: Max. 0.5 mm *

Type of shim: 0.5 mm, 1.0 mm

20-35-l 0

17MF02863

CONVERTER STALL

Measure the stall speed under the following condition. 0 Coolant temperature : Within operating range 0 Power train oil temperature : 70 - 90°C 0 Hydraulic oil temperature : Min. 50°C

Make sure that there is no one near the maA chine before starting measurements. 1. Install tachometer A. For details, see MEASURING

ENGINE SPEED.

Red

2. Depress the steering brake firmly and move the gearshift lever to F3. 3. Set the fuel control lever to FULL, run the engine at high idling, and stall the torque converter. 4. When lamp A at the top of the green range of the torque converter oil temperature gauge lights up, return the gearshift lever to neutral, until lamp B and lower the oil temperature lights up. 5. Repeat Steps 2) -

4) three times.

6. Repeat Steps 2) verter.

4) to stall the torque con-

7. When lamp A at the top of the green range of gauge the torque converter oil temperature IO seconds, then lights up, wait for 5 measure the engine speed. * After completion of the measurement, return the gearshift lever swiftly to neutral, and run the engine at high idling to lower the oil temperature. Precautions when relieving the torque conA, ver-ter

1) Depress the decelerator pedal before pulling the fuel control lever to the FULL position. 2) Release the decelerator pedal to run the engine at high idling. However, for safety reasons, always keep your right foot on the decelerator pedal until the completion of the measurement operation.

20-36

Green

1 17MF02164

MEASURING SPEED AT TORQUE CONVERTER STALL + HYDRAULIC PUMP RELIEF (FULL STALL) Ir

Measure the stall speed condition. 0 Coolant temperature

under

the following

: Within operating

range 0 Power train oil temperature : 70 - 90°C l Hydraulic oil temperature : Min. 50°C Make sure that there is no one near the maA chine before starting measurements. 1. Install tachometer A. For details, see MEASURING 2. Depress the steering brake the gearshift lever to F3. 3. Set the fuel control gine at high idling, verter.

ENGINE SPEED. firmly

and move

lever to FULL, run the enand stall the torque con-

4. When lamp A at the top of the green range of the torque converter oil temperature gauge lights up, return the gearshift lever to neutral, and lower the oil temperature until lamp B lights up. 8 z 6

5. Repeat Steps 2) -

Red \I

Greez

I 17MF021t

4) three times.

6. Repeat Steps 2) - 4) to stall the torque converter, and at the same time, set the ripper control lever to the RAISE position to relieve the circuit. 7. When lamp A at the top of the green range of the torque converter oil temperature gauge lights up, wait for 5 IO seconds, then measure the engine speed. of the measurement, return * After completion the gearshift lever swiftly to neutral, and run the engine at high idling to lower the oil temperature. Note: If this measurement is carried out immediately after measuring the torque converter stall speed, the measurement can be carried out by performing Steps 1) - 6) once. Precautions when relieving the torque conA verter 1) Depress the decelerator pedal before pulling the fuel control lever to the FULL position. 2) Release the decelerator pedal to run the engine at high idling. However, for safety reasons, always keep your right foot on the decelerator pedal until the completion of the measurement operation.

20-37

MEASURING

POWER TRAIN OIL

Stop the machine on level ground, lower the A work equipment to the ground and apply the parking

brake.

When measuring the hydraulic pressure, remove all the sand and dirt from around the nipple and plug. Raise the power train oil temperature to at least 70°C before measuring.

Refer to the diagram and table below to install oil pressure gauge C to the nipple for the circuit to be measured.

Table of centralized pressure pick-up port positions and gauges to use when measuring hydraulic pressure

Measurement

location

1. Right brake actuating

pressure

Gauge (kg/cm*) 60

I 2 Left brake actuating pressure I 3 ” Rrght clutch actuating pressure I 4 Left clutch actuating pressure I 5 Transmission reducing pressure I 6 Transmission modulating pressure 7. Torque

converter

stator

8. Torque

converter

lock-up

clutch

pressure

60 60 60 60 60 60

pressure

I 9 Torque converter outlet pressure I 10 Torque converter inlet pressure I 11 Transmission lubricating pressure

20-38

25 10

11' 17MF02165

1. Measuring

torque converter

oil pressure

Measuring torque converter inlet port and outlet pressure i) Install oil pressure gauge C to torque converter inlet pressure measurement nipple (10) and outlet pressure measurement nipple (9). ii) Set the gearshift lever at neutral, and measure the torque converter inlet port pressure and outlet port pressure with the engine at low idling and high idling. Measuring torque converter lock-up pressure i) Install oil pressure gauge C to torque converter lock-up pressure measurement nipple (8). ii) Set the gearshift lever at neutral, turn the lock-up mode switch ON, and measure the torque converter lock-up pressure with the engine at low idling and high idling. * Start the engine, turn the lock-up mode switch ON, then gradually raise the engine speed. When doing this, check that the lock-up lamp lights up, and at the same time the lock-up oil pressure rises. Reference: Engine speed when lock-up actuation starts (lamp lights up): 1110 - 1170 rpm Measuring torque converter stator clutch pressure i) Install oil pressure gauge C to torque converter stator clutch pressure measurement nipple (7). ii) Set the gearshift lever at neutral, turn the lock-up mode switch OFF, and measure the torque converter stator clutch pressure with the engine at low idling and high idling.

2. Measuring

transmission

oil pressure

1) Measuring modulating and rotating clutch reducing pressure (clutch circuit pressure) i) Install oil pressure gauge C to modulating pressure measurement nipple (6) and reducing pressure measurement nipple (5). Measure the hydraulic pressure when the clutch is actuated with the engine at low idling and high idling when the gearshift lever is operated to all the positions given below. pressure with ii) Measure the modulating the gearshift lever at neutral. carrying out the following * Before measurements, pull the steering levers (left and right) fully and apply the parking brake securely. iii) Place the gearshift lever at Fl. Measure the modulating pressure and reducing pressure. iv) Place the gearshift lever at F2. Measure the modulating pressure. v) Place the gearshift lever at F3. Measure the modulating pressure. vi) Place the gearshift lever in RI. Measure the modulating pressure. the steering levers, * Before returning place the gearshift lever in neutral, then move the steering levers slowly. Combination of speed range and clutches * No. 5 (1st) is the rotating clutch.

20-39

2) Measuring transmission lubricating oil pressure lubricating oil pressure i) Remove measurement plug (11) (PT1/8), and install oil pressure gauge C. ii) Place the gearshift lever at neutral, and measure the lubricating oil pressure with the engine at low idling and high idling. Note:

3. Measuring

The oil pressure differs greatly between high temperature and low temperature, so warm up the oil throughly before measuring. For details, see MEASURING ENGINE SPEED AT TORQUE CONVERTER STALL.

steering

clutch pressure

1) Install oil pressure gauge C to left nipple (4) and right nipple (3) for measuring the steering clutch pressure. 2) Place the gearshift lever at neutral, pull the steering levers fully, and measure the oil pressure with the engine at low idling and high idling.

4. Measuring

steering

brake pressure

1) Install oil pressure gauge C to left nipple (2) and right nipple (1) for measuring the steering brake oil pressure. 2) Place the gearshift lever at neutral, and measure the oil pressure with the engine at low idling and high idling with the steering levers not operated. -j, Check also that the oil pressure is 0 kg/ cm2 with the engine at high idling both when the steering levers are pulled fully and when the brake pedal is locked with the lock lever.

20-40

TESTING AND ADJUSTING WORK EQUIPMENT MAIN RELIEF PRESSURE Stop the machine on level ground, lower the A work equipment to the ground and apply the

When remove

Small pump relief valve

brake.

parking

gauge, the oil pressure installing all the sand and dirt from around the

plug. 0

Measuring

pressure

1) Remove plug (PT1/8) (1) (for large pump) and (2) (for small pump) for measuring main relief pressure, and work equipment install oil pressure gauge C (400 kg/cm*). 2) Measure the relief pressure of the large pump. 0 Operate the ripper to the RAISE position to relieve the circuit, then measure the oil pressure with the engine at low idling and high idling. 3) Measure

the

relief

pressure

of the small

pump. to the 0 Operate the blade tilt cylinder end of its stroke to relieve the circuit, then measure the oil pressure with the engine at low idling and high idling.

Large pump reliel valve

17MF02185

pressure

Adjusting

If the result of measuring the work equipment main relief pressure shows that the value is not within the standard value, adjust as follows.

1) Remove cover (1). 2) Loosen locknut (2), and turn adjustment screw (3) as follows to adjust. Jr TO RAISE pressure, turn CLOCKWISE TO LOWER pressure, turn COUNTERCLOCKWISE screw ad* One turn of the adjustment justs the pressure by approx. 24.8 kg/ cm2.

3 197F430

20-41

BLEEDING AIR FROM HYDRAULIC CYLINDER

for cylinders the hydraulic When operating the first time after replacing or reassembling the cylinders or piping, always bleed the air from the hydraulic cylinders as follows: 1) Start engine and run at low idling for approx. 5 minutes. 2) Run the engine at low idling, and raise and lower the blade or ripper 4 - 5 times. * When operating the hydraulic cylinder, stop the piston rod 100 mm from the end of its stroke. Do not relieve the circuit under any circumstances. 3) Run the engine at high idling and repeat Step 2), then run the engine at low idling and operate the piston rod to the end of its stroke to relieve the circuit.

20-42

If the hydraulic drift exceeds the standard value, check if the cause of the hydraulic drift is in the cylinder or in the control valve. *

Oil temperature

when measuring: 45 -

Measurement

55°C

posture

1. Blade tilt cylinder, ripper tilt cylinder 0 Fully extend the rod of the cylinder to be measured, and lower the tip of the blade or ripper to the ground. 2. Ripper lift cylinder 0 Remove the shank pin and extend the lift cylinder fully. *

The blade lift cylinder has a built-in piston valve, so measurement is impossible.

Measuring

1) Disconnect the head piping, and block the piping plate.

at the

chassis end with

a blind

Be careful not to disconnect the piping at the bottom end.

Start the engine, run the engine at high idling, and apply the relief pressure to the bottom end of the cylinder. Wait for 30 seconds, then measure the amount of leakage over the next 1 minute.

20-43

CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE AND RIPPER *

If hydraulic drift occurs in the blade and ripper (cylinder), check as follows to see if the cause is in the cylinder packing or in the control valve.

1. Inspection

Blade lift cylinder

posture

1) Blade lift cylinder

circuit Extend the blade to raise the chassis. 2) Blade tilt cylinder circuit Extend the tilt cylinder rod fully (maximum tilt), then extend the blade to raise the chassis. 3) Ripper lift cylinder Extend the ripper to raise the rear of the chassis from the ground. 4) Ripper tilt cylinder

197FOl552

(

Blade tilt cylinder

2. Inspection Set the cylinder of the circuit to be checked in the inspection posture, then stop the engine. * For details of the inspection posture, see Item 1) - 4). Ripper lift cylinder

Operate the control lever in the direction extend the cylinder rod. If the downward movement becomes fast, the packing is defective. If there is no change, the control valve is defective. If the pressure in the accumulator has been removed, run the engine for approx. 10 seconds to charge the accumulator before carrying out the operation. Reference:

I555

Ripper tilt cylinder

If the cause of the hydraulic drift is in the packing, the speed of downward movement in the above operation will become faster for the following reasons.

1) With the work equipment in the posture given above, (holding pressure applied to the bottom end), the oil will leak from the bottom end to the head end. However, the volume at the head end is smaller than at the bottom end (proportional only to the area of the rod), so if the oil flows in from the bottom end, the internal pressure at the head end will rise. 2) If the internal pressure at the head end rises, a balance will be made in proportion to this at a certain pressure (this differs according to the amount of leakage).

20-44

I97FO

17MF02166

3) When the pressure becomes balanced, the speed of downward movement becomes slower. In this condition, if the lever is operated as shown above, the circuit at the head end is connected to the drain circuit (the bottom end is closed by a check valve), and the oil at the head end flows to the drain circuit to increase the speed of downward movement.

PROCEDURE FOR SIMPLE TEST OF STEERING BRAKE PERFORMANCE *

Carry out the measurement under the following conditions. 0 Coolant temperature: Within operating range 0 Power train oil temperature: 70 - 90°C

1. Stop the machine on a flat road surface with the blade and ripper in the travel posture. 2. Run the engine at low idling, depress the brake pedal securely, and place the gearshift lever at F2. 3. Depress the decelerator pedal and pull the fuel control lever to the FULL position.

17MF02167

4. Release the decelerator pedal gradually, raise the engine speed to high idling, and check that the machine does not move. During the measurement, keep your A right foot on the decelerator pedal, and if the machine starts to move, quickly depress the decelerator pedal and return the gearshift lever to neutral. 8 z i;

Note:

If this test is carried out in Fl, an excessive load will be brought to bear on the brake. For this reason, never use Fl; always use F2.

20-45

PROCEDURE FOR TESTING SENSORS

1. Radiator water

level sensor

1) Stop the engine, turn the starting switch OFF, and remove the sensor from the radiator. 2) Put the test pin of the tester in contact with the sensor connector. 3) Move the sensor float up and down, and measure the resistance between terminals 1 and 2. *

Judgement Condition

When normal

Float up

Max. 1 Q

Float down

Min. 1 M 8

0 The relationship between the sensor and the position of the float is as follows. Float above specified level: CLOSED (ON) OPEN (OFF) Float below specified level:

1. Float 2. Switch 3. Connector

Structure of circuit

56lFO3177

2. Engine oil level sensor 1) Stop the engine, turn the starting switch OFF, and remove the sensor from the engine. 2) Connect a T-adapter to the sensor connector. 3) Move the sensor float up and down, and measure the resistance between terminal 1 and the bracket. j,

Judgement When normal

Condition

Float up

Max. 1 R

Float down

Min. 1 M Q

The relationship between the sensor and the position of the float is as follows. Float above specified level: CLOSED (ON) OPEN (OFF) Float below specified level:

1. 2. 3. 4.

f Down

Connector Bracket Float Switch

Structure of circuit I97FO2077

20-46

3. Engine oil pressure sensor and turn the starting switch OFF. 2) with the sensor still installed to the engine, disconnect the wiring harness from the sensor. 3) Measure the resistance between the terminal and the chassis with the engine stopped and with the engine running.

1) Stop the engine

\\I///

Judgement When normal

Condition of sensor

@ @ 0 Structure of circuit

Engine stopped

Engine running

Min. 1 M 8 Max. 1 R

1. Plug

The relationship between the sensor and the oil pressure is as follows. Oil pressure above 0.7 kg/cm*: CLOSED (ON) Oil pressure below 0.7 kg/cm2: OPEN (OFF)

4. Engine water temperature, sensor ter oil temperature

torque

2. 3. 4. 5. 6.

202FO5

I 75

Contact ring contact Diaphragm Spring Terminal

conver-

1) Stop the engine, turn the starting switch OFF, and remove the sensor from the engine or torque converter. 2) Measure the resistance between terminals 1 and 2 with the sensor at about the same temperature as the ambient temperature. *

Judgement Ambient temperature

When normal

35°C

Approx. 29 KR

20°C

Approx. 52 KQ

10°C

Approx. 80 KS

1. Connector 2. Plug 3. Thermistor

I96FO2046

Structure of circuit

20-47

5. Hydraulic

oil temperature

sensor

1) Stop the engine, turn the starting switch OFF.

2) With the sensor still installed to the piping at the suction side of the hydraulic pump, disconnect the wiring harness from the sensor. 3) Measure the resistance between terminal 1 and the ground. *

Judgement When normal

Condition of sensor Between terminal and ground

Max. 1 Q

1. 2. 3. 4.

Switch Case Wire Connector

Structure of circuit

6. Fuel level sensor

1) Stop the engine

and turn the starting switch OFF. 2) With the sensor still installed to the fuel tank, disconnect the wiring harness from the sensor. 3) Measure the resistance between terminals 1 and 2. *

Judgement Condition of fuel

When normal

Full

Approx.

Empty

Approx. 85 R

10 R

F91702223

20-48

ISSFO2047

TESTING

AND ADJUSTING

ELPC VALVE POTENTIOMETER

Sr Use the following

procedure to carry out testing and adjusting of the potentiometer set condition and adjustment when the potentiometer has been replaced.

/ 17MF02867

. ._.

Disconnect rods (I) and (2) connected to tne input and output levers of the ELPC valve.

Testing and adjusting manual (input) potentiometer I) Connect the wiring harness checker to the connector (CNSM4) of manual potentiometer 2) 3)

(3). Turn input lever (4) counterclockwise until it stops. Turn the power on, measure the voltage between pins No. 2 and 3 of potentiometer (31, and check that it is within the standard value. Standard voltage: 2.5 + 0.01 V

cNsM4 TWP01245

I D275A-2

TWD01246

20-48-l 0

If the voltage is not within the standard value, loosen mounting bolts (5) of the potentiometer, and move the oblong hole portion to adjust to within the standard value.

TWP01247

Testing and adjusting feedback (output) potentiometer I) Connect the wiring harness checker to the connector (CNSMP) of feedback potentiometer 2) 3)

(6). Turn output lever (7) counterclockwise until it stops. Turn the power on, measure the voltage between pins No. 2 and 3 of potentiometer (61, and check that it is within the standard value. Standard voltage: 1.58 & 0.05 V

TWPOl248

TWD01249

If the voltage is not within the standard value, loosen mounting bolts (8) of the potentiometer, and move the oblong hole portion to adjust to within the standard value.

After installing and adjusting the potentiometer, connect rods (I) and (2). Sr Adjust the linkage. For details, see ADJUSTING FUEL CONTROL LINKAGE. TWP01250

20-48-2 a

D275A-2

TROUBLESHOOTING

.......................................................................................... Point to remember when troubleshooting ............................................................................................... Sequence of events in troubleshooting ..................................................................................... Rrecautions when carrying out maintenance Handling connectors .............................................................................................................................. ............................................................................................................. Checks before troubleshooting Method of using matrix troubleshooting chart ................................................................................... chart.. ............................................................................................. Method of using troubleshooting Type of connector and position of installation ................................................................................... Connector position drowing ................................................................................................................. Connection table for connector ............................................................................................................ Electrical circuit diagrams for each system ........................................................................................ Troubleshooting of engine.. .................................................................................................................. Troubleshooting of hydraulic, mechanical system ............................................................................. Troubleshooting of electrical system ................................................................................................... Troubleshooting of electrical system (with SSC system) ............................................................... Troubleshooting of machine monitor system.. ................................................................................... Troubleshooting of shoe slip controller, ELPC controller system (G mode) ...................................

D275A-2

20- 50 20- 51 20- 52 20- 59 20- 60 20- 62 20- 66 20- 69 20- 71 20- 72 20- 81 20- 85 20-I 05 20-123 20-I 40-I 20-I 41 20-201

20-49 0

POINTS TO REMEMBER WHEN TROUBLESHOOTING

0 0 0 0 0

Stop the machine in a level place; and check that the safety pin, blocks, and parking brake are securely fitted. When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. When disconnecting wiring, always disconnect the negative (-) terminal of the battery first. When removing the plug from a location which is under pressure from oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly. The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible cases of the failure that would produce the reported symptoms.

1. When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately any failure occurs: 0 Parts that have no connection with the failure or other unnecessary parts will be disassembled. 0 It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. 2. Points to ask user or operator 1) Have any other problems occured apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 51 Had any repairs been carried out before the failure? When were these repairs carried out? 61 Has the same kind of failure occurred before? 3. Check before troubleshooting 1) Check for symptoms of any abnormality the machine.

20-50

2) Check the CHECKS BEFORE STARTING items. 3) Other inspection items. 4) Other maintenance items can be checked externally, so check any item that is considered to be necessary. 4. Confirming failure 0 Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. * When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. 5. Troubleshooting 0 Use the results of the investigation and inspection in Items 2 - 4 to narrow down the causes of failure, then use the troubleshooting tables (matrix) to locate the position of the failure exactly. * The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information. 6. Measures to remove root cause of failure. 0 Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause.

f: :6

SEQUENCE OF EVENTS IN TROUBLESHOOTING

Office,shop

,= fl

Jobsite

step1 1Examination, 1)

When

confirmation

a request

of symptoms

for repairs

first ask the following

RIngI Ring1

is received,

points:

Name

of customer

Type,

serial

number

of machine

0 Details of jobsite, etc. 2)

Ask questions

to gain an outline

of the

problem. 0

Condition

Work

of failure

being carried

out at the time

of the failure 0

Operating

Past history,

environment details

of maintenance,

etc.

Step 2 Determining 1)

probable

location

of cause

Look at the troubleshooting shop manual

section

to find locations

of the

of possible

causes.

step

3 Preparation 1)

of troubleshooting

in the shop manual necessary

tools

Look at the table of troubleshooting and prepare

tools

the I

tools.

T-adapter

Hydraulic

pressure

gauge

replacement

kit, etc.

Look in the parts book and prepare necessary

Pinpoint

locations

of failure

(carry out

the

parts.

I 2)

Before

starting

repair

simple

troubleshooting,

locate

and

failures.

Check before

Other

starting

items

check items

See the Troubleshooting shop manual, flowchart

Section

of the

select a troubleshooting

that matches

the symptoms,

and

carry out troubleshooting.

I i

Re-enacting

failure

Drive and operate the condition

I step

to confirm

if there

is really

failure.

1 Step5

4 1 Go to jobsite

the machine

and judge

1 of failure

Was there

I anything

the machine 0 0

before

strange

about

the failure

Did the failure

occur suddenly?

Had any repairs

been carried

occurred? out before

the failure?

20-5 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 “Handling electric equipment” and “Handling hydraulic equipment” particularly hydraulic oil).

PRECAUTION WHEN ELECTRIC EQUIPMENT

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 protector 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.

HANDLING

F20505201

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.

20-52

Improper

insertion

F20505202

(2) Defective

compression or soldering of connectors The pins of the male and female connectors are in contact at the compressed terminal or soldered portion, but there is excessive force on the wiring, and the plating peels to cause improper correction or breakage.

Improper

compressio

F56103079

(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 compression of the connector may be lost, or the soldering may be damaged, or the wiring may be broken.

F20505204

(4) High pressure water entering connector The connector is designed to make it difficult for water to enter (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. The connector is designed to prevent water from entering, but at the same time, if the water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be short-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it.

& F20505205

(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 or dirt stuck to the connector, wipe it off with a dry cloth or blow dry with air, and spray it with a contact restorer. jr When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. F20505206

20-53

If there is water or oil in the air, it will increase the contamination of the points, so clean with air from which all the water and oil has been removed.

Removing, installing, and drying connectors and wiring harnesses. Disconnecting connectors (1)Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors and not the wires. 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. F20505207

(2) 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.

F20505208

Connecting connectors (1) Check the connector visually. a. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). b. Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. c. Check that there is no damage or breakage to the outside of the connector. Sr 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. * If there is any damage or breakage, replace the connector.

20-54

(2) Fix the connector securely. Align the position of the connector correctly, then insert it securely. For connectors with lock stopper Push in the connector until the stopper clicks into position. Cliks into position

(3) Correct any protrusion of the boot and any misalignment of the wiring harness For connectors fitted with boots, correct any protrusion or the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. j, When blowing with dry air, there is danger that the oil in the air may cause improper contact, so clean with air from which all the water and oil has been removed.

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. * If the connector is blown dry with air, there is the risk that oil in the air may cause defective contact, so avoid blowing with air.

F20505209

F20505210

F20505211

(4 Dry the inside

of the

connector

witha

dryer. If water gets inside the connector, use a dryer to dry the connector. * Hot air from the dryer can be used, but be careful not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.

F20505212

20-55

(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. j, After completely drying the connector, blow it with contact restorer and reassemble.

Handling control box (1) The control box contains a micro-computer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the control box. (2) Do not open the cover unless necessary. (3) Do not place objects box. (4) Cover the control a vinyl bag

of the control

T-adapter

F20505213

box

on top of the control

connectors

with

tape or

F20505214

(5) During rainy weather, do not leave the control box in a place where it is exposed to rain. (6) Do not place the control box on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand) (7) Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the controlb box. Fit an arc welding ground close to the welding point.

F20505216

20-56

POINTS TO REMEMBER HANDLING HYDRAULIC

WHEN 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.

Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to confirm the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be confirmed with special test equipment.

F20505217

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 on to the ground, collect it and ask the customer to dispose of it, or take it back with you for disposal. F20505218

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.

F20505219

20-57

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. (Do not 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. 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.

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 ultrafine (about 3 ,~4 particles that the filter built into the hydraulic equipment cannot remove, so it is an extremely effective device.

F20505220

F20505221

20-58

HANDLING CONNECTORS

1. When removing the connectors from the clips, pull the connector in a parallel direction to the clip. * If the connector is twisted to the left and right or up and down, the housing may break.

205FO5609

205FO5610

r I-

2. When disconnecting male and female connectors, release the lock and pull in parallel with both hands. * Never try to pull out with one hand.

205FO5611

3. When the wiring harness clamp of the connector has been removed, always return it to its original condition and check that there is no looseness of the clamp.

205FO5612

20-59

CHECKS BEFORE TROUBLESHOOTING

Judgement

Item

standard

1. Check fuel level 2. Check for dirt or water in fuel 3. Check hydraulic oil level 4. Check hydraulic oil strainer 5. Check power train oil level 6. Check engine oil level (level of oil in oil pan) 7. Check cooling water level

Remedy Add fuel Clean, drain Add oil Clean, drain Add oil Add oil Add water

8. Check condition of dust indicator

Clean or replace

9. Check for loose or corroded

battery terminals

10. Check for loose or corroded alternator

or wires

terminals

Tighten or replace Tighten or

or wires

11. Check for loose or cooroded starting motor terminals

replace Tighten or

or wires

replace

Repair

13. Check for oil leakage

Repair

14. Bleed air from system

Bleed air

12. Check for abnormal

noise or smell

15. Check battery voltage (engine stopped) 16. Check level of battery electrolyte

30 v

20 -

Replace Add or replace

17. Check for discolored, burnt, or bare wiring 18. Check for missing wiring clamps, hanging wires 19. Checks for water leaking onto wiring (check carefully for water leakage at connectors

Replace Repair Dry area

and terminals)

around connector

20. Check for broken or corroded fuses !I. Check alternator voltage (engine running at over half throttle)

Replace

After running engine for

Replace

several

!2. Noise when battery relay is operated. (Turns starting switch ON - OFF)

20-60

minutes 27.5 - 29.5 v -

Replace

METHOD OF USING MATRIX TROUBLESHOOTING

chart is divided into three This troubleshooting questions, check items, and troublesections: shooting. and check items are The questions causes that can used to pinpoint high probability or simple be located from the failure symptoms tools. inspection without using troubleshooting tools or direct inspection Next, troubleshooting causes to are used to check the high probability make final confirmation. [Questions] Sections $9 + @ in the chart on the right corresponds to the items where answers can be obtained from the user. The items in @ are items that can be obtained from the user, depending on the user’s level. [Check items] carries out simple inspection to The serviceman narrow down the causes. The items under 0 in the chart on the right correspond to this. narrows down the causes from The serviceman from the @ that he has obtained information user and the results of 0 that he has obtained from his own inspection. [Troubleshooting] is carried out in the order of Troubleshooting starting with the causes that have probability, been marked as having the highest probability gained from [Questions] and from information [Check items].

20-62

CHART

The basic method of using the troubleshooting chart is as follows. Items listed for [Questions] and [Check items] that have a relationship with the Cause items are marked with 0, and of these, causes that have a high probability are marked with 0 Check each of the [Questions] and [Check items] in turn, and marked the 0 or 0 in the chart for items where the problem appeared. The vertical column (Causes) that has the highest number of points is the most probable cause, so start troubleshooting for that item to make final confirmation of the cause. -*1. For [Confirm recent repair history] in the [Questions] Section, ask the user, and mark the Cause column with A to use as reference for _, locating the cause of the failure. However, do not use this when making calculations to narrow down the causes. *2. Use the A in the Cause column as reference for [Degree of use (Operated for long period)] in the [Questions] section as reference. As a rule, do not use it when calculating the points for locating the cause, but it can be included if necessary to determine the order for troubleshooting.

Confirm

recent

Degree

of “se

repair

history Operated

for long period

20-63

Example of troubleshooting when exhaust gas is black Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms have causal relationship with this problem: [Exhaust gas slowly becomes black], [Power slowly became weaker], and [Dust indicator is red]. If we look from these three symptoms to find the causes, we find that there is a relationship with five causes. Let us explain here the method of using this causal relationship to pinpoint the most probable cause. S-7 Exhaust gas is black (incomplete combustion) General causes l l l

20-64

why exhaust gas is black Insufficient intake of air Improper condition of fuel injection Excessive injection of fuel

Five causes

Step 1

1 Clarify

the relationship between the three symptoms in the [Questions] and [Check items] section and the five Cause items in the vertical column.

Three symptoms A

Steo 2 I-

Add up the total of 0 and 0 marks where the horizontal lines for the three symptoms and the vertical columns for the causes intersect. (1) Clogged air cleaner element: 000 (2) Air leakage between turbocharger and head: 00 0 (3) Clogged, seized injection nozzle: (4) Defective contact of valve, valve seat: g (5) Worn piston ring, cylinder:

Step 3 The calculations in Step 2 show that the closest relationship is with [Clogged air cleaner element]. Follow this column down to the troubleshooting area and carry out the troubleshooting item marked 0. The Remedy is given as [Clean], so carry out cleaning, and the exhaust gas color should return to normal.

20-65

METHOD OF USING TROUBLESHOOTING 1. Category

of troubleshooting

Troubleshooting

CHARTS

code number

code No.

Component

H-00

Power train, work equipment

E-00

Electronic system

M-00

Machine monitor

(Hydraulic, mechanical

system)

2. Method of using troubleshooting table @ Troubleshooting code number and problem The top left of the troubleshooting chart gives the troubleshooting code number and the problem with the machine. @ Distinguishing condition Even with the same problem, the method of troubleshooting may differ according to the model, component, or problem. In such cases, the troubleshooting chart is further divided into sections marked with small letters (for example, a)), so go to the appropriate section to carry out troubleshooting. If the troubleshooting table is not divided into sections, start troubleshooting from the first check item. @ Method of followinn troubleshooting chart Check or measure the item inside the box, and according to the answer follow either the YES line or the NO line to go to the next box. (Note: The number written at the top right corner of the box is an index number; it does not indicate the order to follow.) Following the YES or NO lines according to the results of the check or measurement will lead finally to the Cause column. Check the cause and take the action given in the Remedy column on the right. Below the box there are the methods for inspection or measurement, and the judgement values. If the judgement values below the box are correct or the answer to the question inside the box is YES, follow the YES line; if the judgement value is not correct, or the answer to the question is NO, follow the NO line. Below the box is given the preparatory work needed for inspection and measurement, and the judgement values. If this preparatory work is neglected, or the method of operation or handling is mistaken, there is danger that it may cause mistaken judgement, or the equipment may be damaged. Therefore, before starting inspection or measurement, always read the instructions carefully, and start the work in order form item 1). @ General precautions When using the troubleshooting chart, precautions that apply to all items are given at the top of the page and marked with *. The precautions marked * are not given in the box, but must always be followed when carrying out the check inside the box. @ Troubleshooting tools When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For details, see TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING. @ Installation position, pin number A diagram or chart is given for the connector type, installation position, and connector pin number connection table, so when carrying out troubleshooting, see this chart for details of the onnector pin number and location for details of the connector pin number and locations for inspection and measurement of wiring connector number 00 appearing in the troubleshooting flow chart.

20-66

8 z 6

Example 1

M-3. When starting

al Abnormality .

switch is ON (engine stopped),

in radiator water

Radiator water

CHECK items shown abnormality

level

level monitor flashes

0 Cause

YES

Remedy

Defective radiator water lever sensor.

Replace

Defective monitor module.

Fii?DlPX

Defective contact, or disconnection in wiring harness between CN405 (female) (1) CN202 (11 - CN201 (1) - CNlOl (2) - CN421 (3) - CN-1 (female) (51.

After inspection, repair or replace

Defective contact or disconnection in wiring harness between CN405 (female1 (21 and chassis ground.

After inspection, repair or replace

1 YES

Does radiator

water level monitor

go off? 2 .

e 8

Connect short connector to CN405 (female). Turn starting switch ON.

2 b

Is resistance betwee” CN405 (female) (2) and chassis ground less than 1 Q? l

Disconnect CN405.

3 YES

Is resistance between CN-1 (female) (5) and chassis ground less than lQ? Disconnect

CN-1.

* Before carrying out troubleshooting, check that all the related connectors are properly inserted. jr Always connect any disconnected connectors before going on the next step.

20-67

TYPE OF CONNECTOR AND POSITION OF INSTALLATION

$~I~J.~~?RESS column

Connec-

No.

tor No.

tor type

I of pins

Monitor panel

CN364

Monitor panel

CN371

Monitor panel

CN372

No.

tor type

of pins

CNI

AMP040

CN2

AMP040

CN3

MIC

Place of use

Monitor panel

CN5

Monitor panel

CNlOl

SWP

Intermediate

CN102

position

RESS

Connec-

tor No.

in the connector

ADD-

Connec-

CN4

in this table shows the address

connector

APS nozzle, glow plug

(3-dimensional

drawing

ADD.

Place of use

I RESI D7

Intermediate connector (without cab) intermediate connector (without cab) Caution lamp, lock-up lamp (without cab) Int;;yaiate

CN391

C6 A7

connector

CN399

Caution lamp, lock-up lamp (with cab)

CN401

Intermediate

CN402

Engine water temperature sensor

CN403

Engine oil pressure sensor

CN404

(

connector

CN422

Intermediate

CN423

Fuel sensor

connector

CN151

Neutral safety switch

CN153

SWP

Intermediate

CN161

SWP

Starting switch

CN464

Auxiliary controller

CNI 62

Auxiliary controller

CN465

Connector

Caution buzzer

CN201

Intermediate

connector

CN466

Connector

Caution buzzer

CN202

Intermediate

connector

CN622

SWP

Lock-up controller

connector

CN653 CNSOl CN224

Pin-puller solenoid

CN241

Intermediate

CN242

Working lamp (right)

connector

CNSOZ

CNS03

CNS04

Riooer UP switch

CNSOS

Ripper tilt switch

CN361

SWP

Intermediate

connector

CN362

SWP

Intermediate

connector

CNSIO CNSl2

SWP X

Intermediate

Transmission FORWARD oil pressure switch

connector

H2 Hg

20-69

Place of use

1 CNSMI

MIC

1 21 1 ELPCvalve

controller

I ~8

CNSM2

Feedback potentiometer

CNSMB

Solenoid

I CNSM4

I Throttle potentiometer

CNSM5

Engine speed sensor

CNSSI

MIC

SSC controller

CNSS2

MIC

SSC controller

1 CNSSB

20-70

1 Acceleration

sensor

Connec-

ADD-

I RESS I I

I F8 I

tor No.

Place of use

I I ADD-

RESS

CONNECTOR POSITION DRAWING CN653 CN452 CN263

/ AA

CN399 I

CNSOS

-I

CN423 i

CNS12

CNl CN422 crJ3g1 -_.___

CFj251 \ CN622 N451

CN62 ,

Cd404c’103 17MF02166

.................... ““““““‘~ ............................................................ p:.:.:.:+:.:.:.:.:.:.:.:.:C~-............... . ....................................... :y::::::::::::::::::::::::::::::::::::::: i:i:#:~:i:i:~:i::::::::::::::~~:::~:~::: :~::~::::i::::::::::::::~,~~:~.:.:.:.: .......................................... D B ..........................................

:~!:~:~:i:!:i:i~:i~~.~~~

c ...

: : : : ...........................

............................................

~G:~~l ................ ::::::::::::::::::::::::::::::::::::::::::: ........................A. ........................

~.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:::::::::::jljjii .:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.: ................................................. ........................................... J :.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:+:,

20-71

CONNECTION TABLE FOR CONNECTOR

NO. Oi Pins

X TYPE CONNECTOR Male connector

Female connector

205FO5309

205FO5310

205FO5311

205FO5312

205FO5313

205FO5314

/ 2

4 205FO5315

20-72

2 205FO5316

M TYPE CONNECTOR

No. o f Pins

Female connector

Male connector

205FO5317

205FO5318

205FO5319

205FO5320

205FO5322

4 El

205FO5323

205FO5324

20-73

No. of Pin

M TYPE CONNECTOR Male connector

Female connector 1

6 205FO5325

20-74

205FO5326

Pins

TYPE

AMP040

No. c,f

CONNECTOR Female connector

Male connector

8 \

5 1

5 F56103084

F56103083

‘7

i F56103086

F561 03085

\\ 9 205FO5335

205FO5336

20-75

No. c Pins

S TYPE CONNECTOR Male connector

Female connector

a 205FO5327

205FO5328

205FO5329

205FO5330

1 205FO5331

205FO5332

205FO5333

20-76

205FO5334

No. c Pins

SWP TYPE CONNECT& Female connector

Male connector

H I

205FO5340

205FO5339

5 \

8 205FO5342

205FO5341

i4 F56103087

F56103088

20-77

MIC CONNECTOR

No. of Pins

Female connector

Male connector

142F411

142F410

142F413

142F412

142F415

142F414

F7 I

142F417

20-78

142F416

Total Pins

CONNECTOR Female (mating portion is inset)

Male (mating portion protrudes)

195FO5128

195FO5129

20-79

ELECTRICAL CIRCUIT DIAGRAMS MACHINE

MONITOR

(except

Hydraulic temneratur esensor

Torque converter oil temperature sensor

preheating,

oil Fuel

level

FOR EACH SYSTEM

APS system)

Engine Pressure sensor

Radiator water temperature sens or

Starting

oil Engine level

oil sensor

Radiator water level sensor

Alternator

Starting

Starting motor

jVb_pnerator’s

cab

installed Central

______ warnina

lamp

warnine

lamp

(

Buzzer

sianal

hi---

ill

I I

+l( __

1’2\

““!/OS\

Panel

) _.._

I I I I I

Monitor

Monitor module _____-__-__-__-----Lighting signal [GND

Power source (+I GND Stating signal Charge amount R Radiator water level Engine oil level Engine oil pressure Hydraulic oil temperature

-I

Enain water tennerature Torque converter oil temperature Fuel level Preheating selector GND

CN121

,., -.-I-__ warn’ns lamp Buzzer ____________________I En-b a E

Lock-us

Relay

,o 0

'""P~S'_arY~_Y!~~____________________;

box

3’ 0

0 0 0

40 3 20

Battery

Serviice meter ___________-__-__-__ Lighting signal GND

relax j

T;/

1 cnarae

amount

-a BR a

I I

’ 04

05 I

GND

TDD00706

20-8 1 0

APS SYSTEM Serial No . : 10001 - 10167

APS controller r-------7

APS fuse No. 16

Monitor module

0.5

I I

1.25

Panel switch 0.75

0.75

pwJerro”rce

I I Panel switch GND

I I I

I ’

0.5

II04 APS relay

1Kn l*,I 0.5

II 1

APS pilot

II i-l

Starting switch R2

OH 013 ,012 01

I OIC II09

17MF03001

20-82 @

Serial No. : 10168 and up Start

Nozze

ins

motor

Safety

zzzl

switch

Nl03

?elav box -_-_-__.______________-_-_-______.-.-_-_

Safety

-_-_-_-_-------.-_ relay

N151

APS water sensor

_-_-__ __ r--,^.5 ^^. i1

Fuse

IUH

CN451

ZUA

j CNl21

__________________~_onit_arm_odul

I I

lb8 Ilndl

lbiilliiall

I I

r r__________.-_-_-_-_-_-

1 I

/ I

0 -I

1 0151 014

Grow

016 017 018 ..I9

1 1 I I 2u

CN4

CNl

a I

CN2

I CN361

Panel

Starter

APS L-

L___-_______.__L__1 APS

switch

snitch

oilnt

Ll Relay

controller

77 7-

TDD00709

20-82-l @

SSC CONTROL, ELPC CONTROL MODE SELECTION ELECTRONIC SYSTEM

DIAGRAM

CN251

(X) a

I CNS07

1 AEXI.25P

"E"

j AEXO.85P

Fusible

CNSM5 Engine sensor

,,,

IN>L”“A.L,

(option

C2OOX2)

Transmission forward

oil

Pressure switch

,, AEXIOOR (1201

IinktGOA)

CNSSJ

Acceleration

1 -

OaIIerY

(X)

Back-up alarm limit switch

1 .\rnnn,tn.-.\

(XI

AVZL

II .

AVSO.85LW

II.

AVSO.85LY

11.;

Lx!!

CNSM4 'Sianal5V 7

GND

AVSO.85BW AVSO.85GW

02 w3

2+ 3.

AVSO.858

* 5 . 6

(SWP)

CNSOG

(SWP)

AVSO.85Le

CN122

[ISneed+

(XI

,,A~~.858

For SSC actuator

(SWP)

;&need-

speed xx

CN421

6 -9 1 7 >c., 8 8 . o 3 9

10 11 &AVBS------------~ AtSMA)

" 0

CNSMJ Motor

At+) II,,\\

,,llAVBSO.75W

,3.

AVBSO.15W

I”.

AVBSO.758

; ,7------ ______---------------_. 1I________________-------; i I \_a

SWP)

TWD01251

20-82-2 0

D275A-2

Shoe siio control Monitor Panel

specifications

1Monitor

Panel

Ripper switch @

LOWER

Ripper switch

CNS03

, COM NC NO

RAISE

. 3

02 .

CNS04 COM

(Xl

Caution

AVSO. 858

CNSOS (MI

buzzer /

Monitor

auxiliary

controller

AVSO. 58

AVSO. 5LY

SSC Panel (when ON-OFF available

key

ON)

is switch

Shoe control

:K,’

AVSO. 85GW

(XI

NO TILT

CNS05 COM

(X)

II-?\’

NC NO

Ier

(SSC)

Torque

converter

Ens i ne

speed

Throttle

signal

Rockbed

selection

mode

Torque

converter

speed

Ens ine

speed

Acceleration

sensor

(8V)

Acceleration

sensor

(GNO)

Acceleration

sensor

(sianal)

SSC

AVSl.

25B

AVSO. 5LW AVSO.85BrR

command

Economy

mode

Economy

mode

Ripper

TILT

switch

RIoper

RAISE

switch

Ripper

LOWER

switch

Back-up

alarm

switch

System

abnormality

Power ;4

;;.

15 .,D

15. ,B.

F switch

AVSJ.

I I I I

IIIIII i’llll,

output

(+24V)

supply

GNO Slip

control

I Transmission Reverse

(+I

Transmission CN42

t-1

f-1

Throttle(t5V)

-’

Ripper switch

slip

1st slow

switch

AVBSo’75W !*3 3.1 Solenoid drive AVSo’85GW !*i 1 5.1 F/B notentiotsienal)

t)SLgW

,OC_AVSO.____

I3___/____

- ’r------ -3’ i__

SSC

-I-l--l--

command

GNO Solenoid F/B AVSo.85B

1.19

Starting

l&I

drive(-)

Potent

Input

potent

Sensor

GND

Alarm

output

io (-) io (-1

switch

TWDO 1252

D275A-2

20-82-3 a

TORQUE

CONVERTER

LOCK-UP

SYSTEM

DIAGRAM

Transmission ;;;t;;ess”re

CN652 2

Torque speed

(X) 2.1

AVSO. 858

converter sensor

Front

disnlav(For

CN371

(X)

1.I AVSO.85BrY

I.,

CN651

1 I

CN364

(XI

cab) (X)

I .3 3e1AVSO. AVSO. 85LW I .3 3 85LY 1.4 4 1 4 I

AVSO. 85LW AVSO. 65LYL4

Lock-up amp

(XI

Shoe

CN653

non CN372

sl in

control

Ier

(SSC)

%Z,’

(XI

AVSO. 85LY

Lock-UP solenoid

CN 122 AVSI.

258

. .

AVSO. 85LW

(SWP) AVSl.

258

AVSO. 85LW

6 . 7

6. 7.

AVSO. 85LW

AVSO. 85LY

. 8

AVSO. 85LY

I. 1. ; I

Torque

converter

speed

Torque

converter

speed(t)

1 AVSo’5GW 94 4.

Lock-up

Plus

CNSOG

---‘I4

(SWP)

14.

(-)

switch

for

lock-up

GND

Shoe slip control Monitor Panel

~__________._.._.__..-.._.._..-__

1 Relax

AV20Rt100)

CNl21

(Mic)

i I

box

AVSO. 5BR

AVSO. 5B

AVSO. 5GW

. 3

Power

2 l 3.

GND Lock-up

specifications

(24V)

SUPPIY

switch

, CN362

z &

Monitor

(SWP) AVSO. 858

+24v

auxiliary

output

AVSO. 85LW Front

CN39 1 (M i c) Battery

relax

Battery (opt ion

(600AX2) AEX40B \A~i00B

_ ,I

(NS200X2) C2OOX2)

Fusible I ink

AVSO. 85LW AVSO. 85LY

1. 17 , 18

17.1 18

disnlav(For CN399

-++4

1.3

cab) I

(x1 3 4

Lock-up lamp

I 1 / /

AExlooR (120)

,l,l r

AVLL

77h7 GND

20-82-4 0

TWD01253

D275A-2

PANEL SWITCH SYSTEM

Right working

lamp

. -_ z

CN2.22

Left working

(except APS system)

>sl

lamp

Right rear lamp

Right

lamp

-‘ 7 Left rear lamp

Left lamp -_ 2

Relay box la Workina

Panel switch To monitor power

panel

source

352

CNl

wq------]

Head

:-I

Auxiliary

controller

(monitor

power

ttuo

lamp mitcb

source)

17MF02173

20-83

RELAY BOX ELECTRICAL CIRCUIT DIAGRAM Serial No.

: 10001

- 10127

CN 362

CN361 12345678

Ill

CNl21

197FO2085-1

20-84 8

0. 75 I. 25

017M02

III1

IIIIIIIIIIIIIII

Workino

IamP

0.5r-

l._-

m I. 25

0. 75

017M02

I I

III

1.25

Preheating

25Service

12. 0

\‘

lamPI

1-_--l

,_____ __.

TROUBLESHOOTING

s- 1 s- 2 s- 3 s- 4 s- 5 S- 6 s- 7 S- 8 s- 9 S-IO S-l 1 S-l 2 s-13 s-14 s-15 S-16

OF ENGINE

20- 86

Starting performance is poor. ..................................................... Engine does not start ........................................................... Engine does not pick up smoothly ..................................................

20- 87 20- 90

Engine stops during operations .................................................... Engine does not rotate smoothly ...................................................

20- 91

Engine lacks output ............................................................ Exhaust smoke is black. ......................................................... Oil consumption is excessive. ..................................................... Oil becomes contaminated quickly. .................................................

20- 93

Fuel consumption is excessive. .................................................... Oil is in cooling water, or water spurts back, or water level goes down Oil pressure lamp lights up .......................................................

20- 97

................................................................ Water temperature becomes too high. ............................................... Abnormal noise is made. ........................................................ Vibration is excessive ........................................................... Oil level rises.

20- 92 20- 94 20- 95 20- 96

........................

20- 98 20- 99 20-100 20-101 20-102 20-l 03

20-85

S-l

Starting performance is poor (Starting always takes time) General causes why starting performance is poor. 0 Insufficient supply of fuel 0 Insufficient intake of air 0 Improper selection of fuel (particularly in winter) (At ambient temperature of -10” C or below, use ASTEM D975 No. 1) 0 Defective electrical system j, Battery charging rate

7g time

newow3

000

I Indicator lamp does not light UP

ven when iniection

When compression

pressure is measured,

When air cleaner element to be clogged

it is found to be low

8 f

$ 2

0 a

Yes

or voltage of battery

Speed of some cvlinders does not chanae when owratina on reduced cylin&rs

When check is made using delivery method, injection timing is found to be incorrect When control rack is pushed. it is found to be heaw or does not return (when blinb plug at rear of pump is remdved, it can be seen that plunaer control sleeve does not move1 When fuel cap is inspected directly, it is found to be clogged Overflow

valve is stiff, remains open

When engine oil is inspected directly, it is found to have high

20-86

portion does not become warm

Either specific graviol of electrolyte is low

When feed pump strainer is inspected directly, it is found to be clogged

I l 1l I

is inspected directly, it is found

Voltage is 26 - 30V between alternator terminal and terminal E with engine at low idling

pump

When fuel filter, <trainer are inspected directly, there are found to be clogged

APS combustion

I I I I I I I.1

S-2 0

Engine does not start. Engine does not turn

General causes why engine does not turn 0 *

Internal parts of engine seized If internal parts of the engine are seized, carry out troubleshooting for “Engine stops during operations”. Failure in power train Defective electrical system

0 0

When starting switch is turned START, pinion moves out, but

When starting switch is turned to START, pinion does not

Specific gravity of electrolyte,

P ‘G 8 5 4 a c

voltage of battery is low

For the following conditions 1) - 4). turn the starting switch OFF, wnnect the cord, and carry out troubleshooting at ON 1) When the terminal B and terminal C of starting switch are connected, engine starts 2) When terminal B and terminal C of starting motor are connected, engine starts 3) When terminal B and terminal are connected, engine starts

C of safety relay

4) When terminal of safety switch and terminal B of starting motor are connected, engine does not start

-0 ox ,p 8$ -eZ6W 4 .; g; zt : u-

When ring gear is inspected directly, tooth surface is found to be chipped

20-87

Engine turns but no exhaust smoke comes out. (Fuel is not being injected)

General causes why engine turns but no exhaust smoke comes out. Supply of fuel impossible Supply of fuel is extremely small Improper selection of fuel (particularly in winter)

0 0

When fuel filter is drained, fuel does not come out

E .E % 2

20-88

When engine is cranked with starting motor, 1) No fuel comes out even when fuel filter air bleed plug is loosened 2) No fuel spurts out even when injection pipe sleeve nut is loosened

Rust and water are found when fuel tank is drained

@@,Q hh

Exhaust smoke comes out but engine does not start (Fuel is being injected)

General causes why exhaust smoke comes out but engine does not start 0

Lack of rotating force due to defective electrical system Insufficient supply of fuel Insufficient intake of air Improper selection of fuel (particularly in winter)

0 0 0

Confirm recent reoair historv

Degree of use of machine

1 Operated for long period

@@ heard from @ e .g

Engine oil must be added more frequently

: z to Operation

Manual

When engine is cranked with starting motor, 1) Little fuel comes out even when injection pump sleeve nut is loosened

2) Little fuel comes out even when fuel filter air bleed plug is loosened

% e 0

There is leakage from fuel piping When exhaust manifold is touched immediately engine, temperature of some cvlinders is low

When

furl fil+rr is drsinrd

@ after starting

no fwd comes c-m+

I I

I 1

I I

I 1

Ihl

1-1

When fuel control lever is moved, injection pump lever does not move

When head cover is removed and inspection is made directly, it is found to be abnormal en control rack is pushed, it is found to be heavy, or does

‘G

When nozzle holder is inspected directly, it is found to be clogged

I I I I I I T-I

When fuel cap is inspected directly, it is found to be cloaqed Play, stiffness in fuel control linkage When engine oil is inspected directly, it is found to have high

20-89

S-3

Engine does not pick up smoothly (Follow-up is poor)

General

causes why engine

does not pick up smoothly

Insufficient intake of air Insufficient supply of fuel Improper condition of fuel injection Improper fuel used Defective injection pump

0 0 0 0

I.1 I I I I I I I I I

6 <

When compression

pressure is measured,

When turbocharger

is rotated by hand, it is found to be heavy

When valve clearance standard value

it is found to be low

is checked directly, it is found to be outside

When fuel cap is inspected directly, it is found to be clogged

20-90

S-4

Engine stops during operations

General causes why engine stops during operations 0 0 0

Seized parts inside engine Insufficient supply of fuel Overheating * If there is overheating and insufficient output, carry out troubleshooting for overheating Failure in power train * If the engine stops because of a failure in the power train, carry out troubleshooting for the chassis.

Condition when

Try to turn by hand using barring tool

20-91

Engine does not rotate smoothly

S-5

(hunting)

General causes why engine does not rotate smoothly 0 0

Air in fuel system Defective governor mechanism

Condition of hunting

20-92

S-6

Engine lacks output

(no power)

Measure problem

the speed of the engine to determine is in the engine or the chassis.

General

causes why engine

0 0 0 0 0 *

if the

lacks output

insufficient intake of air Insufficient supply of fuel Improper condition of fuel injection Improper fuel used fuel is used, output drops) (if non-specified Lack of output due to overheating and insufficient output If there is overheating for overheating. carry out troubleshooting

No pulse in injection pipe (all or part) (weak)

When feed pumpstrainer is inspected directly, it is found to be clogged Speed of some cylinders does not change when operating reduced cylinders

20-93

combustion)

Exhaust smoke is black (incomplete

S-7

General causes why exhaust smoke is black 0 l l

Insufficient intake of air Improper condition of fuel injection Excessive injection of fuel

Colorof exhaust gas

harger is rotated by hand, it is found to be heavy

20-94

IC3l

S-8 j,

Oil consumption

(or exhaust

smoke is blue)

To prevent the oil from leaking up or down, do not run the engine at idling for more than 20 minutes continuously. (Both low and high idling)

General . . .

is excessive

causes why oil consumption

is excessive

of oil Abnormal combustion External leakage of oil of lubrication system ear W

When intake manifold is removed, dust is found inside When head cover is removed, dirty

inside is found to be abnormally

20-95

S-9

Oil becomes contaminated

General . . . . . .

causes why oil becomes

quickly

contaminated

Intake of exhaust gas due to internal passage Clogging of lubrication Improper combustion Improper oil used Operation under excessive load Oil change interval too long

Abnormally

quickly

wear

excessive

Oil filter caution lamp stays on even when oil pressure rises

When oil filter is inspected, metal particles are found

Engine oil temperature

rises quickly

Oil is above H level on oil level gauge

20-96

loI

lolol

I >’

S-l 0

Fuel consumption

General

causes why fuel consumption

. . 0

Leakage of fuel Improper condition Excessive injection

is excessive is excessive

of fuel injection of fuel

Condition of fuel consumption

20-97

S-l 1 Oil is in cooling water, or water spurts back, or water level goes down General

causes why oil is in cooling

Internal Internal

: u

leakage leakage

in lubrication system in cooling system

I@,(@,(

Excessive air bubbles inside radiator, spurts back Power train oil is cloudy white

Pressure-tightness

20-98

water

test of oil cooler shows there is leakage

I.1

S-12

Oil pressure lamp lights up (drop in oil pressure)

General

causes why oil pressure

0 . .

lamp lights up

Leakage, clogging, wear of lubricating Defective oil pressure control Deterioration of oil due to overheating Improper oil used (improper viscosity)

Standards

for engine

system

oil selection

8 H I-

Condition when oil pressure

When oil filter is inspected directly, it is found to be clogged When oil pan is removed and inspection is made directly, it is found to be abnormal

E? ‘G 8 5 P

Oil pump rotation is heavy, there is play There is catching of relief valve or regulator valve, spring or valve guide is broken

4 e I-

0 0 .;

00 0.0

8 2

0 08

: j

When oil level sensor is replaced, oil pressure sensor lamp goes O”t )

Wlyn

oil pressure is measured,

it is found to be within standard/

I I I I I I I I I I 1-l;

20-99

S-13 jr

Oil level rises

If there is oil in the cooling water, troubleshooting for “Oil is in cooling

General 0

. .

carry out water”.

causes why oil level rises

Water in oil (cloudy white) Fuel in oil (diluted, and smells of diesel fuel) Entry of oil from other component

Exhaust smoke is white When enaine is first started, draw

of water come from muffler

Leave radiator cap open. When engine is run at idling, an abnormal numbe of bubbles arxxar. or water swrts back

1 I

Water pump breather hole is clogged with mud When water DU~D breather hole is cleaned. water comet out Oil level goes down in damper chamber Enaine oil smells of diesel fuel

20-100

S-l 4 Water temperature

becomes too high (overheating)

General causes why water temperature l

0 l

0 *

becomes too high

Lack of cooling air (deformation, damage fan) Drop in heat dissipation efficiency Defective cooling circulation system Rise in oil temperature of power train Carry out troubleshooting for chassis.

Water temperature

gauge

S-l 5 Abnormal j,

noise is made

Judge if the noise is an internal

General

causes why abnormal

noise or an external

noise.

noise is made

Abnormality due to defective parts Abnormal combustion noise Air sucked in from intake system

. .

Confirm recent repair history

When compression

pressure is measured,

When turbocharger

1s rotated by hand, it is found to be heavy

it is found to be low

When gear cover is removed and inspected directly, it is found to be abnormal

Speed of some cylinders does not change when operating reduced cvlinders

f ;

Injection pump test shows that injection amount is incorrect

20-l 02

0 0

When control rack is pushed, it is found to be heavy, or does not return

4 I

S-l 6 Vibration *

If there is abnormal noise together vibration, carry out troubleshooting normal noise is made”.

General

. l l

is excessive

causes why vibration

Defective Improper Abnormal

parts (abnormal alignment combustion

with the for “Ab-

is excessive wear,

breakage)

Condition of vibration

20-l 03

TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM Table of failure modes and causes. ........................... H- 1 Brakes do not work. ................................. H- 2 Machine does not turn ............................... H- 3 There is travel deviation .............................. H- 4 Machine turns only in one direction ...................... H- 5 Time lag is excessive ................................ H- 6 Machine travels only in one direction ..................... H- 7 Machine does not move .............................. H- 8 Machine does not move in any speed range ................ H- 9 Torque converter oil temperature is high .................. H-l 0 Abnormal noise from around hydraulic pump ............... H-II Blade RAISE speed slow or work equipment lacks power. H-l 2 Ripper lift speed slow, or lacks power. .................... H-13 Excessive hydraulic drift of blade. ....................... H-14 Excessive hydraulic drift of ripper ....................... H-l 5 Torque converter lock-up does not work. .................. H-16 Pin-puller cylinder does not work. .......................

......

........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........

20-I 06 20-l 07 20-I 08 20-I 09 20-I 10 20-l 11 20-I 11 20-I 12 20-I 14 20-I 16 20-I 18 20-I 18 20-I 20 20-I 21 20-121 20-I 22 20-I 22

8 E 6

20-l 05

TABLE OF FAILURE MODES AND CAUSES (ELECTRIC, HYDRAULIC, MECHANICAL SYSTEMS)

Torque

20-106

is travel

Work

converter

deviation.

000

There

Machine

Time

Machine

travels

Machine

does not move.

Machine

does not move in any speed

Torque

Abnormal

Blade RAISE speed

Ripper

Excessive

hydraulic

drift of blade

Excessive

hydraulic

drift of ripper

Torque

converter

lock-up

does not work.

Torque

converter

lock-up

display

Torque

converter

lock-up

fuse 8 is blown.

Pin-puller

cylinder

Preheating

fuse 11 blows.

Actuation

of APS is defective.

0000

When

light switches

are turned

ON, lamps do not light up.

When

light switches

are turned

OFF, lamps

do not go out.

Panel switch does not work power source)

turns only in one direction

(lever

operated).

lag is excessive only in one direction

converter

lift speed

(2nd, 3rd. engine

oil temperature

noise from

(forward

around

H- 6

H- 8

0000

00000000

H- 9

H-10

H-l 1

H-l 2

H-13

H-14

E-S1

H-l 5

E-S2

E-S3

E-l

H-l 6

E-2

E-3

E-4

E-5

E-6

00000

0 0

000

slow.

000

H- 5

00000

slow or lacks power.

H- 4

H- 7

does not work.

pump.

is abnormal.

H- 3

00000

in panel switch

00000

running)

is high.

(abnormality

or in reverse)

range.

hydraulic

equipment

0000

00 0

H-l

Brakes do not work.

* Check the power train oil level before starting troubleshoooting.

’ See Note 1.

Defective seal of clutch piston

Is oil pressure in brake, clutch circuit normal?

YES -

3 *

When brake linkage is adjusted, does condition become normal?

z‘0

ReplaCe

Does brake valve spool nlO”z? smoothly?

See Table 1.

_ NO

See TESTING AND ADJUSTING.

Defective actuation of spool

Repair or replace

Defective adjustment linkage

Adjua

Note 1: Depress the brake pedal fully, place the transmission in IV, and pull the steering lever on one side fully. When the engine speed is raised gradually from deceleration machine must not move.

slow (stall) to high idling, the

Table 1 1

Oil pressure (left and right)

Conditions

Engine speed: Brake pedal not depressed

Brake pedal depressed

20-107

H-2

Machine

does not turn. (Machine

can travel only in a straight

line.)

* Check the power train oil level before starting troubleshoooting.

Cause

See H-l

YES

Is clutch disengaged?

*See Notes

1 and 2.

When steering linkage is adjusted, does condition become normal?

I NO L

*See TESTING AND ADJUSTING.

Seized clutch disc, plate

Replace

4 YES

Defective seal of clutch piston

ReplaCe

’

Defective actuation of spool

Repair or replace

Defective adjustment of linkage

Adjust

‘See Table 1.

Remedy

Note 1: Raise the chassis with the blade and ripper, run the engine at low idling, and place the transmission in F3 (R3). When the steering lever on one side is pulled, the track must stop. Note 2: Travel in Fl (RI) with the engine at low idling. When the steering lever on one side is pulled slowly, the machine must stop or must turn slowly. Table 1 Oil pressure

(kg/cm*)

Conditions

Engine speed: Steering lever not operated

High id’ing Low idling

Engine speed:

High idling

Clutch

Brake

0 (left and right)

273~2 (left and right)

0 (left and right)

25 k 2 (left and right)

Right: 0 Left: 27f

Right: 27 + 2 Left: 0

Left lever Low idling

Steering lever operated

Engine speed:

High idling

Right: 0 Left: 25f2

Right: 25 f 2 Left: 0

Right: 27 f 2 Left: 0

Right: 0 Left: 27+

Right: 25 k 2 Left: 0

Right: 0 Left: 255

Right lever Low idling

20-l

8 2 b 6

H-3

There is travel deviation.

Cause

1 YES

Remedy

See H-l.

See H-2.

clutch disengaged?

SI H b 6

See Notes 1 and 2.

20-109

H-4

Machine

turns only in one direction

(lever operated).

Cause

YES 2

YES -

Remedy

Worn brake disc, plate, scuffing

Repair

Defective seal of clutch chamber

Repair or replace

Defective actuation of spool

Repair or replace

Is clutch, brake pressure normal?

3 YES

l_ * See Table 1.

Does valve spool

Is adjustment of steering linkage normal?

move smoothly?

NO *

See TESTING AND ADJUSTING. Defective linkage

Table 1: Oil pressure (kg/cm?) Conditions

Engine speed: Steering lever not operated

Engine speed:

Clutch

Brake

High id’ing

(left ant right)

27 + 2 (left and right)

Low idling

0 (left and right)

25 f 2 (left and right)

High idling

Right: 0 Left: 27+

Right: 27 k 2 Left: 0

Low idling

Right: 0 Left: 25*2

Right: 25 f 2 Left: 0

High idling

Right: 27 f 2 Left: 0 .

Right: 0 Left: 27+2

Right: 25 ? 2 Left: 0

Right: 0 Left: 25*

Left lever Steering lever operated

Engine speed: Right lever

Low idling

20-110

Adjust

H-5

Time lag is excessive.

Remedy

YES

Defective transmission valve Defective actuation of spool

Repair or replace

Defective hydraulic pump

Replace

Defective spring, clogged with dirt

Replace or clean

4 YES

YES

IS adjustment of gear shift lever linkage normal?

Engine speed: High idling Oil pressure: 27 !c 2 kg/cm?

Is free length of main relief valve spring normal? Does valve spool move smoothly?

Free length of spring: 120.3 mm

* See TESTING Is brake free from dragging?

AND ADJUSTING.

Defective adjustment linkage

* See Note 1.

See H-l.

Note 1: When the chassis is raised with blade and ripper, the track should move with the engine at low idling and the transmission

H-6

Machine

in F3 (R3).

travels only in one direction

(forward or in reverse).

* Conditions: Oil pressure is normal (27 + 2 kg/cm2)

Remedy

Cause

1 YES

Is adjustment of war shift linkaae

See TESTING AND ADJUSTING.

Defect inside transmission, or defective valve

Repair or replace

Defective adjustment linkage

Adjust

‘L

20-111

H-7

Machine

does not move. (2nd, 3rd engine is running)

* Check the power train oil level before starting troubleshoooting.

YES 5 YES_

Is modulating pressure normal?

4 l

YES_

IES

Is brake free of dragging when traveling in Fl (Rl)?

Is main relief pressure normal?

. -

Engine speed: High idling Oil pressure: 27 + 2 kg/cm?

8 YES

Engine speed: High idling Oil pressure: 27 rt 2 kg/cm2

El-

z 6

N0 Does gear shift lever

YES -

enter position normally? Is adjustment

* Free length of spring:

of link-

age normal? L

* See TESTING

AND ADJUSTING.

Is parking brake released?

Table 1

Engine speed: Steering lever not operated

Engine speed:

High idling

Right: 0 Left: 27f2

Right: 27 f 2 Left: 0

Low idling

Right: 0 Left: 25+2

Right: 25 + 2 Left: 0

Right: 27 5 2 Left: 0

Right: 0 Left: 27f2

Right: 25 f 2 Left: 0

Right: 0 Left: 2522

Left lever Steering lever operated

Engine speed:

High idling

Right lever Low idling

20-112

120.3 mm

Cause

Remedy

7 YES Repair or replace

YES

-(l....“.::.rr:H-

* See Table 1.

Is oil pressure at

Defective steering clutch (See H-2)

torque converter outlet normal?

Engine speed: High idling 011 pressure: 5 - 7 kg/cm2

L NO

Defect inside torque cOn”erter

Repair or replace

Defective pump

R62pl.Xe

Defective spring, spool scuffing, clogged with dirt

Replace or repair, Clean

Brake dragging

(See H-l)

Defective adjustment linkage

4djust

20-113

H-8

Machine

does not move in any speed range.

Sr Check the power train oil level before starting troubleshoooting.

YES

YE S pressure normal?

3 . .

pressure normal?

Engine speed: High idling Oil pressure: 27 + 2 kg/cm2

Is free length of main relief valve spring

. normal?

Does valve spool move smoothly? l

Free length of spring: 120.3 mm

Table 1

1 Oil pressure

(left and right) (kg/cm*)

I Conditions

Engine speed:

Clutch

Brake

High idling

27 f 2

Low idling

25+_2

Brake pedal not depressed

Brake pedal depressed

20-l 14

Remedy

Cause ‘ES

Defect inside steering clutch

YES_

Is steering clutch

Replace

pressure normal?

5 Defective steering clutch SeaI

* See Table 2. -

Is oil pressure at torque converter outlet port normal?

Engine speed: High idling ^.. “II pressure: 27 * 2 kg/cm2

Replace

See TESTING AND ADJUSTING.

Defective adjustment linkage

I NO

Repair or replace

Defect inside torque converter

Defective transmission

Adjust

valve

Repair or replace

Defective pump

Replace

Defective spring, spool scuffing, clogged with dirt

Replace or repair, clean

Defective adjustment linkage

Adjust

brake (See H-l)

Defective

Table 2 Oil pressure

(kg/cm2)

Conditions Clutch

Engine speed: Steering operated

lever not

Steering lever operated

tnglne

speea:

High id’ing

(left an”d right)

Brake

(left%:

fight)

I-llC

Rigt

20-115

H-9 *

Torque

converter

oil temperature

is high.

Check the power train oil level before starting troubleshooting.

YES

YES -

IS engine speed at F3 stall normal?

Engine speed: 1580 * 50 rpm

IS main relief pressure normal?

2 YES _ 1

8 YES

IStOrq”e C0”“WtW oil temperature SOT normal?

sen-

_ -

NO l

Is brake free from dragging?

Remove oil pressure sensor. Check resistance V&E.

Is free length of main relief valve spring normal? goes valve spool move smoothly? l

Free length of spring: 120.3 mm

See Note 1.

Note 1: When the chassis is raised with blade and ripper, the track should move with the engine at low idling and the transmission in F3 (R3).

20-l

Cause

Remedy

Defective cooling system (see Engine Volume)

7 YES YES _ 6

YES

rl 1 ’ _ -

Does machine stop with operation in Item 4?

IS pressure at torque converter inlet/outlet port normal?

Does transmission output shaft stop with operation in Item 4?

=__:__ ____,’ 1 L,,!j,,lc: >prru. NO High idling Torque converter Inlet port: 7 - 10 kg/cm2 Outlet port: 5 - 7 kg/cm’

Remove the case at the rear of the transfer to check.

Adjust

Steering clutch slipping

R&W?

1 Defect inside torque

CO”“WtW

- Brake disc slipping

I Repair or replace

Repair or replace

Defective pump l Air leaking in through joint in suction circuit

Tighten

Defective spring, spool scuffing, clogged with dirt

Replace or repair, clean

Defective oil temperature sensor

ReplaCe

Transmission clutch slipping l Increase in engine output

Brake dragging

R@Xe

%DlWX

(See H-l)

20-117

H-10

Abnormal

noise from around hydraulic

pump.

* Check the hydraulic oil level before starting troubleshooting.

YES 2 i -

Is air being sucked into hydraulic pump suction circuit?

YES -

Is strainer clogged?

4 YES

When hydraulic oil is strained, are metal wear particles found?

H-11

Blade RAISE speed slow or work equipment

lacks power.

A Check the hydraulic oil level before starting troubleshooting. Note:

Check for any modification

of the blade. YES I 4 YES

Is hydraulic drift normal when lever is at HOLD?

3-p

. l

YES -

Is pump discharge pressure normal?

Engine stopped Hydraulic drift of hl.adC=. 200mml15 min

6 YES l

Does cylinder extend and contract smoothly?

Engine speed: High idling Oil pressure: 210 ‘To

kg/c”?

When relief valve is adjusted, does pump discharge pressure return to normal?

. l

Engine speed: High idling Oil pressure: 210 ‘7,

. = See TESTING AND ADJUSTING.

H I 1

Is adjustment of blade control linkage

20-118

_.___.

2 YES

kg/cm2

Pressure adjustment for 1 turn: 24.8 kg/cm2

Cause Defecrive seal l Lowe piping clamp . Damaged O-ring

Remedy

Tighten

Clogged strainer

Defective pump

RePlaCe

Operate for a short time and look for any change in the condition

Inspect again (according to change in condition)

Improper oil

AL?PlWt?

Cause

5 YES

When cylinder head circuit is blocked, does amo”nt O+ hydraulic drift return to normal?

Remedy

Defective actuation of valve . Defective actuation of unload valve l Defective actuation of check valve

Replace

Excessive leakage inside valve l Leakage inside lift valve

Replace

Excessive leakage inside cylinder l Defective piston seal

ReplaCe

Defective

relief valve

Clean or replace

Defective

pump

Replace

parts

Air in circuit

Bleed air

Defective linkage

Adjust

20-l 19

H-12

Ripper lift speed slow, or lacks power.

Sr Check the hydraulic oil level before starting troubleshooting. -)r If the relief pressure is not normal, go to failure mode H-II lief

(blade RAISE speed slow) and adjust the re-

pressure.

Cause

YES

Remedy

Defective main spool of Hi valve (including shuttle valve)

?eplace

Defective fixed differential valve of Hi valve

?ep1ace

Defective cylinder piston seal

Rt?plXX

Defective shuttle valve

R&W2

Defective Lo valve pilot circuit

Repair

3 YES

Is hydraulic drift of ripper lift cylinder normal? l

. YE3

4 YES

Engine stopped Hydraulic drift:

Is ripper tilt speed normal? NO Tilt FULL: 4.5 - 5.5 sec. SLOW: 12 - 18 sec. Tilt back FULL: 3 - 4 set SLOW: 8-lzSeCN

1 Is adjustment

of ripper control linkage

* See TESTING AND ADJUSTING.

5 YES Is blade lift cylinder speed normal?

Blade speed RAISE: FULL (3 - 5 set) SLOW (8 - 13 LOWER: FULL (1 - 1.5set) SLOW (1 - 1.5 set)

6 YES Is Lo valve pilot pressure normal?

Engine speed: High idling Oil pressure: 210 r:, kg/cm2

Carry out troubleshooting of Items 3 and 6 of H-l 1

Defective linkage

N’

20-120

4djust

H-13

Excessive hydraulic drift of blade

Cause

1 YES

Remedy

Excessive leakage inside valve Leakage inside blade lift

Replace

VdW

When hose at cylinder _ end is blocked, does hydraulic drift return to normal? l l

Engine stopped. Hydraulic drift: Max. 200 mm/15

H-14

Excessive leakage inside cylinder . Defective piston seal

Replace

min

Excessive hydraulic drift of ripper

I 2 YES

I YES _

..I

When oil line between npper LO valve and ripper Hi valve is blocked, does hydralit drift return to normal?

1 Engine stopped. ) Hydraulic drift: Max. 80 mm115 min P.I~ I””

Hydraulic drift: Max. 80 mm/15

Remedy

Defective

ripper Lo valve

Replace

Defective

ripper Hi valve

Replace

Excessive leakage inside cylinder a r,s<ar+i.,~ nic,nn CPQI

Replace

1 .

Nhen hose at cylinder _ ?nd is blocked, does lydraulic drift return 0 normal?

Cause

NO min

20-121

H-l 5 Torque converter

lock-up does not work.

When actuation of lock-up solenoid is normal (if it is abnormal, see E-Sl)

Cause

2 YES

Remedy

Defective lock-up clutch

Replace or repair

Defect inside torque converter

Repair

Defective selector valve

Replace or repair

Scuffing of spool

Replace or repair

drive normal?

I Speed range: F3 Stall speed: 1580 * 50 rpm

Is torque converter lock-up pressure normal?

4 YES YEI

Engine speed: High idling Oil pressure:

13+1 _O kg/cm2

Is operation of lockUD solenoid SDOOI

Is main relief pressure normal?

5 YES Defective Engine speed: High idling Oil pressure: 27 * 2 kg/cm2

normal? Does valve spool move smoothly? l

H-l 6

Pin-puller

pump

Free length of spring: 120.3 mm

Defective spring, spool scuffing, clogged with dirt

Replace or repair, Clean

cylinder does not work.

A When actuation of pin-puller solenoid is normal (if it is abnormal, see E-l)

YES YE 1

Does pin-puller solenoid valve spool move by hand?

h I

Is transmission relief pressure normal?

main

Engine speed: High idling Oil pressure: 27 + 2 kg/cm2

20-l 22

Disassemble noid valve.

sole-

Cause

Remedy

Defective pin-puller cylinder

Repair or replace

Defective spool of pin-puller solenoid valve

Replace

Go to H-7

TROUBLESHOOTING SYSTEM E- 1

Pin puller cylinder

E- 2

Preheating

E- 3

Defective

OF ELECTRICAL

fuse No.1 1 is blown operation

No. : 10001 - 10167) .............................................

20-125

No. : 10001 - 10167). ....................................................

.20-126

(Serial

of APS (Serial

switch

is pressed,

the monitor

panel does not light up .. . . ..__....................__..................................................

Approx.

80 seconds

after panel preheating

goes out, but starting

e) E- 3

performance

. . . .._............. 20-130

can be started with the APS, but when the starting

motor stops,

APS does not stop . . .. . . .. . . .. . . . . . . . .. . . . . . . . . . . . .. . . . .. . . . . . . . .. . .. .._.............................................. operation

of APS (Serial

on monitor

on panel is pressed

b) APS pilot 12 seconds

on monitor

b-2. APS pilot flashes

panel does not light up when

up (glow

plug system

panel lights up when

20-134-4

short circuited) ._._................._...._._ 20-134-4

starting

sensor) . . . . . .. . . . .. . . . . . . 20-134-4

switch

is at START

in nozzle system) . . . . . .. . . . . . . . . .. . . . . . . .. . . . . .. . . . . .. . . . . . . . . . . .. . . . .. .. . . . .. . . .. . 20-I 34-5 in Items a) - c) for Defective

of APS) .. . . . . .._...................................._..............................................._.................

Disconnection

20-134-I

more than

in APS water temperature

APS does not work (When there is no abnormality

d-l.

switch

up . .._.....................................................................

APS pilot

operation

preheating

panel does not go out even when

(short circuit with ground

. . . . . . . .. . 20-133

.. . . . . . .. . . .. . . ..___..................._._._...............................................

(disconnection

on monitor

20-I 32

No. : 10168 and up) . . . . . . . .. . . . . . . . .. . .. . .. . . . . .. .. . . . .. . . .. . . . . . . . .. . . . . . 20-I 34-l

has passed after lighting

b-l. APS pilot stays lighted

in C signal input system

20-I 34-6

. .. . . . . .. . . . . . . . . .. . . . . . . .. .. . . .. .. . . .. . .. . . . . . . .. . . . .. . . . . .. . . . .. . 20-134-6

d-2. Disconnection

in glow plug system . . .. .. . . .. . .. . . . .. . . .._...................................................

20-I 34-8

d-3. Disconnection

in nozzle system . . .. . . . . . . . .._._.....................__..........................................

20-134-g

APS does not stop even when water (short circuit with ground

E- 6

plug works normally)

stops also . .. . .. . .. . . .. . . . . . . .. . . . .. . . . . . . . . . . .. . . . . . . .. . . .. . .. . . . . . . . .. . . . . .._....................................

E- 5

ON, APS pilot

. . . . . . . . .. 20-128

The engine

a) APS pilot

E- 4

is poor (glow

20-126

on the monitor

the range of 60 - 100 seconds

switch is turned

the engine

Defective

is ON, the APS pilot

panel lights up, but it does not go out within

panel preheating

switch

the APS pilot

Even when

b) When panel preheating cl

20-124

does not work ...........................................................................................

Even when the light switch

temperature

in APS water

is turned

temperature

is above 20°C sensor system) . . .. . .. ..__............. 20-134-10

ON, the lamps do not light up ...............................

20-135

........................................................................................................

20-135

@j .........................................................................................................

20-136

...................................................................................................

20-I 37

Head lamp switch m

Rear lamp switch

Working

lamp switch @

Even when the light switch

is turned

OFF, the lamps do not go out.. ..............................

20-138

Head lamp switch ...............................................................................................................

20-I 38

Rear lamp switch ................................................................................................................

20-138

Working

lamp switch ..........................................................................................................

20-138

Panel switch does not work. - Abnormality

in panel switch

power

source.. ....................

20-139

20-123 @

Pin puller cylinder does not work (For giant ripper)

E-l

Before carrying out troubleshooting, check that all the related connectors are properly inserted. After checking, connect the disconnected connectors and relays again immediately unless otherwise specified.

* *

I I

Cause

Remedy

Defective solenoid

of operation valve (spool)

Defective

solenoid

- Disconnect

Replace

j NO

CN224.

1 is voltage CN224 between (1) and (2) 20 - 3ov7

YES

* Turn starting ON. switch * Turn pin puller ON. switch

3 -

’

Is voltage CN263 between (1) and (female) chasis ground 20 - 3ov7

1 Defective

_ NO

Is voltage CN162 between (2) ;;a~&;:)~and

Table

- (2)

Between CN224 (2) and chassis (l),

80&-l

1 Ml

Replace

I%%]

harin wiring between circuit 1: j.and

Defective controller

supplementary system.

See Troublefor shooting monitor (M-l ).

pin puller switch

I ON

1 Cl or below I

1 s2 or above

CN162

\CN263

Pin-puller

switch

circuit diagram

Supplementary .controller

puller

At pin puller switch OFF 1

Related electrical

or above

E-l

Disconnection “ass, or short

YES

Table 1

(1)

CN263.

* Turn starting ON, switch

CN224

ness,

Is resistance CN263 between (1) and (2) (male) asshown Table 27 * Disconnect

* Turn starting ON. switch * Turn pin puller OFF. switch

Between

bar. in wiring disconnection between short circuit Or CN122 (2) (female) CN263 (1). (female) (3) - CN224

YES

CN 122

CN224

switch

Pin-puller solenoid

F19702206

20-l

E-2

Preheating

fuse No. 11 is blown

Serial No. : 10128 - 10167 * Before carrying out troubleshooting, check that all the related connectors are properly inserted. *

Always connect any disconnected connectors before going on the next step.

1 3 2

-{Es

$~~~~and

ground 1 MQ.

more than

betweenCNl21

--Tnd more than 1 M Q?

0 Turn starting switch OFF. Disconnect CN121.

Turn starting switch OFF. l Disconnect CNl21.

l Turn starting witch

YES Is resistance

.l-3QP)

t I

YES

NO 8

Wiring harness between relay 1161 (4) - R3 - heater relay Ll, and between connector [5] (3) - Rl - heater relay Ll inside r&v box short circuiting with chassis ground, or defective relay

Wiring harness between relay 1161 (31 - R4 - connector [41 (11 - connector 151 (2) - R4. R2 CN121 (4). (19)inside relay box short circuiting with chassis ground

1 NO

OFF.

C2tJ.W

Wiring harness between CNl21 (4). (191 - CNlOl (11, (11) CN102 (1). (4) - glow plug 1. qlow plug 2 short circuiting with chasdis ground Wiring harness between L2 and fuse 11 inside relay box short circuiting with chasks ground

Remeday

Iepair or replace

epair or replace

E-2 Related electric circuit diagram

CNl02

Glow 1

r Timer

Glow 2

20-125 8

E-3

Defective

operation

of APS

Serial No . : 10128 - 10167 a)

Even when panel preheating does not light up. Only when water temperature

switch

g UF is pressed, 0

on the monitor

the APS pilot

is below 2O’C.

If the red lamp for the switch

also does not light up when the preheating

switch is pressed, the panel switch

defective. Before carrying out troubleshooting, Always connect any disconnected

check that all the related connectors are properly inserted.

connectors before going on the next step. YES

2 YES -

voltage

Is between CN361 (13) and chassis ground 16-ZOV? * Turn starting switch ON. * Turn preheating switch ON.

YES

4 3

Is voltage between con;ztc&r, [,“I(?& * Turn starting switch ON. * Turn preheating switch ON.

YES -

Is voltage between connectar (51 (1) and chassis ground 16-ZOV?

* Turn starting NO switch ON. * Within 30 set of turning preheating switch ON.

YES

I minal L2 inside Is voltage between CN121 (4). (19) and chassis ground IF: -%-Iv,

panel

0 Turn starting switch ON.

* Turn starting switch ON. * Turn preheating switch ON.

YES

* Turn starting switch

ON.

Cause

See M-4

Defective contact or disconnection in wiring harness between connector [5] (1) and CN361 (13).

3efective

timer

Defective contact, or disconnection in wiring harness between connector [5] (2). (31 Rl, R2.

Defective heater relay contact. or disconnection in wiring tiarness between heater relay Ll - Rl, R3.

defective contact, or disconsection in wiring harness >etwee” fuse 11 and L2 nside relay box.

Defective preheating

relay

[201.

Defective YES

Is resistance

beYES wee” co”“%t‘,r -;;!, [yle) (1)

nection between [201

contact,

or discon-

in wiring harness preheating relay -

connector

[Sl (2). (l)-CN362 CN261 (6) - panel

socket

(4)

(6) switch.

9 Is voltage

rz”szt

be-

* Disconnect (3)

and chassis ground 20--nOV?

YES

Is resistance between APS water temperature sensor _ CN106 and chassis groundless than 1 Q., * Disconnect

CN106.

Defective

heater

relay.

Defective contact or disconnection in wiring harness between relay [201 socket (3) relay [15] socket (2) - J3.

. Turn starting switch ON. 11

[6]

Defective contact or disconnection in wiring harness between J3 - preheating relay [20] socket (2). (1) - CN121 (13) - CNlOl (12) - CN106. Defective APS water temperature sensor, or defective grounding.

20-l

OL7-C When panel preheating switch I 0 is ON, the APS pilot it does not go out within the range of 60 - 100 seconds.

Before carrying out troubleshooting,

Always connect any disconnected connectors before going on the ,next step.

If.the abnormality

When the APS pilot (preheating monitor)

on the monitor panel lights up, but

check that all the related connectors are properly

inserted.

is only in the display, go to M-4. goes out in lessthan 60 seconds.

Cause

Remedy

,YES

1 between

Defective

CN121

2 chassis

ground

switch ON. * Turn preheating switch ON.

terminals

of resIstor 1 and rer,sitars 2 Ins,** relay box ar* remove*, I‘ rer,*tence of both reslstor. less than la? When

YES

H NO

Replace

timer

Defective contact, or disconnection in wiring harness between Ll - Rl * R3. R2’R4 -CN121 (4). (19) inside relay box.

Repair replace

Defective resistor (resistor with resistance of more than lsl,.

Replace

Defective

Replace

When the APS pilot (preheating monitor) does not go out even after 100 seconds.

timer.

Defective cOntact nection in wiring * Turn starting switch ON. * Turn preheating switch ON.

YES * Turn starting switch ON. . Turn preheating switch ON.

or diwonharries*

Defective contact or disconnection in wiring harness between RZICN121 (4) or R4 -CN121 (19) inside relay box. Defective contact or disconnection in wiring harness between CN121 (4) (19) CNlOl (1). (llkkN102 (1). (p)‘-glow plug 1, glow Plug 2. Defective glow plug plug with resistance than 3a2).

20-128

(glow of more

Repair replace

Repair

replaCf3

Replace

Approx. 80 seconds after panel preheating switch is turned ON, APS pilot & El performance is poor (glow plug works normally).

Only when water temperature

Before carrying

out troubleshooting,

Always

any disconnected

connect

goes out, but starting

is below 20°C. check that all the related connectors connectors

are properly

inserted.

before going on the next step. YES

- Remove

CN103 and cm104

Does head lamp work normally ‘when relay [16] is inserted in socket of relay [14]? I

Turn starting switch ON. l Turn head lamp switch ON.

20-130

Cause fuel

Defective system

APS

nozzle

Defective

APS

controller

9 YES

Defective contact or disconnection in wiring harness between Connector (41 (5). (6) and CN121 (7). (10).

~~~

and CN104. relay 1161. ’ Remove switch starting position. at START

Defective contact or disconnection in wiring harness between CN121 (2) and connector [4] (4).

’ Put

Defective contact or disconnection in wiring harness between connector (41 (1) - R2, Connector [4] (7) - J2.

* Turn starting ON. switch * Turn preheating ON. switch

CN103 * Hemove and CN104. switch * Put starting position, at START

or disconcontact Defective harness in wiring nection (2)lCN121 between (1). (~)‘-cNIo~ c~ioi Disconnection

in fuse

11 YES

or disconcontact Defective harness in wiring nection (lO)l(7) CN121 between ch1102 (8)‘_ y2y31)~(7).

Defective ‘esistance 3 - 5s2).

with (nozzle nozzle value not within

Defective contact or disconnection in wiring harness between relay (161 socket (4) R3, (3) - R4. Defective contact or disconnection in wiring harness between relay [16] socket (1) snd relay (201 socket (1). or disconcontact Defective harness in wiring vxtion (3) and CN161 xtween (12). 3N361

defective

starting

Defective preheating relay (161.

switch

backup

20-131

d) The engine can be started with the APS, but when the starting motor stops, the engine stops also. + Before carrying out troubleshooting, check that all the related connectors are properly inserted. +

Always connect any disconnected connectors before going on the next step.

When checking the operation

of the nozzle, the monitor

gives a mistaken display (low engine oil pressure warning),

but this is not an abnormality.

1 Can operating sound be heard from nozzle when 4 battery relay BR is connected to R? . Connect battery relay BR to R with crocodile clip. . Turn starting witch ON. . Turn preheating switch ON.

II voltape between CN121 (12) and chsrrll wound 20 -i3ov when b-ttery relay BR Ir connected to R? . Connect battery relay BR to R with crocodile clip. * Turn starting

e YES

No{xH-

E-6 d)

Relay

electrical

circuit

Remedy

40 abnormality in electrical ystem; defective fuel system.

After inspection, repair

Iefectlve

Replace

APS controller.

kfective contact, or disconwction in wiring harness bewee” CN121 (12) and connec :or [41 (3).

. Connect battery relay BR to R with crocodile clip. * Turn starting switch ON.

Cause

jee M-5 a) Abnormality :harge amo”nt.

Defective contact, or disconnection in wiring harness between CN121 (12) - CNlOl (9) - CN105.

Repair or replace

diagram

box

F91702208

20-132

APS does not stop

e) *

Before carrying out troubleshooting,

Always connect any disconnected connectors before going on the next step.

Th! *

operation

check that all the related connectors are properly inserted.

of the APS is normal,

but the APS does not stop even when the water temperature

Check when the engine water temperature

goes above 20°C.

is above 20°C.

Cause 3

YES

Defective preheating

Remedy relay

[201. Contact of + 24V with wiring harness between preheating relay [201 (4) and connector [61 (21. Wiring harness between relay [20] (1) and CN121 (13) short circuiting with chassis ground.

. Disconnect

Wiring harness between CN121 113) - CNlOl 1121 CN106 ;hdrt circuiting with chassis ground.

CN121.

Defective APS ture se”sor.

APS operates even though panel preheating switch is not

IS resistance between CN362 (male) (6) and chassis ground more than lM11’

YES -

1 Does operation of APS stop when connector [61 is disconnected?

* Oisconneci CN362. Disconnect CN261.

YES Defective

161. CN362.

YFS

Wiring harness between CN362 (female) (6) and CN261 (male) (6) short circuiting with chassis ground.

Wirina harness between CN362 (male) (6) and connector 161 (11 short circuitina with ch&& ground. Contact of + 24V with wiring harness between glow plug 1.2 - CN102 (1) (4) - CNlOl (1) (11) - CN121 (4) (19) resistor R2. R4 - Rl R3.

Defective heater

switch.

Ll and L2 inside relay box more * Remove relay.

panel

* Disconnect connector Disconnect

tempera.

pressed.

Is resistance bewee” CN261 (male) (6) and chassis ground more than 1 MFi-l?

YES 2 c

water

heater

relay.

20-133

E-3

Related electrical

circuit diagram

APS SYSTEM

Serial

No. : 10001 - 10167 Monitor module

Panel switch

mcltor starting

z 6

Starting switch

I-----

@-j-

Alternator

n 0

Relay bo x I

17MF02177

20-l

34 @

E-3 Defective Serial

operation No.

of APS

: 10168 and up

)‘1161

on monitor

panel does not light up when

preheating

switch

on panel

APS pilot is pressed

When an abnormality occurs and the system returns to normal when the connector has been disconnected and a T-adapter inserted, or when the T-adapter has been disconnected and the connector connected, the system has been reset. Only when the water temperature is below 20°C. It is possible to carry out troubleshooting when the cooling water temperature is above 20°C by short circuiting the APS water temperature sensor. Check that fuses 9 and 11 inside the fuse box are normal. Always turn the starting switch OFF before disconnecting the connector or connecting the Tadapter (or socket). Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.

20-l 34-1 @

, YES

3 YES Is voltage between CN2 (5) and chassis ground normal?

NO -12-30V * Turn starting switch ON. * 12 seconds after turning preheating switch ON. 4 YES

ground normal?

-12-30V Is voltage between * Turn starting connector 151(l) switch ON. and (4) inside relay * 12 seconds after N 1 box normal? turning preheating *12-30V switch ON. * Turn starting

switch ON. - 12 seconds after turning

YEIS 1 Is voltage between CN121 (4). (19) and chassis ground normal? 7 -ll-14v -Turn starting switch ON. -Turn preheating switch ON.

Is voltage between

YES relay terminal L2 - (inside relav box) ground ;“,r;r;i”

,20-30V Turn starting switch ON.

6 YE

30 v -20 * Turn starting switch ON. -Turn preheating switch ON.

between CN261 I-

NO - Preheating switch: ON: Max. 1 V OFF:20-30V * Turn starting switch ON.

12 YES Is voltage between CN261 (6) and (2) normal?

Is voltage between CN362 (6) and (2) normal?

-2O-30V -Turn starting switch ON. -Turn preheating switch OFF.

*20-30V * Turn starting switch ON. * Turn preheating switch OFF.

-IO-IOOR

* Turn starting switch OFF. - Disconnect connector [61.

connector 161(2) and chassis ground *20-30V -Turn starting switch ON. * Turn preheating switch ON.

20- 134-2 @

I NO

14 YES

Cause

See M-4 a)

Remedy

Defective contact, or disconnection in wiring harness between CN2 (female) (5) and CN361 (female) (13)

lepair or eplace

Defective contact, or disconnection in wiring harness between connector 151 (female) (4) inside relay box and CN361 (male) (13)

lepair or eplace

Defective APS controller

leplace

Defective APS controller

leplace

Defective contact, or disconnection in wiring harness between connector [51 (female) (1) inside relay box and chassis ground

lepair or eplace

between connector (inside relay box) NO

connector 151.

11 YES Is resistance mween relay -terminal Ll and LZ

switch OFF. YE

inside relay box normal?

Is resistance

between connector [dlWnale)(l) and (2) NO inside relay box normal? I -IO-

Max.

1 R

lepair or eplace

Defective relay contact

Zeplace

Defective relay coil

Zeplace

Defective contact, or disconnection in wiring harness between relay terminal L2 and fuse 11 , inside relay box

Repair or replace

Defective panel switch

Replace

Defective contact, or disconnection in wiring harness between CN362 (female) (6) - CN261 (6) panel switch

Repair or replace

Defective contact, or disconnection in wiring -I harness between connector 161 (female) (I) inside relay box and CN362 (male) (6)

Repair or replace

- Disconnect terminals Ll and L2. *Turn starting switch ON. *Turn preheating switch ON.

1OOR

-Turn starting switch OFF. - Disconnect connector 161.

I -

Defective contact, or disconnection in wiring harness between relay terminal Ll and connector 141 (female) (1) inside relay box

I NO

Defective relay coil

Replace

Defective contact, or disconnection in wiring harness between connector 161 (female) (21 inside relay box and fuse 9 inside relay box

Repair or replace

20-134-3 8

on monitor APS pilot passed after lighting up

When an abnormality occurs and the system returns to normal when the connector has been disconnected and a T-adapter inserted, or when the T-adapter has been disconnected and the connector connected, the system has been reset. Only when the water temperature is below 20°C. it is possible to carry out troubleshooting when the cooling water temperature is above 20°C by short circuiting the APS water temperature sensor. Check that fuses 9 and 11 inside the fuse box are normal. Always turn the starting switch OFF before disconnecting the connector or connecting the Tadapter (or socket). Before carrying out troubleshooting, check that all the related Remedy connectors are properly inserted. Always connect any disconnected connectors before going on Wiring harness between the next step.

* * t * * * b-l.

APS pilot stays lighted

panel does not go out even when

up (glow

plug system

short circuited)

Y==

more than

12 seconds

CN121 (male) (4),(19) and connector 141 (female) (2),(3) inside relay box chassis ground Wiring harness between CN121 (female) (4),(19) CNlOl (l),(ll) - CN102 - (female) (l),(4) short circuiting with chassis

between CN121 (female) (4). (19) YES

Is resistance between CN 102

-0.8-1.3R . Turn starting switch OFF. - Disconnect CN121.

(disconnection

in APS water

temperature Cause

3 connector [51(2) relay box normal? * Max. 0.5 V + Turn starting switch ON. Reference: The voltage when the water temperature is above 20°C is 7 IOV.

Is resistance between CN106 (water temperature end) and chassis around as shown i Table I?

* Turn starting switch OFF. * Disconnect CN106.

Is resistance tE S between CN121 - (female) (13) and chassis ground as shown in Table I?

value

Below 20°C

Max.

1 Q

Above 20°C

(

Min. 1 MR

20-l 34-4 @

Defective contact, or disconnection in wiring harness between CNl06 CNlOl (12) - CN121 (female) (13) Defective contact, or disconnection in wiring harness between CN121 (male) (13) and connector 151(female) (2) inside relay box Defective APS water temperature sensor

Resistance

* Turn starting switch OFF. * Disconnect CN121.

1 temperature

YES

Remedy

Defective APS controller

( Coolant

3epair or .eplace

Replace

It is normal if the lamp flashes when the water temperature above 20°C.

Table

?epair or .eplace

-0.8-1.3R . Turn starting switch OFF. - Disconnect CN102.

b-2. APS pilot flashes sensor) Ir

has

qeplace

qepair or .eplace

?epair or ‘eplace

3eplace

APS pilot with ground

on monitor panel lights up when in nozzle system)

starting

switch

is at START

(short circuit

Cause

Remedy

Defective APS controller YE

z between CNl21 (female) (7) and .1.5-2.5R . Turn starting switch OFF. . Disconnect CNl21.

1.5-2.5R . Turn starting switch OFF. Disconnect connectors [41 and 151.

‘ES

Is resistance between CN102 (male) (2) and (3) I normal? . 1.5 2.5 R * Turn starting switch OFF. - Disconnect CN102.

4 YES

Wiring harness between CNl21 (male) (7) and connector [41 (female) (4) inside relay box short circuiting with chassis ground

Repair or

Wiring harness between CN121 (female) (7) CNlOl (7) - CN102 (female) (2) short circuiting with chassis ground

Repair or replace

Wiring harness between CN102 (male) (2) and nozzle short circuiting with chassis ground

Repair or replace

FH_

*3-5R -Turn starting switch OFF. * Remove nozzle.

Defective nozzle

xl- 134-5 @

d) APS does not work (when there is no abnormality

in Items a) - c) for Defective

operation

APS) When an abnormality occurs and the system returns to normal when the connector has been disconnected and a T-adapter inserted, or when the T-adapter has been disconnected and the connector connected, the system has been reset. Only when the water temperature is below 20°C. It is possible to carry out troubleshooting when the cooling water temperature is above 20°C by short circuiting the APS water temperature sensor. Check that fuses 9 and 11 inside the fuse box are normal. Always turn the starting switch OFF before disconnecting the connector or connecting the Tadapter (or socket). Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. d-l.

Disconnection

in C signal input system

YES

YES nozzle actuation switch is turned YES

2 - Disconnect Is voltage between CN103 and connector 151(3) CN104. -Turn preheating NO and (1) inside raiav box normal? switch ON. 4 *Turn starting switch to START.

-lo-3ov - Disconnect CN103 and

YES

between CN121 switch ON. * Starting switch to START.

ground normal? _ *lo-3ov * Disconnect CN103 and . CN104. * Turn preheating switch ON. * Starting switch to START.

ground normal? -IO-3ov - Disconnect Is voltage CN103 and CN104. between CN361 *Turn preheating NO (3) and chassis switch ON. ground normal? - Starting switch to 4 START. *IO-3ov 7 - Disconnect Is voltage CN103 and CN104. between CN161 . Turn preheating NO (4) and chassis switch ON. ground normal? - Starting switch to START.

20-134-6 @

*lo-3ov . Disconnect CN103 and CN104. *Turn preheating switch ON. - Starting switch to START.

NO YES

Cause

Remedy

Defective APS nozzle fuel system

Go to Troubleshooting S-l and S-2 for engine

Defective contact, or disconnection in wiring harness between CN121 (male) (2) and connector [51 (female) (3) inside relay box

Repair or replace

Defective contact, or disconnection in wiring harness between CN121 (female) (2),(3) - CN451 (7),(8) - CN151 (female) (l).(3)

Repair or replace

Defective safety switch

Replace

Defective contact, or disconnection in wiring harness between CN361 (male) (3) and CNl21 (male) (3)

Repair or replace

Defective contact, or disconnection in wiring harness between CN361 (female) (3) and CN161 (female) (4)

Repair or replace

Defective starting switch

Replace

Go to d-2. Defective contact of glow PLUG system.

YES

Is resistance _ between CN151 _ (male) (1) and (3) normal? . Gear shift lever NO N: Max. 1 R . Gear shift lever at any position except N: Min. 1 MR * Turn starting switch OFF. * Disconnect CN151.

20-134-7 8

d-2. Disconnection * *

in glow

plug system

in C signal input system first. Before starting, carry out d-l. Disconnection in installation of glow plug. Check if there is abnormality

Go to d-3. Defective of nozzle -contact system.

YES 3 YES 2

YES 1 Is voltage between CN121 (4Lf19) and chassis ground normal? -ll-14v -Turn preheating switch ON. -Turn starting switch ON.

Is voltage between CN102 (l).(4) and chassis ground normal? .ll-14v . Turn preheating switch ON. * Turn starting switch ON.

.0.8-1.3R * Turn starting switch OFF. - Disconnect CN102.

5 Is voltage between connector I41 L (2).(3) inside relay NO box and connector f51 (1) inside relay box normal? .ll-14v -Turn preheating switch ON. * Turn starting switch ON.

20-134-8 @

Is resistance between CN102 (malehl),(4) and chassis ground normal?

YES

Is resistance between each glow plug and chassis ground normal?

4 YES -

K -0.8. 1.3R * Turn starting switch OFF. * Disconnect glow plug terminal.

Defective contact, or disconnection in wiring harness between CN102 (male) (l),(4) and glow plug Defective glow plug

Defective contact, or disconnection in wiring harness between CN102 (female) (l),(4) - CNlOl (l),(ll) - CN121 (female) (4).(19) Defective contact, or disconnection in wiring harness between connector I41 (female) (2),(3) inside relay box and CN121 (male) (4),(19) Defective APS controller

d-3. Disconnection *

in nozzle system

Before starting, carry out d-l. glow plug system first.

Disconnection

in C signal

input system

and d-2. Disconnection

Cause

Remedy

Defective contact, or 4YES 3 Is voltage between CN102 (male) (2) and chassis ground normal? 2

1 Is resistance between CN102 (female) (3) and chassis ground nnrmal? -Max. 1R * Turn starting switch OFF. * Disconnect CN102.

between CN121 (7) and chassis

-3-50 * Turn starting switch OFF. * Disconnect nozzle terminal.

*0.4-5v * Disconnect CN103 and CN104. * Turn preheating N switch ON. * Starting switch to START.

~ 1’

6 YES

(male) (IO) and chassis ground normal?

* Turn starting switch OFF. . Disconnect CN121.

Iepair or ,eplace

Defective nozzle

FIeplace

Defective contact, or disconnection in wiring harness between CN102 (female) (2) - CNlOl (7) CN121 (female) (7)

Ftepair or replace

Defective contact, or disconnection in wiring harness between CN121 (male) (7) and connector I41 (female) (4) inside relay box

Ftepair or r eplace

Defective APS controller

FXeplace

Defective contact, or disconnection in wiring harness between CN102 (female) (3) and CN121 (female) (IO)

FXepair or replace

. Disconnect CN103 and CN104. . Turn preheating switch ON. . Starting switch to START.

‘betweenCN121

- Max. IQ

harness between CN102 (male) (2),(3) and nozzle

Is resistance of nozzle as individual part normal?

0.4 - 5 v Disconnect CN103 and CN104. NO . Turn preheating switch ON. . Starting switch to START.

Is voltage

YES disconnection in wiring

Defective contact, or disconnection in wiring Fsepair or harness between CN121 r eplace (female) (IO) - J2 inside relay box - chassis groun d

20-134-9 @

APS does not stop even when water temperature APS water temperature sensor system)

is above 20°C (short circuit with

ground

When an abnormality occurs and the system returns to normal when the connector has been disconnected and a T-adapter inserted, or when the T-adapter has been disconnected and the connector connected, the system has been reset. Only when the water temperature is below 20°C. Check that fuses 9 and 11 inside the fuse box are normal. Always turn the starting switch OFF before disconnecting the connector or connecting the Tadapter (or socket). Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.

Cause

YES

2 YE 1 between CN 106 ground normal? .7-1ov * Turn starting switch ON. *Turn preheating switch ON.

20-134-10 @

Is voltage between CN121 (13) and chassis around normal? .7-1ov

-Turn starting

switch ON. -Turn preheating switch ON.

Remedy

Wiring harness between CN121 (male) (13) and connector [51 (2) inside relay box short circuiting with chassis ground

Repair or replace

Wiring harness between CN106 - CNlOl (12) CN121 (female) (13) short circuiting with chassis ground

Repair or replace

Defective APS water temperature sensor

Replace

E-3 Related

electrical

circuit diagram

N’S SYSTEM Serial No. : 10167 and up Monitor

nodul

_ _Q2

Safety

switch

CN151

ADS Pilot ureheatino signal

Starting

%0 L 40

motor

Panel

switch

Starter

switch

-FJ-_-_

CNl61

CNlO

---------I

APS

controller

GND

Water temperature Starting motor Preheating Iamp

switch C

TDD00710

20-134-11 @

Even when the light switch is turned ON, the lamps do not light up

E-4 *

Before carrying out troubleshooting,

Always connect any disconnected connectors before going on the next step.

Head lamp switch

a) *

check that all the related connectors are properly

inserted.

g 10 cl

When fuse No.14 is normal (If fuse No.14

is blown, check if the wiring harness between fuse No.14

- relay [13]

[141 (3) (4) ‘- lamp is in

contact with the chassis ground.)

Cause

YES

Defective relay on side that does not light up (Defective contact).

31 Does condition become normal YES relay [131 -when or 1141 is replaced?

_ NO

?ls voltage between CN203 (I) or CN204 (1) and chassis ground 20 - 3OV?

on one side

Defective lamp, or defective contact with ground.

. Turn starting switch ON. . Turn head lamp switch ON.

Are lamps that

or disconDefective contact nection in wiring harness between lamps and relay on side that does not light up.

Defective contact or disconnection in wiring harness be. tween fuse 14 and relay [13]

..-

P41 (31.

Of Panel

switch

* Turn starting switch ON. * Turn head lamp switch ON,

6p YES

5 Do red lamps of other switches

Defective relay on side that does not light up (Disconnection in coil).

YES

Are lamps that do not light up on one side only?

7 YEE

_ NO

Do lamp light UP when CN261 (3) _ is grounded to chassis?

-I-

starting switch ON. * Turn other switches ON.

* Turn

* Turn starting switch ON. * Turn head lamp switch OFF. * Connect T-adapter to CN261.

Defective

panel switch.

Defective contact or disconnection in wiring harness between relay 1131[14] (1) CN362 (3) - CN261 (male) (3).

See E-6 (panel switch BOUrce system).

power

20-135

Rear lampswitch

0O0: 0

When fuse No.1 3 is normal (If fuse No.13

is blown, check if the wiring harness between fuse No.13 -relay

[171

1181 (3) (a)-

lamps is in

contact with the chassis ground.)

Cause

Defective relay on side that does not light up (Defective contact).

YES Does condition when

relay

[171

YES

Defective lamp, or defective contact with ground.

Is voltage between CN243 (1) a CN223 (1) and ;hgaywy;und

YES

* Turn starting switch ON. * Turn rear lamp switch ON.

Are lamps that do not light UP on one side only?

Defective contact or disconnection in wiring harness between lamps and relay on side that does not light up.

Defective contact or disconnection in wiring harness between fuse 13 and relay [171

[I81 (3).

* Turn starting

switch ON. * Turn rear lamp. switch ON.

Defective relay on side that does not light up (Disconnection in coil).

YES

1 Are lamps

I ;

1 ’ Turn startina switch ON. . Turn other switches ON.

IL *

20-136

Turn

startina switch ON. * Turn rear lamp switch OFF. ’ connect T-adapter to CN261.

Defective

panel switch.

Defective contact or disconnection in wiring harness between relay [171 [181 (1) CN362 (4) - CN261 (male) (4).

See E-6 (panel switch power *ource system).

Remedy

c) *

Working

lamp switch

Iz AC?

When fuse No.12 is normal (If fuse No.12

is blown, check if the wiring harness between fuse No.12-

relay [221 (3) (4)-lamps

is in contact

with the chassis ground.)

Cause

YES

Remedy

Defective lamp, or defective contact with ground.

voltage

YES -

* Turn starting switch ON. * Turn working lamp switch ON.

2 Y

Is between CN242 (1) or _ CN221 (1) and chassis ground 20 - 3ov7

Are lamps that do not light up on one side only?

Defective contact or disconnection in wiring harness CN242 (1) CN221 (1) and CN121 (female) (21).

YES

Defective relay tive contact).

4 _ NO

Does condition become normal I”hen relay 1221 1s replaced?

[22]

(Oefec-

Defective contact, or disconnection in wiring harness between fuse 12 - relay [22] (3) (4) - CN121 (male) (21).

NO Panel switch

. Turn starting switch ON. * Turn working lamp switch ON.

YES

00 red lamps of other switches light/up?

switches ON.

Does condition become normal _ when relay [221 is replaced?

* Turn starting switch ON.

* Turn other

I NO

Defective relay [221 nection in coil).

\Does UP when CN261 (5) is grounded to’chassis?

* Turn starting switch ON. Turn working switch OFF. Connect T-adapter to CN261.

YE!

Defective

(Olscon-

panel switch.

Defective contact, or disconnection in wiring harness between relay [221 (1) - CN362 (5) - CN261 (male) (5).

lamp

SeelE-6 (panel switch power source system).

20-l

E-5

Even when the light switch is turned OFF, the lamps do not go out

Before carrying out troubleshooting,

Always connect any disconnected connectors before going on the next step.

Head lamp switch

check that all the related connectors are properly inserted.

Cause

3 YES 2 -

YES -

Are lamps that do not go out on one

Do lamps go out when relay is removed on side where lamps do not go out7

YES Defective

* Turn

starting switch ON.

* Turn

Contact of + 24V with wiring harness between relay [131 [14] (4) and lamps.

Wiring harness between relay [131 [141 (1) - CN362 (3) CN.261 (male) (3) short circuiting with chassis ground.

1 Does red lamp Of Panel switch go out7

relay

starting

Defective

panel

Defective

relay.

switch,

* Turn head lamp switch OFF.

Rear lamp switch

g 0:

3 YES

YES

SH-

* Turn starting switch ON.

Wiring harness between relay [171 [181 (1) - CN362 (41 CN261 (male) (4) short circuiting with chassis ground.

NO Does panel out?

red lamp of switch go

. Turn starting switch ON. * Turn rear lamp switch OFF.

Working

Defective

lamp switch

2 YES 7

red lamp of switch go

20-138

90 Out [22]

starting switch ON.

NO lamp

Does IamP when relay is removed7

YES

Is resistance between relay [22] (3) and (4) more than 1 Ma? * ri2yjlpve

* Turn

. Turn starting switch ON. Turn working switch OFF.

panel

switch.

yEL

Does panel out?

Contact of + 24V with wiring harness between relay [171 [la] (4) and lamps.

relay

Defective contact, or disconnection in wiring harness between relay [221 (1) - CN362 (5) - CN261 (male) (5).

3efective

relay

[22]

Defective contact or disconnection in wirinq harness between rela;[221 (4) - CN121 (21) - left and right lamps.

Defective

Panel

switch.

Remedy

E-6

Panel switch does not work. -Abnormality (Even when

the switch

is pressed,

in panel switch power source

the red lamp for that switch

does not light up.)

When fuses No.9 and 15 are normal If fuse is blown, check for short circuit with chassis ground in wiring harness between fuse No.9’(2) pin of each (1) - CN261 (panel switch), or fuse No.15 - CN162 (1) (supplementary controller)

relay, fuse No.9 - CN362

* .* *

When the battery is normal. Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step.

inserted.

Remedy

3 j _

IS “Okage between CN261 Ill and (2120 - 3OV?

YES

Turn starting switch ON.

Defective

Does

teplace

switch.

Defective contact, or disconnection in wiring harness between fuse 9 and (2) of each 1 relay, or between fuse 9 CN362 (1) CN261 (1) (2) CN362 (2) - chassis ground.

Defective * Turn starting switch ON.

panel

safety

relay

(121

Seplace

condition

- CN361 (7) [121 (1).

(2.

YES

safety relay’

Repair or

Defective contact or disconnection in wiring har”e*s between CN464 (1) and CN361 (7).

replace

Defective controller.

Replace

ISvoltage between CM64 11) and chass,s ground 20 - 3OV?

6 Turn start,&! SWltChON

Is voltage between CNl62 (1) and chassis ground 20 - 3OV? * Turn starting switch ON.

YES

supplementary

Defective contact or disconnection in wiring harness between battery terminal (+) -CN361 (lo)CN162 (1).

Repair replace

20-l 39

E-4, E-5, E-6.

Related electrical

circuit diagram

Workhng lamp (R H.) : :

CN242 /

Workong lamp 1L.H

Head lamp 03 Hi

Redr lamp 1L.H.)

Head lamp 1R.H I

Relay box

Panel switch

F19702203A

20-l 40

TROUBLESHOOTING

OF ELECTRICAL SYSTEM

(MODE SELECTION ELECTRONIC SYSTEM WITH SSC SYSTEM) (WITH SSC SYSTEM)

Table of failure

and causes (mode.selection

modes

electronic

E-S1

Torque

converter

lock-up does not work (lock-up

E-S2

Torque

converter

lock-up display

20-I 40-7 20-I 40-7 20-140-7

Lock-up display Lock-up display

lamp lights up but lock-up is not actuated ........................................

Mode

E-S5

Reverse slow is not actuated

does not switch when

(monitor

mode

is pressed

when

is not actuated

REVERSE slow switch

when

shoe slip control

when

rockbed

selection

be controlled,

Shoe slip is not detected

E-S10

Starting

modulation

is no up/down

when

stalls, engine

shoe slip control

does not work when of drawbar

shoe slip control

Abnormality

engine

switch

.20-140-9

mode switch

cannot

20-I 40-I 1

is pressed

be started ..........................

is ON .................................................

shoe slip control

20-I 40-10

is pressed

is ON ................................

20-I 40-I 2 20-I 40-13 20-I 40-I 4 20-I 40-15

pull by using ripper lever

is ON ............................................................................................

in ripper UP, DOWN,

20-140-8

is pressed

panel LED is normal) ..........................................................................................

E-S9

D275A-2

economy

level does not change

Engine cannot

when

relay inside relay box .............................

panel LED is normal) ..........................................................................................

(monitor

E-S1 1 There

lock-up

panel LED is normal) ..........................................................................................

Shoe slip control

Selected

converter

panel LED is normal) ...........................................................................................

(monitor

E-S12

....................................................................

E-S4

E-S8

lamp does not light up) ....... 20-140-4

Blown fuse No. 8 of torque

E-S7

display

lamp does not go out ...........................................................................

E-S3

E-S6

is abnormal

system) . . . . . . . . . . . . .. . . . . . . .. .. . . .. . . . .. . . . . 20-I 40-2

TILT signal,

REVERSE signal ...................................

20-140-15 20-140-16

20- 140- 1 0

TABLE OF FAILURE MODES AND CAUSES (MODE SELECTION SYSTEM)

Mode does not switch when economy mode switch is pressed

REVERSE slow is not actuated when REVERSE slow switch is pressed

’

Shoe slip control is not actuated when

’

shoe slip control

Selected

switch

Engine cannot be controlled, engine stalls, engine cannot be started

Shoe slip is not detected when shoe slip control is ON

000

level does not switch when

rockbed selection

is pressed

’ 6

000

mode switch is pressed

0 0

Starting modulation does not work when

* shoe slip control is ON g

’

There is no up/down of drawbar pull by using ripper lever when shoe slip control is ON

Abnormality in ripper UP, DOWN, REVERSE signal

20-140-2 0

TILT signal,

000

0000

D275A-2

For abnormalities in machine monitor system, go to Troubleshooting (YES/NO) M-OX

Switch module

E-S1

Torque converter lock-up does not work (lock-up display lamp does not light up)

When the torque converter is locked up, an input signal is being received from the SSC controller, so check for any error in the function of the SSC system, and check that there is no failure code displayed on the SSC controller. Always turn the starting switch OFF before disconnecting any connector to connect the T-adapter (or socket adapter). When connecting a T-adapter, connect the male and female; when connecting a socket, connect to the part specified inside ( 1. Always connect any disconnected connectors before going on the next step. Connectors CN364, CN371, and CN372 become connectors CN391 and CN399 on machines equipped with a cab.

YES

. Start engine. * Turn lock-up switch ON. - Transmission: Neutral * Short circuit between CN622 (2) and (5)

Table 1

NO YE

(Tolerance: +O.lV)

* Turn starting switch OFF.

YIES

* Turn starting switch ON. Table

* Turn starting switch ON. -

and (2)

40 - 80 Min.

1 MQ

NO YES

I 17

by[151isrepbced. isvokagebetween

YES

(I)

Between (l)(2) and chassis

Is vokaga between CN121 (II) and _ chassis ground 20 -3ov7

YES_

Between

tween CNSS2 (4) * Turn starting switch ON.

* Turn starting switch ON. * Turn lock-up switch ON.

* Turn starting switch ON.

tween CNSOl (3)

* Turn starting switch ON. * Turn lock-up switch ON.

* Turn starting switch ON.

20-140-4 a

D275A-2

YES

Cause

3emedy

Defective lock-up display lamp

Ieplace

Iefective contact or disconnectior n wiring harness between CN121 11) - CN122

- Start engine. NO * Turn lock-up switch ON. * Transmission: Neutral - Short circuit between CN622 (2) and (5)

YE!

:N372

YES

(7)

- CNlPl

sepair or ,eplace

(3). (4)

Defective lock-up controller

teplace

Defective contact or disconsection in wiring harness be ween CN622 (1) (3) - CNSOE 111) (14) - CNSSI (I), CNSSi 112)

Iepair or eplace

Defective shoe slip controller

Ieplace

Defective contact or disconsection in wiring harness be. ween CNSSI (female) (l)(8). CNS06 (l)(4) - CN451 (4)(5) ZN651 (female) (l)(2)

3epair or .eplace

Defective torque speed sensor

seplace

Is vottage between CN622 (I) and (3) more than 0.5V (AC range)? P - Start engine. * Run at high L idling. NO . T&;cocDk-Nup

Is resistance be

tweenCN622lfe male) (2) and (5) less than 1 M

* Start engine.

YES

10 Is voltage between CNSSP (12) and (14) more than O-5V (AC range)?

YES 11 P Is voltage between CNSSI * Start engine. - (I) and 18)more 12 YES * Run at high NO than 0.5 V (AC Is voltage be- range)? idling. . tween CN651 * Turn lock-up * Start engine. _ (l)andt2)mo-e _ switch ON. * Run at high NO thaha,W (AC idling. * Turn lock-up * Stan engine. NC switch ON. - Run et high

converter

idlino.

YES

Isresistamebe tWeJlCN622ffe male) (2) and f5l lessthan IQ? f Connect short NO connector to CN652 (female).

- (male) (I) and (2) as shown in Table 2? . ;urnt;a&Fg

(7). CN622

8). CN122 G’L (8) - CN364 (3), (4). :N371 (3), (4) - CN371 (3), (4)

Defective transmission pressure sensor

Defective contact or discon, nection in wiring harness be, tween CN622 (female) (2L (5 - CN652 (I), (2) Defective contact or discon nection in wiring harness be, tween CN622 (female) (7L (8 - CN653 (1). (2)

qeplace

?epair or veplace

qepair or peplace

Defective lock-up solenoid

qeplace

Defective contact or discon nection in wiring harness be tween CN121 (female) (11) CN622 (4)(5) -chassis grounc

qepair or veplace

Defective lock-up relay [I51

Replace

Defective contact or disconnec tion in wiring harness be&veer fuse No. 8 - k&up relay [I5 (3)(4) - CN121 (male) (11)

Repair or replace

Defective contact or discon nection in wiring harness be tween CN362 (female) (7) CN122 (male) (6)

Repair or replace

Defective contact or disconnec ‘ion in wiring harness betweer, use No. 9 - lock-up relay [151 2)(l) - CN361 (male) (7)

Repair or eplace

)efe&e contact or disconnecion in wiring harness between :NSOl (3) and CNSS2 (4)

lepair or eplace

30 to M-12

D275A-2

20-140-5 a

E-S2

Torque

converter

lock-up

display

is abnormal

Turn the starting switch OFF before connecting or disconnecting a T-adapter (or socket). When connecting a T-adapter, connect the male and female; when connecting a socket, connect to the part specified inside ( 1. Always connect any disconnected connectors before going on the next step. Connectors CN364, CN371, and CN372 become connectors CN391 and CN399 on machines equipped with a cab.

a) Lock-up display lamp does not go out

Cause short circuit with chassi: ground in wiring harness be ween CN622 (female) (7) ZN153 (3) - CN653 (female) (2 )r between CN622 (female) (7 CN122 (8) - CN364 (4) - CN37’ 4) - CN372 (female) (4)

YES

1 Is resistance between CN622 (female) (7) and chassis more than 1 MQ? * Turn starting switch OFF. * Disconnect CN622.

Lock-up

Defective lock-up controller

display

lamp lights up but lock-up 2

YES

qeplace

;;eo;ir

YES

Defective hydraulic system nspection

Defective lock-up controller

leplace

%ctive contact or disconnecon in wiring harness between :N622 (female) (7) - CN153 (3) CN663 (2)(l) - CN153 (2) :N622 (female) (8)

Iepair eplace

)efective lock-up solenoid

leplace

Table 1

s Disconnect CN622.

(Tolerance:

YES

Is resistance be- I tweet-rCN653 (male) (1) and (2) 40 - 80 D? * Disconnect CN653.

D275A-2

3epair 01 ,eplace

is not actuated

Is voltage between CN622 (7) _ and (8) as shown in Table I? - Start engine. * Transmission: Neutral * Turn lock-up switch ON. * Short circuit between CN622 (2) and (5).

Remedy

+0.5V) or

20-140-7 0

E-S3

Blown fuse No. 8 of torque

converter

lock-up

relay inside relay box

Always turn the starting switch OFF before disconnecting any connector to connect the T-adapter (or socket adapter). When connecting a T-adapter, connect the male and female; when connecting a socket, connect to the part specified inside ( 1. Always connect any disconnected connectors before going on the next step. Connectors CN364, CN371, and CN372 become connectors CN391 and CN399 on machines equipped with a cab. Cause

YES 1 Does fuse 8 blow when starting _ switch is turned ON?

YES

2 Is resistance between CN121 (fe male) (11) and chassis ground more than 1 MQ?

* Disconnect CN121. NO

E-S2, E-S3. Related

electrical

Is resistance between CN622 (female) (4) and chassis ground more than 1 MQ?,

YES ~

Remedy

Short circuit with chassis ground in wiring harness between fuse 8 inside relay box - lock-up relay [I51 socket (3)

Repair replace

Short circuit with chassis ground in wiring harness be tween CN121 (male) (11) lock-up relay [151 socket (4).

qepair replace

Defective lock-up controller

Replace

Short circuit with chassis ground in wiring harness between CN121 (female) (11) CN622 (male) (4) - CN122 (7) - CN364 (3) - CN371 (3) CN372 (female) (3)

- Disconnect CN622. No

3epair

circuit diagram r-

With cab

CN391

CN399

cN372

Lock-up display

Lock-up display lamp

Lock-up con^troller +24y Lock-up valve

Lock-&Ienoid

Valve power source

CN362

Relav box Lock-up relay

CN121

I 20-140-8 0

Safety

relay

In 197F01512A

D275A-2

E-S4

Mode does not switch normal)

when

economy

mode is pressed (monitor

[Check for any error in the function of the SSC system and for any failure code displayed on the SSC.1 * Before carrying out troubleshooting, check that all the related connectors are properly inserted. * Always connect any disconnected connectors before going on the next step. 3 YES w

YES -

2 YES 1 Is voltage between CNSOI (4) _ - (2). (5) - (2) as shown in Table I?

Is voltage between CNSS2 (3) - (14), (2) - (14) as shown in Table I? - Turn starting switch ON. * Turn economy mode switch ON.

panel LED is

Remed)

Cause

GotoA

Are ripper lever signal and trans mission REVERSE signal normal?

So to E-S12

* Go to item in Troubleshooting E-S12.

NO Iefective contact or disconsection in wiring harness be:ween CNSOI (4)(5) and :NSSZ (3)(2)

- Qr$-$~$y

qepair .eplace

30 to M-12

- Turn economy No mode switch ON. Table 1

YES

Defective shoe slip controller

Replace

Iefective contact or disconnec:ion in wiring harness between 3NSS2 (male) (5) - CN421 (14). 3N451 (13) - CNSIZ (female1 Repair J)(2) CN451 (14) - chassis replace ground, or between CNSS2 (141 CN122 (6) - chassis ground * Brake * When gearshift lever is at F: IO-3ov * When gearshift lever is at N: o-1v * Start engine. * Run at low idling. * Brake . Whengeanhii lever is at Fl: 10 - 30 v * When gearshi lever is at N: O-IV I

- Start engine.

electrical

Defective transmission FORWARD oil pressure switch

Replace

* Run at low idling. * Brake * When gearshift lever is at F: Min. 1 MQ * When gearshift lever is at N: Max. 1 fi

YES

* Start engine. NO * Run at low idling. * Brake * When gearshift lever is at Fl: Min. 1 MQ * When gearshift lever is at N: Max. 1 R

E-S4. Related

Defective contact or disconnec lion in wiring harness between ZNSS2 (male) (16) - CNSO6 (131 Repair CN451 (12) - CNS07 (female1 :1)(2) - CN451 (14) - chassis replace ground, or between CNSSZ (141 CN122 (6) - chassis ground Defective transmission 1st oil oressure switch

Replace

circuit diagram

Mode selection switch

Transmission 1st oil pressure switch Transmission FORWARD oil pressure switch

197F01513

D275A-2

20-140-9 0

E-S5

Reverse slow is not actuated panel LED is normal)

when

REVERSE slow switch

is pressed (monitor

[Check for any error in the function of the SSC system and for any failure code displayed on the SSC.1 Ir Before carrying out troubleshooting, check that all the related connectors are properly inserted. * Always connect any disconnected connectors before going on the next step.

I 2

YES 1 Is voltage between CNSOI (6) and (2) 0 - 1 V7

YES -

Is voltage between CNSS2 _ (Il$and (14) 0 - Turn starting switch ON. * Turn REVERSE slow switch ON.

* Turn starting switch ON. - Turn REVERSE slow switch ON.

Cause

YES

-GotoA

Is transmission REVERSE signal normal? * Go to item in Troubleshooting E-S12.

Go to E-S12

Defective contact or disconnection in wiring harness be tween CNSOI (female) (6) CNSS2 (female) (17)

E-S5

3epair eplace

Go to M-12

+iiiiiq(l,ytiem

Defective shoe slip controller

Remedy

electrical

qeplace

has beenreset -

circuit diagram

Mode selection

switch

SSC controller CNSOI

REVERSE

CNSS2

slow

1 I

REVERSE ~10~

GND

_-I 197F01514

20-140-10 0

D275A-2

E-S6

Shoe slip control is not actuated (monitor panel LED is normal)

when

shoe slip control

[Check for any error in the function of the SSC system and for any failure code displayed on the SSC.] * Before carrying out troubleshooting, check that all the related connectors are properly inserted. Sr Always connect any disconnected connectors before going on the next step.

2 YES -

1 Is voltage between CNSOI (7) and (2) 0 - 1 V7

3l YES

Are npper lever YES signal and transmission REVERSE signal normal?

Is voltage between CNSSl (15)-(14)0-Iv?

* Go to item in Troubleshooting E-S12.

switch

is pressed

Cause

3emedy

GotoA

Go to E-S12

Defective contact or disconnection in wiring harness between CNSOl (7) and CNSS2 (15)

- Turn starting switch ON. NO * Turn shoe slip control switch ON.

Turn starting I switch ON. NO Turn shoe slio control switch ON.

* Start engine. * Run at low idling. ND * Brake * When gearshift lever is at F: 10 - 30 v * When gearshift lever is at N: o-1v * Stan engine. . Run at low idling. * Brake * When gearshii lever is at Fl: lo-3ov - When gearshii lever is at N: 0 - 1 Y No

Defective shoe slip controller Defective contact or disconnec tion in wiring harness between CNSSZ (male) (5) - CN421 (14). 6 YES CN451 (13) - CNS12 (female1 (1)(2) - CN451 (14) - chassis Is resistance beground, or between CNSS2 (141 tween CNSl2 _ CN122 (6) - chassis ground (male)(I) and(2) normal? _ Defective transmission FOR

ND * Start engine. . Run at low idling. . Brake * When gearshift lever is at F: Min. 1 MR . When gearshift lever is at N: Max. 1 R

YES

Is resistance between CNS07 (male) (1) and (2) normal? * Start engine. . NO : ;;ik; low rdlrng.

Go to M-12

YES

Iepair eplace

WARD oil pressure switch

3eplace

lepair eplace

Ieplace

pefeyztive,conpct or di?onnec tlon In wrnng hXneSS DeNveer CNSS2 (male) (16) - CNSO6 (131 - CN451 (12) - CNS07 (female1 (1)(2) - CN451 (14) - chassis ground, or between CNSS2 (141 - CN122 (6) - chassis ground

3epair ,eplace

Defective transmission 1st oil pressure switch

Ieplace

* When gearshift lever is at Fl: Min. 1 MR - When gearshift lever is at N: Max. 1 .Q

E-S6. Related electrical circuit diagram

Mode selection switch

SSC controller

Transmission 1st oil pressure switch

Transmission FORWARD oil pressure switch

197F01515

D275A-2

20-140-11 0

E-S7

Selected (monitor

level does not change panel LED is normal)

when

rockbed

selection

[Check for any error in the function of the SSC system and for any failure code displayed on the SSC.1 Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.

switch

is pressed

Remedl

Cause

Go to E-S12

- (14) as shown

Troubleshooting E-S12.

Defective contact or disconnection in wiring harness between CNSOI (9) and CNSSP

+^.+:..-1 tween CNSOl (9) and (2) as shown

qepair .eplace

* Turn shoe slip control switch ON. . Switch rockbed_ _ celectinn _ __. _. mode. _- -

* Turn starting switch ON. * Turn shoe slip control switch ON. - Switch rockbed selection mode.

1 E%D;izoG;de

selection

YES

S Is voltage between CNSS2 (5) and (14) normal?

_ . Start engine. . Run at low idling. NO * Brake * When gearshift lever is at F: IO-3ov * When gearshift lever is at N: O-IV . Start engine. * Run at low idling. . Brake * When gear&ii lever is at Fl: IO-30v . When gear-shift lever is at N: o _ , v No

Defective shoe slip controller

Is resistance between CNSIZ _

(male)(1)and (2) normal?

YES

Is resistance between CNS07 ;;;;$?

and f2)

* Start engine. . : ;yaRzt low tdllng.

Replace

Defective contact or disconnection in wiring harness between CNSS2 (male) (5) - CN421 (14) CN451 (13) - CNSIZ (female) Repair (1)(2) - CN451 (14) - chassis replace ground, or between CNSS2 (141 - CN122 (6) - chassis ground

YES _

_ ND * Start enaine. . Run at low idling. * Brake . When gear&ii lever is at F: Min. I MR - When gearshift lever isatN:Max.lQ

qeplace

Defective transmission FORWARD oil pressure switch

Replace

Defective. contact or disconnectcon rn wtnng narness oetween CNSS2 (male) (16)- CNSO6 (131 Repair - CN451 1121 - CNS07 (female1 replace (l)(2) - CN451 (14) - chassis ground, or between CNSSZ (141 - CN122 16) - chassis ground Defective transmission pressure switch

1st oil

Replace

* When gearshift lever is at Fl: Min. 1 MR * When gearshift lever is at N: Max. 1 R

E-S7. Related

electrical

circuit diagram Table

Mode selection switch K-G

r’::$$A”” 0

~F&++--j

ssc cant--“--

Rockbed g n

Torque converter speed Transmission

L F GND

Transmission 1st switch

CN421

’

(Tolerance:

t O.lV)

CN4!

CNSOI

@CNSSZ

197FOl516

20-140-12 0

D275A-2

E-S8 + *

Engine cannot

be controlled,

engine

stalls, engine

cannot

be started

Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. Cause

4 YES YES -

3 yEs

* Turn starting switch ON. * Turn shoe slip control switch ON. - Start engine.

E-S& Related

Is voltage between CNSMI _ (8)(9)(5) - (12) as shown in Table I? . Turn starting switch ON.

Is LED display on - shoe slip controller normal?

* Start engine. - Move throttle lever Hi-Lo-Stop.

inserted.

Remedy

Defective fuel injection pump, engine system

Is output lever rctating angle as shownin Table l? . Tz;ctaoag No

Repair replace

Defective ELPC controller

Replace

* Start engine. * Move throttle lever Hi-Lc- Stop. 5 YES

Go to G,,

G,2

Is voltage between CNSSI (4) (13) - (II) as shown in Table I? NO

Defective shoe slip controller

Replace

* Turn starting switch ON. * Turn shoe slip control switch ON. s Start engine.

electrical

circuit diagram Table

SSC controller

% The FULL position

is taken

CN421

7-l-l

hlpur potentiometer

ack iometer

L____.-.J

D275A-2

17MF02179

20-140-13 0

E-S9 Shoe slip is not detected

when

shoe slip controller

is ON

[Check for any failure code displayed on the SSC.] * Before carrying out troubleshooting, check that all the related connectors are properly * Always connect any disconnected connectors before going on the next step.

4 YE:

mr Does problem appear again? IL

CNSSl

(12) and

inserted.

Cause

qemedy

Defective shoe slip controller

teplace

System has been reset

Table 1 when an2

CNSS3 (2) and (3) as shown in Table 1 when angle of acceleration sen* Remove acceleration sensor. * Turn starting switch ON.

tween CNSS3 (1)

* Turn starting switch ON.

1 lgle ofacceferation 1 1 sensorischanged7 * Remove acceleration sensor. . Turn starting switch ON.

1 I

Defective contact or discon nection in wiring harness between CNSS3 (female) (2) CNSlO (2) - CNSOG (7) CNSSI (female) (12)

lepair eplace

Defective acceleration

sensor

leplace

Defective contact or disconnection in wiring harness between CNSS3 (female) (l)(3). CNSIO (l)(3) - CNS(6)(8) CNSSl (female) (1O)Ul)

iepair eplace

Table 1

CNSSS (2) - (3)

1.25 V

CNSSI (12) - (11)

1+25v

I (Tolerance: ~k0.3V)

E-S9. Related

electrical

circuit diagram

SSC controller

I-I ieration sensor ‘Acceleration

sensor (8V)

Acceleration

sensor (signal)

,Acceleration

sensor (GND)

197FOl518

20-140-14 0

D275A-2

E-S10 E-S11

Starting modulation does not work when shoe slip controller is ON There is no up/down of drawbar pull by using ripper lever when shoe slip controller is ON

[Check for any failure

code displayed

2 YES

YES

D275A-2

Cause

qemedy

Defective shoe slip controller

3eplace

Does problem appear again? NO

* Go to item in Troubleshooting E-S.12.

on the SSC.1

System has been reset

Go to E-S12

20-140-15 0

E-S12

Abnormality

in ripper UP, DOWN,

TILT signal, REVERSE signal

[Check if any failure code is displayed on the SSC.] * Before carrying out troubleshooting, check that all the related connectors are properly Sr Always connect any disconnected connectors before going on the next step.

1 Is lighting up of LED display on SSC as shown in

Table I?

inserted.

YES

+yGJHNO YES

- See Table 1. Turn starting switch ON. Operate gearshift lever to REVERSE.

Does transmission REVERSE

,j!zz&&-

NO switch ON. * Operate gearshift lever to REVERSE.

* See Table 1.

YES

If ripper UP display . . *

Table

1. Check of ripper lever signal, transmission REVERSE signal

Individual

operation

Green LED

Red LED

Ripper UP

Ripper DOWN

al”

Transmission FORWARD

Ripper TILT Transmission REVERSE

YES

SSC LED display

* Do not operate two levers at the same time.

Procedure 1) Turn starting switch ON. 2) Select Economy mode 2. 3) Turn shoe slip control switch ON. 4) Select Rockbed selection 1.

If ripper TILT display is given when gearshift lever is operated to FORWARD

_...._.

_..jO5 is

1disconnected?

YES

* Turn starting switch ON. I NO - Operate gearshift lever to FORWARD.

20-140-16 0

D275A-2

Cause

Remedy

Normal (system has been reset)

Defective contact or disconnection in wiring harness for signal which is not displayed or defective adjustment oi limit switch

Adjust, repair, or replace

Defective shoe slip controller

Replace

System has been reset

YES

Is voltage between CN252 (female) and chassis ground 20 - 30 V? - Turn starting switch ON.

YES

Does condiion become normal when ripper UP switch positionis adjusted?

Defective contact or disconnection in wiring harness between CNSS2 (female) (9) CS06 (IO) - CN451 (IO) CN251 (male)

Repair replace

Defective backup alarm switch

Replace

Defective contact or discon nection in wiring harness be. tween CN252 (female) - CN451 (6) - CN121 (8) -fuse No. 10

Repair replace

Defective adjustment of position of ripper UP switch

Adjust

Defective ripper UP switch NO

YES

Dces mndiion be come normal when iipflsrD(sIMJswitch positionisadjusted!

Short circuit with chassis ground in wiring harness be tween CNS04 (female) (3) ant CNSS2 (female) (7)

Repair replace

Defective adjustment of posi, tion of ripper DOWN switch

Adjust

Defective ripper DOWN switch

Replace

Short circuit with ground ir wiring harness betweer CNS03 (female) (3) ant CNSSZ (female) (8)

Repair replace

Defective adjustment of posi tion of ripper TILT switch

Adjust

- Defective ripper TILT switch

Replace

Short circuit with chassis ground in wiring harness be tween CNS05 (female) (3) ant CNSSL (female) (6)

Repair replace

Defective shoe slip controller

Replace

YES

Dces condition be mrnenorrnalwhen ripper TILT swkch 1p&ion isadjusted?]

jGHHisytiern 16 -

YES

Is voltage between CNSS2 (9) and (14) 0 - 1 V7 * Turn starting No switch ON. * Operate gearshift lever to REVERSE. . Disconnect CN251.

D275A-2

has beenreset

Defective backup alarm switch

Replace

Contact of +24V with wirinc harness between CN25j (male) - CN451 (IO) - CNSOt (10) - CNSSZ (female) (9)

Repair replace

20-140-17 0

E-SIO,

E-Sll,

E-S12. Related

electrical

circuit diagram

CNS05 Ripper tilt switch SSC controller

Ripper tilt

Ripper UP switch

Ripper UP

i I

Ripper DOWN

Backup alarm

1 GND

Ripper DOWN

switch

Backup alarm switch

Relay box 197F01519

20-140-18 0

0275A-2

TROUBLESHOOTING OF MACHINE MONITOR SYSTEM Table of failure

and causes . .. . . . . .. . . . . .. . . .. . . . . .. . . . . . . . . . . . .. . . . .. . . . . .. . .. . . . . .. . . . . .. .. . . . . . .. . . . . . .. . . . . . .. .. . . . .. . . . . . . . . 20-I 43

modes

M-2

When starting switch is turned ON, monitor

M-3

When starting switch is ON (engine stoped), CHECK items show abnormality

M-5

on the monitor

in coolant level

b) Abnormality

in engine oil level

. . . . . . . .. . . . .. . . . .. . . . . . .. .. . . . . . . . . . . . . . . . .. . . . . .. . . . . .. . .. . . . . . . . . . . . . .. . . . 20-I 46 6 SC) ,“001‘10

Preheating

monitor

Preheating

monitor

stays light up . . .. . . .. . . .. . . . . .. .. . . . .. . . .. . . . . .. . . .. . . . . . . . . . . .. . . .. .. . . .. . . . . . .. . . . . . .. . . . . . .. . .. . . . 20-147

switch

is ON and engine

When

M-9

. . . . . . .. . . . .. . . . . . . . 20-145

in preheating

starting

is stoped,

CAUTION

items flash . . . . . .. .. . . . .. . . . .. . . . . . . 20-148

Charge level flashes ....................................................................................................

20-I 48

Engine oil pressure flashes.. .......................................................................................

20-I 48

Coolant level flashes ...................................................................................................

20-I 48

flashes .......................................................................................

20-I 48

Hydraulic

M-8

panel lamps all stay on and do not go out . . . 20-144

01111 .. . . . . . . . . . . .. .. . . . . . . . . .. .. .. . .. . .. . . .. .. .. . . . . . . .. . . . . .. . .. . .. .. .. . . . .. . . . . . . .. . . . .. . . . .. . . 20-I 47 1”00>101 does not light up . .. . . . .. . . . . . . .. . . .. . . . . . .. . ... .. . .. . .. . . . . . . . . . . . . . . . . . .. .. . . . . .. . .. . . . . . . . . . . . .. 20-147

Abnormality

Torque converter

M-7

the starting

. . .. . . . . .. . . . . . . .. . .. . . . . .. . .. .. .. . .. . . . . . . .. . . . . . . . . . . . .. .. .. . . . . . .. . . . . . . . . . . . . . 20-I 45 SC) re(,nl

a) Abnormality

Coolant temperature

M-6

panel when

is ON .. . . . . .. .. . . .. . . . . . . . . . 20-144

No display

M-4

appears

switch

M-l

Electronic

20-I 49

flashes ...............................................................................

oil temperature

system

flashes ..................................................................

oil temperature

abnormality

flashes

20-I 49 20-151-I

...........................................................................

Abnormality

in buzzer.. ...............................................................................................................

CAUTION

items are flashing,

No abnormality

20-152

but does not sound ..............................................................

display is given on monitor,

20-I 52

but buzzer sound.. .....................................

.20-152 20-I 53

lamp ...................................................................................................

Abnormality

in warning

CAUTION

items are flashing,

No abnormality

20-I 53

but lamps do not flash ........................................................

display is given on monitor,

but lamp light up ......................................

-20-153 20-I 54

in gauge .................................................................................................................

Abnormality

gauge ........................................................................

20-1.54

a) Abnormality

in coolant temperature

b) Abnormality

in torque converter

c) Abnormality

in fuel level gauge ...........................................................................................

20-I 56

Service

does not move after engine

..........................................................

.20-l 57

panel does not light up ......................................................................

20-I 58

metor

M-10

Panel lighting

monitor

M-l 1

After starting

switch

even when

is turned

mode selection

oil temperature

ON, display

switch

is started

LED does not light up

is pressed

LED on panel is normal,

but there is no output from mode selection

M-13

LED on mode

switch

M-l 4

Defective

Initial setting cannot

Initial setting

D275A-2

panel does not flash when

lighting

switch

module ..... 20-160

is ON ............

initial setting ..............................................................................................................

be made when

is made when

.20-159

.......................................................................

M-12

selection

20-I 55

gauge ....................................................

initial set switch is ON ..........................................

initial set switch

is OFF.. ....................................................

20-161 20-I 62 20-I 62 .20-162

20-141 a

TABLE OF FAILURE MODES AND CAUSES (MACHINE MONITOR, MODE SELECTION SWITCH)

Sensors

Causes Z! =I

Failure

Monitor

panel display

starting

switch starting

monitor

is not given when

is turned

switch is turned

ON, all

Abnormality is display in Check before starting item when starting switch is at ON position (engine stopped)

Abnormality

CAUTION

item flashes

Abnormal

in buzzer

Abnormality

in warning

Abnormality

in gauge

Service

in preheating

meter

after engine

display

when

engine

is started

does not move

lighting

Monitor

After starting switch is turned ON, display LED does not

LEDs on panel output

from

,3.

When

lighting

are normal

switch

0 0

does not light up

light up even when mode selection switch is pressed

000

is started

panel

lamp

panel lamps light up and do not go out

’

fZ!?

mode

When

’

?Z I11 i;;

but there is no

module

switch

is ON,

LEDs on panel do not dim

14.

Initial setting cannot be made when initial set switch is ON Initial setting is made when initial set switch is OFF

20-142 a

D275A-2

E &z

2 i

z -ii z z

_m t l-0 = rr

E E

5 .e

z .E

‘5

u -

-2 -S

3 -

0 -

M-2

M-3

3 -

0 -

M-4

M-5

0 -

3 -

M-l

0 -

M-6

M-7

M-8

3 -

1 -

3 -

1 -

3 -

1 -

0 -

3 -

D275A-2

E ii g

rroubleshootinc

F .o 3 8 r’ 8 _c 0 2 2

0 -

Monit :01 am -

M-9

M-10

M-l 1 -

M-12

M-13

M-14

20-143 0

M-3

When starting switch is ON (engine stopped), CHECK items show abnormality (Liquid levels is normal for check items before starting)

Before carrying out troubleshooting,

Always

a) l

check that all the related connectors are properly

inserted.

connect any disconnected connectors before going on the next step.

Abnormality

in coolant

level

8 /_

Coolant level monitor flashes

Remedy

Cause Defective 1 sensor

YES

After inspedtion sensor. repair or replace accord-

coolant level

ing to table of standard 1values

1 3

Does coolant level monitor go Off?

yES 2

. Connect short connector to CN405 (female). * Turn starting switch ON.

Is resistance between CN405 (female) Q) and

_ NO

chassis ground than lSZ7 * Disconnect

* Disconnect

YES

Defective

Is resistance between CNl (female) (5) and chassis ground less than Q-L? \CNl

monitor

Defective contact nection in wiring NO

module.

Replace

or disconharness

~@~e~%$%J$

G%J?LF$F-

Defective contact or disconin wiring harness between CN405 (female) (2) and chassis ground.

After inspection, repair or replace

less

. nection

CN405. NO

E 6

M-3 a) Related electrical

circuit diagram

CN I CN201

CNIOI

CN421 Monitor

Down

Coolant -

level

sensor

Connector

panel

F19702211

561 FO3177A

20-145

b) l

Abnormality

in engine

oil level

Engine oil level monitor flashes.

Cause Defective

YES

engine oil level

sensor or defective chassis ground.

1 Doer engine level monitor off? -

oil go

Is resistance between CN 1 (female) (6) and chassis ground than la?

P NO

* Ground CN404 (female) (1) chassis. * Turn starting switch ON.

of standard VallleS

YES Defective

Disconnect

M-3 b) Related electrical

CNl.

monitor

module.

Defective contact. or disconnection in wiring harness between CN404 (female) (1) CN401 (4) - CN421 (5) - CNl (female) (6).

less

h Remedy

After inspection sensor, repair or replace according to table

REplaCe

After inspection, repair or replace

circuit diagram

CN I Engine oil level sen*or

CN401

CN404

CN421 Monitor

panel

197FO1522

Engine

oil

level

sensor

F19702213

20-146

M-4

Abnormality

in preheating

Before carrying out troubleshooting,

Always connect any disconnected connectors before going on the next step.

When operation

check that all the related connectors are properly

of the APS is normal (if it is abnormal, carry out troubleshooting

inserted.

E-6 first.)

Preheating monitor does not light UP

Cause YES Defective

* Turn starting switch ON. * Turn preheating switch ON.

monitor

module.

Defective contact, or disconnection in wiring harness between connector [51 (female) (1) - CN361 (female) (13) CN2 (female) (5). or defective bimetal timer.

I N”

Preheating monitor stays lighted up Contact of + 24V with wiring harness between connector [51 (female) (1) - CN361 (13) - CN2 (5), or defective bimetal timer.

‘ES

off when CN2 disconnected?

* Disconnect

CN2.

Defective

monitor

module.

M-4

Related electrical

circuit diagram

Relay box

CN36l Check module

I97FO

I523

20-147

M-5

When starting switch is ON and engine is started, CAUTION items flash (When there is no abnormality in the CHECK items or engine)

Before carrying out troubleshooting,

Always connect any disconnected connectors before going on the next step.

check that all the related connectors are properly inserted.

Charge level flashes

a) m

2 YES _

1 Is voltage between alternator terminal R and chassis ground 20 -_,3OV?

* Start engine. * Engine at half throttle or more.

. Start engine. * Engine at half throttle or more.

b) +&

YES Defective

Is voltage between CNl (4) and chassis ground 20 -3ov7

monitor

module.

Defectlve contact or disconnection in wiring harness between alternator tekinal R - CN107 CN105 - CNlOl 19)battery relay tern&l R - CN122 (1) CNl (female (4).

Replace

Remedy

Engine oil pressure flashes

Does display go off when CN403 is disconnected?

* Disconnect CN403. * Start engine.

YES I

Defective engine sensor system.

Coolant temperature

flashes 2

YES

Does display go off when short Is connected tcl CN402 (female)?

1 Defective

module.

Replace

Wiring harness between CN403 - CN401 (3) - CN421 (4) 1 CNl (female) (7) short circuiting with chassis ground.

Repair replace

monitor

Remedy

Cause

DefectIvecoolant se”sor system.

temperatur

I . cOnnectOr

’ Connect short connector to CN402 (female). * Start engine.

*start

YES

Is resistance between CN 1 (female) (7) and chassis ground morelthan 1 MA-L?

See M-3 a)

* Engine throttle

pressure

Coolant level flashes

oil

After inspection sensor. repair or replace according to table of standard YalUeS

* Disconnect CNl. * Turn starting switch OFF. * Disconnect CN403.

Repair replace

After inspection sensor. repair or replace accord ing to table of standard V&_VZS

Defective

monitor

module.

Replace

Defective

monitor

module.

Replace

engine. at half or more.

20-148

Torque converter

oil temperature

flashes

Sfter inspec:ion sensor. epair or

2 YES -

1 Is torque converter oil temperature gauge within red range?

* Start * Engine throttle

YES

Does display go off when short connector is connected to CN453 (female)7

Defective torque converter oil temperature sensor system.

Defective

monitor

module.

Defective

monitor

module.

.eplace accordng to table ,f standard lalues

-NO . Connect

short connectclr to CN453 (female). . Start engine,

engine. at half or more. jji

Hydraulic

oil temperature

flashes Cause

Remedy After inspection sensor,

YES

Defective hydraulic oil temperature sensclr system.

’

Does display go off when CN452 is grounded to chassis7 P . Disconnect CN452, and ground (fema,ej (1) * Start

2 Is resistance between CNl (female) (8) and chassis ground less than 1 a7

_ NO

to chassis. engine.

repair or replace according to table of standard

* Disconnect CNl. Ground CN452 to chassis. * Turn starting switch OFF.

values

YES Defective

monitor

module.

FlepkX3

Defective contact, or disconnection in wiring harness between CNl (female) (8) CN421 (12) - CN451 (3) CN452 (female).

20-149

M-5 a) Related electrical

circuit diagram

CN I Monitor module

Alternator terminal

Service

F19702215

M-5 b) Related electrical CNI

circuit diagram CN401

CN421

Engine oil pressure sensor

CN403

Monitor module

F19702216 If the

condition

Engine

is es shown

oil pressure

0.5

in the table

kg/cm2

below,

or above

I Engine oil pressure below 0.5 kg/cm’ M-5 d)

Related electrical CN2

it is normal No continuity

Continuity

circuit diagram CN42

CN401

Coolant temperature sensor

CN 402

Monitor module

F19702217 If the condition it is normal

is es shown in the

table

below,

Coolant

temperature

sensor

IILL

F19702218

M-5 e) Related electrical

circuit diagram CNOFjl

CN453

Torque converter nil +amn0rs+,,m ..,%“r.-.v

Monitor module

F19702219 If the condition is as shown in the table below, it is normal.

M-5 fl

Rerated

electrical

circuit diagram

CNI

CN421

CN451

Hydraulic oil temperature sensor

CN452

Monitor

F 7TJT 198FO2242

w-71 Structure

circuit

SAD01536

1. 2. 3. 4.

D275A-2

Switch Case Wire Connector

20-151 0

Electronic

system

abnormality

flashes

YES

Cause

I3emedy

F:ailure in shoe slip controller -( 20 to Troubleshooting for G. FvlODE

-c )efective monitor module

2i/

Is voltage between CNI (9) and (2) 0 - 1 V?

-C Iefective shoe slip controller

Fleplace

CDefective contact or discon r section in wiring harness be- Ftepair (female) (9) andI replace C:NSS2 (female) (II)

M-5. g)

electrical

Monitor

I ,

circuit diagram

panel

I-lCNl

CNSSE

Electronic system abnormality GND

r ween CNI

NO * Connect T-adapter to CNSS2. * Short circuit between CNSS2 (1 I) and (14).

-1

System abnormality output GND

_I 197 FO1530

20-151-l 0

D275A-2

M-6

Abnormality

in buzzer

Before carrying out troubleshooting,

Always connect any disconnected connectors before going on the next step.

Of the CAUTION

CAUTION

items, the buzzer will not sound if there is an adnormality

items are flashing,

in the charge level.

but buzzer does not sound.

YES

1 Does buzzer sound when

check that all the related connectors are properly inserted.

Defective

module.

ReplaCe

Defective contact, or disconnection in wiring harness betree” CN454 (male) (1) CN465 - buzzer - CN466 CN2 (female) (EL or defective buzzer.

NO chassis. * Turn starting switch ON.

monitor

CN2

No abnormal

display is given on monitor,

but buzzer sound.

Cause

Remedy

YES

Does buzzer stop when CN2 is removed? - Remove CN2. * Turn starting switch ON.

M-6

Wiring harness betwee” CN2 (female) (8) and CN466 short circuiting with chassis ground, or defective buzzer.

electrical

circuit

Repair or replace

diagram

Monitor supplementary cO”trOller

+24V

I CN464 CN465 (

1 Buzzer

CN466 Monitor module

CN2

20-152

F91702220

M-7 t

Abnormality

in warning

lamp

Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.

CAUTION *

items are flashing,

but lamps do not flash.

Check visually to confirm that there is no disconnection in the lamp.

(If the lamp bulb is blown, replace the bulb.)

Remedy

1 Does lamp light up when CN2 (female) (7) is connected to chassis ground?

YES

Defective

monitor

module.

’ Ground CN2 (female) (7) to chassis. * Turn starting switch ON.

Defective contact or disconnection in wiring harness between CN2 (female) (7) - CN364 (2 - CN371 (2) -CN372 (2 1*(l) - CN371 (1) - CN364 (1) - CN464.

5 6

No abnormal

display is given on monitor,

but lamp lights up

Defective

* Remove CN2. ’ Turn starting switch ON.

M-7

monitor

module.

Replace I

Does lamp go out when CN2 is removed?

Wiring harness between CN2 (female) (7) - CN364 (2) CN371 (2) - CN372 (2) short circuiting with chassis ground, or defective lamp.

electrical

circuit

Repair or rePlaCe

diagram with cab _-___-,

CN372 Caution Lamp 198FO2270

20-153

M-8

Abnormality

in gauge

Before carrying out troubleshooting,

Always connect any disconnected connectors before going on the next step.

a) l

Abnormality

check that all the related connectors are properly

in coolant temperature

Engine coolant temperature

inserted.

gauge

gauge shows abnormally

low temperature.

Remedy

Cause

After inspection sensor,

1 DOBS temperat”re

display go off when Short COnnectOr IS connected to CN4027

* Connect Short

connector to CN402 Ifemalel. * Turn start!ng switch ON.

Defectwe

YES

repair or replace according to table

coolant

temperature

sensor system

of standard values Defective contact or disconnection in wiring harness between CN402 (female) (1) CN401 (1) CN421 (1) CN2 (female) (11, Or between CN402 (female) (2) - CN401 (21 - CN421 (2) -chassis ground.

Repair replace

.~.

Engine coolant temperature

is not displayed Remedy

Cause

I ifter inspect ion sensor. r epair or 1

Defective coolant temperature sensor

YES

system.

I eplace

accordng to table

Ic)f standard \/alues

Wiring harness between CN402 (female) (I) CN401 (1) -CN421 (1) CN2 (female) (1) short circuiting with chassis ground.

* Disconnect connector of CN402 (female). * Turn starting switch ON.

M-8

electrical

circuit

CN2

If the condition it is normal

is as shown

table

diagram

CN421

in the

Repair replace

below,

CN401

CN402

Coolant temperature sensor

198FO2239

F19’702218

20-154

b) l

Abnormality

in torque converter

Torque converter oil temperature

oil temperature

gauge

gauge shows abnormally

low temperature.

After ~nspection sensor.

YES

Defective torque converter oil temperature sensor wstern.

Does temperature display go off when short connector is connected to CN4537 NO

* Connect short connector to CN453 (female). * Turn starting switch ON.

Torque converter oil temperature

Defective contact or dixonnection in wiring harness between CN453 (female) (1) -CN451 (1) - CN421 (8) -CN2 (female) (2). or between CN453 (2) - CN451 (2) - CN421 (2) -chassis ground.

repair or replace accord,ng to table of standard values

Repair

is not displayed. Remedy

Cause

lfter

Defective torque converter oil temperature sensor system.

YES

Does temperature gauge display appear when CN453 is removed?

- Disconnect

electrical

circuit

diagram

CN421

CN2

inspec-

:ion sensor, xpair or replace accordng to table ,f standard ralu?S

Wiring harness between CN453 female) (1) CN451 1) - CN421 (8) CN2 (female) (2) short circuiting with chassis ground.

connector of CN453 (female). * Turn starting switch ON.

M-8

replaCe

CN451

CN453

Torque converter oil temperature sensor

Monitor module

F19702221 If the

condition

it is normal.

is es shown

in the

table

below,

Oil temperature 58”SOT

F19702218

20-155

c) l

Abnormality in fuel level gauge Fuel gauge always displays FULL.

Cause

Remedy

After inspection sensor, repair or YES

Defective system.

1’

fuel

level

replace according to table of standard VIIUBS

sens0r

Does fuel display

gauge go off?

. Remove CN423 (fuel level

YES

Repair replace

_.. .-. ,.,

(3) short circuiting.with chassis ground.

Does fuel gauge display go off?

SWWX).

Turn starting switch ON. * Wait for approx. 1 min. *

Defective * Remove CN2 *ITurn stamng switch ON. * Waltforapprox.

monitor

Replace

module.

1ml”

Fuel level is not displayed. Cause

Is FULL given7

YES

Defective svstem.

fuel

Defective

monitor

level

Remedy

sensor

display 2

* Remove CN423 (fuel level SellSOr). . Connect short

I NO

connector.

Is resistance between CN2 (female) (3) and chassis ground less than 15-Z?

. Connectshort

* Turn starting switch ON.

CN2

replace according to table of standard ValUeS

YES module.

ReplaCe

Defective contact or disconnection in wiring harness between CN423 (female) (1) -CN422 (1) - CN421 (7) -CN2 (female) (3).

COnnectOr to CN423 (female) (1) (2).

M-8 c) Related electrical

After inspection sensor. repair or

Repair replace

circuit diagram

CN421

CN422

CN423 Fuel level sensor

Monitor module

F19702222 Level sensor

F19702223

20-156

M-9

Service meter does not move after engine is started

Before carrying out troubleshooting,

Always connect any disconnected connectors before going on the next step.

check that all the related connectors are properly

inserted.

Remedy

Cause

YES

See M-5

Does charge abnormality display flash?

* Start

engine.

Is voltage between CN3 (1) and (4) 20-3OV?

’ start

M-S

engine.

Related electrical

YES

Defective

service

meter.

REplfdCe

Defective contact or dirconnectlon in wiring harness beNyya CN122 (I) and

Repair replace

circuit diagram

CN I Monitor module

Alternator terminal R

CN3 Batteryrelay Service meter

F91702224

20-l 57

M-10

Panel lighting for monitor panel does not light up (Liquid crystal display is normal)

Before carrying out troubleshooting,

Always connect any disconnected connectors before going on the next step.

check that all the related connectors are properly

Check visually to confirm that there is no disconnection

\hE.henfuses No. 5 is normal (If fuse is blown, check for short circuit between CN361

inserted.

in the lamp. (If the lamp bulb is blown, (female) (8) - CN4 (11, CN5 (1)).

Cause

1 Is voltage between CN361 (8) and chasis ground 20 - 3OV?

Remedy

Defective contact, or disconnection in wiring harness between CN4 (1) and CN361 (8). or between CN5 (1) and CN361

YES

(6).

* Turn starting switch ON.

M-l 0

electrical

replace the bulb.)

1; circuit

jee

E-7,

Relay

box

diagram.

CN4

CN361 8 --F

Monitor module

H.H.

working

Fuse 6

CN5

F91702225

20-158

M-II

* a) l

After starting switch is turned ON, display mode selection switch is pressed

LED does not light up even when

Before carrying out troubleshooting, check that all the related connectors Does not light up for any switch When monitor panel display is normal (if it is abnormal, go to M-1)

are properly

Remedy

Cause

Defective mode switch module

Is voltage

between CNSOl (female) (1) and * ConnectTadapter to CNSOI (female). - Turn starting switch ON.

selection

Defective contact or disconnection in wiring harness between CN464 (1) - CNSOl (female) (I), or between CN464 (4) - CNSOI (2)

b) Does not light up for some switches (Note that the rockbed mode switch does not work when the shoe slip control

Iefective mode witch module

electrical

Repair replace

IRemedy

selection

circuit diagram

CNSO I

Replace

is OFF.)

Cause

M-l 1. Related

inserted.

I Fleplace

Sub controller

CN464

+24V output Switch ,module GND

CNI

Monitor module 197FOl535

D275A-2

20-159 0

M-12

LED on panel is normal, but there is no output from mode selection switch module

M-12. Related

electrical

Cause

Remedy

One of signal wires below is in contact with +24V (check all wires)

After inspection, repair or replace

circuit diagram

CNSOI

CNSS2

Mode selection switch module

I98FO225

20- 160 0

D275A-2

M-13 *

LED on mode selection switch panel does not flash when lighting

Before carrying

out troubleshooting,

check that all the related

switch is ON

are properly

connectors

I3emedy

Cause

2 YI 1

. Check visually.

YES

beIs voltage CNSOl tween - (female) (IO) and (2) 20 - 30 VI NO * Connect Tadapter to CNSOI (female). * Turn starting switch ON.

electrical

selection

’ Fleplace

Defective contact or discon nection in wiring harness be FIepair tween CNSOI (female) (1011 r eplace and CN361 (8)

Go to M-10

M-13. Related

mode Defective switch module

inserted.

circuit diagram

CNSOI

CN361 Relay box

Switch module

CNSOP

Bulb for mode lighting

Bulb for monitor lighting

panel

Bulb for service meter lighting

197FO1536

D275A-2

20-161 0

M-14

Defective initial setting

Before carrying

Initialsetting cannot be made when initial set switch is ON

out troubleshooting,

check that all the related

connectors

are properly

inserted.

Remedy

Cause

YES

jefective mode witch module

Is there continuity between CNSOI _ Eyale) (11) and * Turn starting switch OFF. - ConnectTadapter to CNSOI (female). * Turn initial set switch ON.

initial setting 1

is made when

initial set switch

YES

Is there continuity between CNSOl (female) (11) and (2P - Turn starting switch OFF. * Connect Tadapter to CNSOl (female). * Turn initial set switch OFF.

M-13.

electrical

CNSOI

module

selection

ieplace

jefective contact or disconsection in wiring harness be. ween CNSOl (11) -CNSOS(lI initial set switch - CNSOS (21 chassis ground

lepair eplace

Contact of chassis ground tih wiring harness between :NSOl (11) - CNSOS (1) - inial set switch

iepair eplace

Iefective mode witch module

teplace

is OFF

selection

circuit diagram

CNSOS Initial set switch

198FO2253

20-162 0

D275A-2

TROUBLESHOOTING OF SHOE SLIP CONTROLLER, ELPC CONTROLLER SYSTEM (G MODE) Shoe slip controller

ELPC controller

Display

I65 I

when

normal

[Abnormality

in engine]

G-2

[Abnormality

in acceleration

G-3

[Abnormality

in torque

converter

G-4

[Abnormality

in engine

speed sensor] is displayed..

[Abnormality

in economy

[Abnormality

in control

[Abnormality

in acceleration

[Abnormality

in ripping

[Abnormality

in ELPC controller]

[Abnormality

in sensor power

G-l

G-7

G-9

is displayed..

: Rapid flashing

(5 times/set)

.20-202

.....................................................

sensor power

source]

speed sensor]

is displayed

mode selection]

20-205

..........................

20-207

.................................

20-208

20-209

..........................

......................................

20-210

..............................

20-211

.........................

20-212

...............................

20-213

GmYebwFW

L-J L-J

G-10

l ee

GCSlYedmREd

G-II

G-12

is displayed

source]

l oe

GMllW

GmYekwRxl

ooe

[Abnormality

cl I I I--

[Abnormality

in feedback

potentiometer]

in input potentiometer]

is displayed

GlWlY&WR&

G-13

l eo

[Abnormality

in shoe slip control

command]

is displayed

...................

20-214

............

20-215

GmYdb.vFkd

Ioeo I

[Disconnection,

G-14

G-15

u L-l Green Red

G-16

D275A-2

short circuit in solenoid

[Abnormality

in shoe slip controller]

[Abnormality

in power

system]

is displayed

.................................

20-216

.........................................

20-217

is displayed

GCBlY&.VW 000

source]

is displayed..

20-204

20-206

is displayed

is displayed..

.............

.......................

is displayed

sensor]

........ 20-203

.............................

is displayed

mode selection]

is displayed

20-201 a

GCBlRed

G-l

I I 5 6

[Abnormality

YES

Is ELPC controller giving abnormality display? NO

20-202 0

in engine]

is displayed

Cause

Remedy

Carry out troubleshooting according to abnormality display on ELPC controller

Mechanical failure between ELPC valve - link system - governor system

Repair or replace

0275A-2

G-2 * *

‘zz u

[Abnormality

in acceleration

sensor power

source]

is displayed

Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step.

inserted.

Cause

YES

2 YES

Is same abnor-

mality display given again?

Replace

System has been reset witch

YES

Is voltage between CNSSB (I) and (3) 7 - 9 V?

electrical

ON.

* Turn starting switch ON.

G-2.

Defective controller

* Turn starting

Is voltage between CNSSI (11) and(10)7-9V? * Turn starting switch ON.

Remedy

Defective acceleration sensor Short circuit with ground OI short circuit in wiring harness between CNSSI (IO) - CNSOE (6) - CNSIO (I) - CNSS3 (I), or contact with other wiring harness

Replace

Repair or replace

circuit diagram

Shoe slip controller

ration Acceleration sensor (8V) Acceleration sensor (signal) Acceleration se

197FOl518

D275A-2

20-203 a

Green R&d

G-3 * *

0 .

[Abnormality

in torque

converter

speed sensor] is displayed

Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step.

inserted.

Cause

YES

Remedy

Defective controller

Replace

vfHu-2

1again?

Is resistance beYES 1

tween CNSSl he- _ * Start engine. male) (8) and chas- -I NO sis min. 1 MQ? * Turn starting switch OFF.

* Turn starting

Is resistance betweet CNfEl (male) _ (2) and (1) 480 l.oxrR?

YES 4

* Turn starting switch OFF.

G-3. Related

electrical

INO YES

Is resistance between CNSSI _ (female) (I) and (8) 480 - 1,000 M switch OFF.

System has been reset Defective contact, disconnection, or short circuit with ground in wiring harness between CNSSI (1) - CNSO6 (I) - CN461 (5) - CN651 (2). or between CNSSl (8) - CNSO6 (4) - CN461 (4) - CN651 (1). or short circuit with other wiring harness

Repair or replace

Defective speed sensor

Replace

Defective speed sensor

Replace

circuit diagram

Shoe slip controller

I Torque converter speed t-)

Torque converter speed sensor

Torque converter speed (+)

I98FO2255

20-204 0

D275A-2

u Green Red

G-4

O 5

[Abnormality

in engine

Sr Before carrying out troubleshooting, j,

Always

connect

any disconnected

speed sensor]

is displayed

check that all the related connectors are properly connectors before going on the next step.

inserted.

Remedy

Cause

YES

3 I

Defective controller

qeplace

System has been reset

tween CNSSI (female) (2) and . Turn starting switch OFF. * ConnectTadapter to CNSSl.

G-4. Related

* Turn starring switch OFF.-

1 I-

5 I

YES I

YES i4I I.

* Turn starting switch OFF. * Turn starting switch OFF.

electrical

Defective contact, disconnection, or short circurt with ground in wiring harness between CNSSI (2) - CNSO5 (2) - CNSIO 15) - CNSM5 (21, or between CNSSI (9) - (4) - CNSO5 (5) CNSIO (4) - CNSM5 (I), or short circuit with other wiring harness

Repair or replace

Defective speed sensor

3eplace

Defective speed sensor

Replace

circuit diagram

Shoe slip controller

Engine speed sensor

197FO1537

D275A-2

20-205 0

G-5 * *

[ 6 6 1 [Abnormality

in economy mode selection]

is displayed

Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step.

YES

3 . Turn starting switch ON.

tween CNSS2 (female) (2)(3) -

lNO

YES

inserted.

Cause

Remedy

Defective shoe slip mode setting panel

Replace

Defective shoe slip controller

Replace

s/j-

System has been reset NO

* Turn starting switch OFF. * Disconnect CNSOI.

G-5. Related

Short circuit between chassis and wiring harness with defective resistance, or contact with other wiring harness

I NO

electrical

Repair or replace

circuit diagram

Shoe slip controller

CNSSE Economy

mode B

Economy

mode A

r-7 Mode selection

panel switch

Economy

mode IB

Economy

mode A

I ’

197FO1538

20-206 0

D275A-2

q GreenRed

G-6 Ir *

Q d

[Abnormality

in control

mode selection]

is displayed

Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step.

inserted.

Remedy

Defective shoe slip controller

switch ON. * Turn lock-up switch OFF. . Turn economy mode OFF. * Turn shoe slip control OFF. - Turn REVERSE slow OFF.

tween CNSS2 We male)(2) (3) (15) (17) * Disconnect CNSOI. . Turn starting switch ON.

System has been reset

Replace

Defective shoe slip mode set :ing panel

Replace

Short circuit with chassis ir Niring harness with defective resistance, or contact witt zther wiring harness

Repair or replace

G-6. Related electrical circuit diagram

Shoe slip controller

Mode selection

panel switch

I-I

Economy

mode B

Economy

mode ,B

Economy

mode

Economy

mode #A

,Shoe slip control switch Reverse

slow

Lock-up switch

Shoe slip control switch Reverse slow Lock-up switch

GND

197FO1539

D275A-2

20-207 a

Green Ped l 6

L-l

G-7 * *

[Abnormality

in acceleration

sensor]

is displayed

Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step.

2 YE

YES

inserted.

Cause

3emedy

3efective shoe slip controller

leplace

Is abnormality display given again?

System has been reset NO 5 CNSSl

(12)

and

* Turn starting switch ON. * Set machine horizontal. . Check that acceleration sensor is properly installed.

* Turn starting switch OFF.

G-7. Related

YES

Is resistance beYE6 tween CNSS3 ffe- _ male) (2) and 4CNSS3 (3) 4.7 KQ? YES Is voltage be_ _ tween CNSS3 (2j _ * Turn starting NO switch OFF. and chassis 0 V7 3 - Connect T-adapter to NO Is voltage bemeen CNSS3(1) CNSS3 (female). * Turn starting and (3) 7 - 9 V7 ~ switch ON. 6 YES * Turn starting Is resistance be switch ON. tween CNSS3 (fe _ ~5 male) (3) and chassis less than 1 R?

electrical

Defective acceleration sensor

Ieplace

Short circuit, defective contact, or disconnection in wiring harness between CNSSl (11) and CNSSJ (3). or between CNSSl (12) and CNSS3 (2). or contact with other wiring harness

iepair or eplace

Wring harness between 3NSSl (12) and CNSS3 (2) in :ontact with other wiring harless

fepair or eplace

defective contact, disconnec :ion, or short circuit in wiring narness between CNSSI (101 snd CNSS3 (I)

lepair or eplace

Defective contact or disconnection in wiring harness be tween CNSSI (11) and CNSS3 (3)

sepair or eplace

circuit diagram

Shoe slip controller

r-7

CNSS I

CNSOG

CNSIO

CNSS3 I

A.::Fatic

Acceleration sensor (SW Acceleration sensor (signal) Acceleration sensor (GND)

197FO1518

20-208 a

D275A-2

u GreenRed

0 6

G-8 * Ir

[Abnormality in ripping mode selection] is displayed

Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step.

2 YE

YES

Iefective

Cause

3emedy

shoe slip controller

ieplace

Does abnormaliw appear again?

. Is v&age between CNSSS (15) and (14) 7 lessthan lV?

- TschtaaFg

Is resistance between CNSSI (female) (6) and CNSOl (female) (9). or between CNSSZ (female) (15) and CNSOl

. Turn shceslip control switch ON. * Select mode I- 5. N

YES Is resrstance oetween CNSSl He YES male) (6) and (11). _ or ix+ween CNSSZ 4YES (female) (15) and Is voltage between c (14) min. 1 MCI? CNSSI (6) and (II), _ NO * Turn starting or between CNSS2 switch OFF. (15) and (14) 0 V? * Disconnect CNSOI. * Disconnect CNSOI. NO * Turn starting switch ON.

3efective shoe slip mode set:ing panel

teplace

Short circuit with chassis or shon :ircuit with other wiring harness n wiring harness between :NSSl (6) - CNSOl (9). or be ween CNSS2 (15) - CNSOI (7)

lepair or eplace

Short circuit with other wiring ,amess in wiring harness be. Nveen CNSSl (6) - CNSOl (9). OI oetween CNSSZ (15) - CNSOl VI Defective contact or discon nection in wiring harness witt defective resistance

electrical

System has been reset

. Is voltage between CNSSl 0”;;” (11) 0.6 -

G-8. Related

inserted.

3epair or ,eplace

tepair or eplace

circuit diagram

Shoe slip controller _-

Mode selection

panel switch

I-I Shoe slip control switch Shoe slip control switch r

GND

Rockbed selection Rockbed

selection

Acceleration

I_L

D275A-2

mode

sensor

(GND) -l-

* 197FO1540

20-209 0

G-9

* Ir

m ,m

[Abnormality

in ELPC controller]

is displayed

Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step.

YES 1

Go to other than G-9

El-iL

Is shoe slip controller giving ab nonalii display?

* Turn starting switch ON.

- tween CNSSI (4) and(ll)2-3V?

* Turn starting switch ON.

YES

electrical

Is voltage between CNSMI (21) and (12)2-3V? * Turn starting switch ON. -

G-9. Related

inserted.

YES

3efective shoe slip controller

seplace

Disconnection, short circuit in wiring harness between CNSSl (4) and CNSMl (21)

tepair or eplace

. Defective ELPC controller

teplace

circuit diagram

Shoe slip controller

jCNSS2

Acceleration sensor (GND)

ELPC controller Warning

20-210 0

ICNSSI

output

D275A-2

G-10 j, *

E/, PI

[Abnormality

in sensor power

source]

is displayed

Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step.

inserted.

3emedy

Cause

tween

each pin

Defective ELPC controller

Fieplace

System has been reset

* CNSMl i-I, - (18): . CNSMl(6) - (16):

Defective wiring harness ir ’ FIepair or system with defective resist replace ante

YES

. CNSMl (71 (6) chassis: Min. 1 * Turn starting switch OFF. * CNSMI female

Defective potentiometer in system with defective resistance

FIeplace

sis: Min.‘1 MR? - Turn starting switch OFF. . CNSM4 male * CNSM2 male

G-10, G-II,

G-12. Related

electrical

circuit diagram

CN421

Input potentiometer 1-l ack potentiometer

potentiometer FeedbacktSig’ potentiometer H 4

17MF02181

D275A-2

20-211 a

G-II * *

El,

[Abnormality in feedback potentiometer] is displayed

Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step.

4 YES

Iefactive

inserted.

Cause

temedy

ELPC controller

leplace

Is resistance between._each pin I

eacn pm normaIr - CNSMl (7) - (18): 4-6M * CNSh4lV7)-cha+ sis Min. 1 MQ?

I I

. &%M2 (2) - (3):

20-212 0

I I

tween each pin nor-

System has been reset

defective wiring harness in system with defective resistance

lepair or eplace

Is resistance between each pin normal? . CNSMP (1) - (3): 11 kQ * CNSM2 (I) - (2):

* Turn starting switch OFF. . CNSM2 male

-I 3efective input potentiometer , - Turn starting switch OFF. * CNSX4 male * Turn starting switch OFF. * CNSMl female

NIO

IIefective

wiring harness in system with defective resist3nce

Idefective feedback potentiNO

r>meter

leplace

iepair or eplace

leplace

D275A-2

G-12 El,

[Abnormality in input potentiometer] is displayed

I”,‘;;“,“/

Cause

4 YES

2 IIs resistance

be-

* CNSM4 (1) - (3):

* CNSM2 (I) - (3):

. CNSX4 male * Turn starting switch OFF. . CNSMI female

Defective ELPC controller

leplace

System has been reset

i Defective wiring * Turn starting switch OFF.

3emedy

harness in system with defective resistonce

iepair or eplace

Defective feedback potentiometer

ieplace

Defective wiring harness in ;ystem with defective resistonce

{epair or ,eplace

3efective input potentiometer

leplace

* Turn starting switch OFF. - CNSM4 male

D275A-2

20-213 0

3%3lY&Wl?&

l l O

G-13 16.1, Ir *

[Abnormality in shoe slip control command] is displayed

The battery voltage should be 20 - 30 V. The ELPC voltage between CNSMI (I) and (12) should

be 20 - 30 V.

Cause

YES

* Turn starting switch ON.

tween CNSSl (13) and (11) 0.9

4 * Turn starting switch ON. ND

qemedy

Defective ELPC controller

?eplace

System has been reset

Defective contact, disconnection, or short circuit in wiring harness between CNSSI (131 and CNSMI (9)

3epair or eplace

Defective shoe slip controller

seplace

YES

Does abnormality appear again? System has been reset

G-13. Related

electrical

Shoe slip controller

circuit diagram

ELPC controller

Sensor GND SSC command Acceleration sensor (GND) SSC command

20-214 0

0275A-2

G-14 El,

[Disconnection,

short circuit in solenoid

system]

is displayed

If there is a short circuit or disconnection when engine is running: 1) Engine speed rises, then becomes manual operation. 2) Engine does not stop. Ir When engine is stopped: 1) Engine starts but becomes manual operation. _ 2) Engine does not stop. AStop the engine. (push the fuel lever of the fuel injection pump to the NO INJECTION position.) before carrying out the inspection. * Before carrying out troubleshooting, check that all the related connectors are properly inserted. * Always connect any disconnected connectors before going on the next step. Cause

qemedy

YES I-

Is resistance- between each pin of CNSMl (female) and between each pin and chassis as

3YES

>efective ELPC controller

3eplace

Disconnection in wiring harless of applicable pin No. CNSMI - CNS08 - CNSIO :NSM3}

Defective solenoid * Disconnect CNSMB.

G-14. Related

CNSMI

electrical

circuit diagram

CNSIO

CNSM3 ELPC solenoid

ELPC controller 17MF02182

Table 1

D275A-2

20-215 0

q Green Red

G-15 * * *

l l

[Abnormality

in shoe slip controller]

is displayed

The battery voltage should be 20 - 30 V. Check that fuse No. 4 is normal. If it is blown, repair or replace the wiring harness between CNSS2 (13) - CNSMI Always connect any disconnected connectors before going on the next step.

YES

Is voltage between CNSS.2 _ :b”’ ;gndWyhassls

5 * Turn starting switch ON.

G-15. Related

electrical

Defective shoe slip controller

Replace

System has been reset

Defective contact or disconnection in wiring harness be Repair or tween CNSSP (14) - CN122 (61 replace - chassis ground

YES

* Turn starting switch ON.

Remedy

* Turn starting switch OFF.

Cause

Does abnormal.kY appear again?

Is resistance beYES tween CNSS2 0% _ male) (14)anddmssislessthan 1M 3

Is voltage between CNSSP (13) and (14) 20 - 30 v? . Turn starting switch ON.

YES

(1 j(2) - CN361 (1 I).

Defective contact or discon nection in wiring harness be tween CNSS2 (13) - CNSMl (1X2) - CN361 (II)

Repair or replace

Defective contact or discon nection in wiring harness be tween fuse No. 4 inlet ant battery terminal (+I

Replace

circuit diagram

Relav box

Shoe slip controller .-

jjFF

CNSSZ Power source i (24V)

GND

I L_ ELPC controller

1 Battery

Starting

switch

17MF02183

20-216 0

D275A-2

[Abnormality *

It Ir

in power

Check that fuses No. 1 and 4 are normal. If they are blown, short the wiring harness between (I I,(2). The battery voltage should be 20 - 30 V. Always connect any disconnected connectors

source] is displayed

fuse No. 4 - CN361 (11) - CNSS2

(13) - CNSMI

before going on the next step.

Cause

Remedy

Defective shoe slip controller

Replace

Is voitage between CNSSZ (13) - (14). CNSMI (l)(2) - (12)

Replace

Repair or replace

* Turn starting switch ON.

Y * Turn starting switch ON.

-1 ‘ES 5 1Is voltage between starting _

. Turn starting switch ON.

electrical

_ NO

6 YES Is voltage betweenCN361(1) _ and chassis 20 30 W _ ND

Defective contact or disconnection in wiring harness between starting switch BR CN161 (2) - CN122 (5) - battery relay BR

Repair or replace

Defective starting switch

Replace

Defective contact or disconnection in wiring harness be tween CN161 (1) - CN361 (1) fuse No. 1

Repair or replace

circuit diagram

Shoe slip,controller ---

Relay box --

Fuse

CN361

CNSSP

Power source -@4d)

Repair or replace

--i

G-16. Related

battery relay

LtEZe

GND @---

__I

ELPC controller

Starting switch Power source (24W

Sub controller

GND

17MF02103

D275A-2

20-217 0

30 DISASSEMBLY

Method of using manual ............................ .30- 3 Precautions when carrying out operation . . 30- 4 Special tool list ............................................. 30- 6 STARTING MOTOR Removal. ................................................. 30-13 Installation .............................................. 30-13 ALTERNATOR .30-l 4 Removal ................................................. Installation ............................................. .30-l 4 ENGINE OIL COOLER Removal .................................................. 30-15 Installation ............................................. .30-15 TORQUE CONVERTER OIL COOLER Removal ................................................. .30-16 Installation .............................................. 30-16 FUEL INJECTION PUMP Removal ................................................. .30-17 Installation .............................................. 30-17 WATER PUMP Removal .................................................. 30-18 Installation .............................................. 30-18 TURBOCHARGER Removal .................................................. 30-19 .30-19 Installation ............................................. NOZZLE HOLDER Removal ................................................. .30-20 Installation .............................................. 30-20 CYLINDER HEAD Removal ................................................. .30-2 1 Installation .............................................. 30-25 FUEL TANK Removal ................................................. .30-26 Installation .............................................. 30-26 RADIATOR AND FRONT GUARD Turning over.. ........................................ .30-27 .30-27 Installation ............................................. RADIATOR Removal ................................................. .30-28 Installation .............................................. 30-28 RADIATOR GUARD Removal .................................................. 30-29 Installation ............................................. .30-31

AND ASSEMBLY

ENGINE Removal .................................................. Installation .............................................. DAMPER Removal .................................................. Installation .............................................. Disassembly .......................................... Assembly ................................................ POWER TRAIN UNIT Removal .................................................. Installation .............................................. Disconnection ......................................... Connection ............................................. PTO, TORQUE CONVERTER Disconnection ........................................ Connection ............................................. TORQUE CONVERTER Disassembly ........................................... Assembly ............................................... PTO Disassembly ........................................... Assembly ................................................ TORQFLOW TRANSMISSION Disassembly ........................................... Assembly ................................................ STEERING CASE Disassembly ........................................... Assembly ............................................... STEERING CLUTCH, BRAKE Disassembly ........................................ Assembly ............................................. TRANSFER GEAR HOUSING Disassembly ........................................ Assembly ............................................. TORQUE CONVERTER VALVE Removal ............................................... Installation .......................................... Disassembly ......................................... Assembly ............................................. TRANSMISSION CONTROL VALVE Removal ............................................... Installation .......................................... Disassembly ....................................... Assembly .............................................

30-32 30-34 30-35 30-36 .30-37 30-38 30-40 30-42 30-43 30-45 .30-46 30-47 30-48 .30-53 30-55 30-63 30-68 30-78 30-91 .30-94 .30-100 .30-104 .30-108 .30-l 10 .30-l 12 ..30-112 30-I 14 .30-l 16 .30-l 17 ..30-117 ..30-118 .30-l 19

30-l @

STEERING CONTROL VALVE Removal ................................................ 30-120 Installation ............................................ 30-120 Disassembly ........................................ .30-122 Assembly .............................................. 30-I 22 SCAVENGING PUMP Removal ................................................ 30-124 Installation ............................................ 30-124 POWER TRAIN PUMP Removal ................................................ 30-125 Installation ............................................ 30-125 FINAL DRIVE Removal ................................................ 30-126 Installation ............................................ 30-127 Disassembly ......................................... 30-I 28 Assembly .............................................. 30-136 TRACK FRAME Removal ................................................ 30-148 Installation ............................................ 30-148 IDLER YOKE Reinoval ............................................ .30-148-l Installation ........................................ .30-148-2 RECOIL SPRING Removal.. .............................................. 30-149 Installation ........................................ .30-150-3 Disassembly ...................................... 30-150-4 Assembly ........................................... 30-150-4 IDLER Removal ................................................ 30-152 Installation ............................................ 30-152 Disassembly ........................................ .30-153 Assembly .............................................. 30-154 TRACK ROLLER Removal.. .............................................. 30-156 Installation ............................................ 30-156 Disassembly ......................................... 30-157 Assembly .............................................. 30-158 CARRIER ROLLER Removal ................................................ 30-I 59 Installation ............................................. 30-159 Disassembly ......................................... 30-160 Assembly .............................................. 30-161 TRACK SHOE Removal ................................................ 30-163 Installation ........................................ .30-l 63-2 Overall disassembly ........................... .30-164 Overall assembly ................................ .30-169 Press-fitting jig dimension table for link press .................................. 30-184 Field disassembly of one link ............. 30-185 Field assembly of one link.. ............... .30-187 Disassembly of master link ............... .30-189 Assembly of master link .................... .30-191 PIVOT SHAFT TWISTING SEAL Removal ................................................ 30-194 Installation ............................................ 30-194

30-2 0

PIVOT SHAFT Removal ................................................ 30-195 Installation ............................................ 30-195 EQUALIZER BAR Removal ................................................ 30-196 Installation ............................................ 30-198 EQUALIZER BAR SIDE BUSHING Removal ................................................ 30-199 Installation ............................................ 30-200 SUSPENSION CUSHION Removal ................................................ 30-201 Installation ............................................ 30-20 1 SEGMENT TOOTH Removal ................................................ 30-202 Installation ............................................ 30-202 HYDRAULIC PUMP Removal ................................................ 30-203 Installation ........................................... .30-203 BLADE LIFT VALVE Removal ................................................ 30-204 Installation ............................................ 30-204 Disassembly ......................................... 30-206 Assembly .............................................. 30-208 BLADE TILT, RIPPER LOW VALVE Removal .... _........................................... 30-210 Installation ............................................ 30-2 10 Disassembly ......................................... 30-212 Assembly .............................................. 30-214 RIPPER HIGH VALVE Removal ................................................ 30-216 Installation ............................................ 30-216 Disassembly ......................................... 30-218 Assembly .............................................. 30-220 BLADE LIFT CYLINDER Removal ................................................ 30-222 Installation ............................................ 30-222 BLADE TILT CYLINDER Removal ................................................ 30-223 Installation ............................................ 30-223 RIPPER LIFT CYLINDER Removal ................................................ 30-224 Installation ............................................ 30-224 RIPPER TILT CYLINDER Removal ................................................ 30-225 Installation ............................................ 30-225 HYDRAULIC CYLINDER Disassembly ......................................... 30-226 Assembly .............................................. 30-228 WORK EQUIPMENT Removal ............................................... .30-231 Installation ............................................ 30-232 Disassembly ........................................ .30-233 Assembly .............................................. 30-235 RIPPER Disassembly ......................................... 30-236 Assembly .............................................. 30-237

METHOD OF USING MANUAL

1. When removing (1) (2)

or installing

unit assemblies

When removing or installing a unit assembly, the order of work and techniques used are given for the removal operation; the order of work for the installation operation is not given. Any special techniques applying only to the installation procedure are marked m, and the same mark is olaced after the relevant step in the removal procedure to indicate which step in the installation procedure it applies to. (Example) REMOVAL OF 0 0 0 ASSEMBLY

. . . . . . . . . Title of operation

Precautions related to safety when carrying out the A .................................. operation 1. xxxx (1) ........................... * ................................ 2.

A A A (2):

. . . . . .._................

Step in operation Technique or important point to remember when removing XXXX (1). m Indicates that a technique is listed for use during installation

3. 0 Cl q 0 assembly (3) n

. . . . . . .._......................

INSTALLATION l

OF 0 0 0 ASSEMBLY

See Lubricant and Coolant Table

....

Title of operation

Carry out installation in the reverse order to removal. m.............................. Technique used during installation * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : Technique or important point to remember

Adding water, oil . . . . . . . . . . . . . . . . . . * .............................. Q

..........................

when in-

stalling A A A (2). Step in operation Point to remember when adding water or oil Quantity of filling oil and water

2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given together as PRECAUTION WHEN CARRYING OUT OPERATION, so be sure to follow these precautions when carrying out the operation. 3. Listing of special tools (1)

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

30-3 0

PRECAUTIONS

WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] 1. Precautions . . . . . . . . . l

when carrying out removal

work

If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering. When draining oil, prepare a container of adequate size to catch the oil. Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. Check the number and thickness of the shims, and keep in a safe place. When raising components, be sure to use lifting equipment of ample strength. When using forcing screws to remove any components, tighten the forcing screws alternately. Befor removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. Precautions when handling piping during disassembling Fit the following blind plugs into the piping after disconnecting 1) Hoses and tubes using sleeve nuts Sleeve nut (elbow end) Use the two items below as a set

Nominal number

Plug (nut end)

07376-50210

07221-20210

(Nut), 07222-00210

(Plug)

07376-50315

07221-20315

(Nut), 07222-00312

(Plug)

0737650422

07221-20422

(Nut), 07222-00414

(Plug)

]

07376-50522

] 07221-20522

(Nut), 07222-00515

(Plug)

1 07376-50628

/07221-20628

(Nut), 07222-00616

(Plug)

1 07376-51034

107221-21034

(Nut), 07222-01018

(Plug)

07376-51234

07221-21234

(Nut), 07222-01219

(Plug)

it during disassembly operations.

2) Split flange type hoses and tubes Nominal number

Flange (hose end)

Sleeve head (tube end)

Split flange

07379-00400

07378-l 0400

07371-30400

07379-00500

07378-l 0500

07371-30500

3) If the part is not under hydraulic pressure, the following corks can be used.

i Taper l/8

n -a 1

-0 ?a 7

ZOZF2001

2. Precautions

. . *

. . .

operations

Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pin or lock plate securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 - 3 drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with antifriction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side. When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1. Start the engine and run at low idling. 2. Operate the work equipment control lever to operate the hydraulic cylinder 4 - 5 times, stopping 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. * When using the machine for the first time after repair or long storage, follow the same procedure.

3. Precautions

for installation

when completing

the operations

If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine to circulate the water through the system. Then check the water level again. If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been removed for repair, always bleed the air from the system after reassembling the parts. * For details, see TESTING AND ADJUSTING, Bleeding air. Add the specified amount of grease (molybdenum disulphide grease) to the work equipment related parts.

30-5 0

SPECIAL TOOL LIST

Nature of work

Symbol

Removal of radiator guard assembly

Installation of dumper Assy

Disassembly, assembly of torque converter assemblv

Part Name

Parts No.

Q’ty

Remarks

791-654-I 100

Remover

790-I 01-2102

Puller (30 t)

790-I 01-l 102

Pump

791-600-I 100

Installer assembly

195-12-11210

Plate

790-I 01-4200

Puller (30t)

790-I 01-l 102

Pump

790-413-I 010

Bracket

790-501-5200

Repair stand

790-415-I 011

Bracket

790-501-5200

Repair stand

791-615-I 130

Push tool

I:lutch piston

791-615-I 200

Ring assembly

Installment of snap I-ing of No. 4 carrier

791-615-1101

Ring assembly

799-301-I 600

3il leak tester

791-622-I 1 IO

3racket

790-337-I 032

_ifting tool

791-627-I 210

‘late

791-627-I 320

shackle

0101 O-52090

3olt

791-627-I 400

3emover assembly

790-I 01-2102

Puller (30 t)

790-I 01-l 102

Pump

790-431-1801

Remover assembly

791-627-I 260

Plate

790-I 05-I 100

Cylinder (30 t)

790-I 01-l 102

Pump

791-627-I 600

Remover assembly

790-I 01-2102

Puller (30 t)

790-I 01-l 102

‘ump

Removal of guard pin

IPress-in of ,dumper bearing

IFor overseas

Disassembly, assembly of TORQFLOW transmission assembly

Disassembly and assembly of steering case Ass’y

Removal, installation of final drive assembly

Disassembly, assembly of final drive assembly

30-6 Co

IRemoval of No.5

Installment of snap

I.ing of No. 2 and 3 (3peration check of (:lutch piston f3emoval of cluth

kxa ke Ass’y

fRemovable of final -c drive Ass’y

-r Removal of’ sprocket bearing

IRemoval of Irubber bushing

-1 qemoval, press_I iitting of carrier Ilin

Nature of work

Symbol

Parts No.

Part Name

791-627-l 200

Remover assembly

Remarks

W 1

Fitting of pinion and gear

790-I 01-2102 790-I 01-l 102

6 Disassembly, assembly of final drive assembly

z 2 6

791-627-I 250

Guide

791-627-I 300

Installer assembly

790-I 01-2102

Puller (30 t)

790-I 01-l 102

Pump

791-627-I 700

Installer assembly

790-I 01-2102

Puller (30 t)

790-I 01-l 102

Pump

791-627-I 500

Installer assembly

790-I 01-2102

Puller (30 t)

790-I 01-l 102

Pump

791-627-I 280

Installer

791-775-I 110

Spacer

791-635-3160

Extension

790-I 01-l 600

Cylinder (70 t)

790-I 01-l 102

Pump

Press-fittings of center bearing

Press-in of carrier pin

_ Press-fitting of _ sprocket bearing

Installation of floating seal

791-630-I 300

Removal, installation of recoil spring assembly

790-I 01-2102 790-I 01-l 102 791-685-8500 or 790-434-I 700

Disassembly, assembly of recoil spring assembly

I 1 I I 1 I

I 1 I

791-630-I 200 1

790-I 01-2102 790-I 01-l 102

Assembly of front idler assembly

791-630-I 400

J 2

790-I 01-2102

hiss-i-zf

floating

790-I 01-l 102 3

791-515-I 520

Installer

Installation of floating seal

30-7 0

track roller assembl

Assembly of track roller Ass’y

Disassemby and assembly of track roller Ass’y

Removal of center bar bushing

Replacement of equalizer side bushing

791-650-I 800

Remover & installer

790-I 01-2102

Puller (30 t)

790-I 01-l 102

Pump

790-502-I 003

1 Repair stand

790-5&3000 2

Disassembly and assembly of hydraulic cylinder

790-I 02-3802

Multi wrench

790-I 02-3300

Wrench

790-720-I 000

Expander

796-720-I 670

Ring

07281-01279

Clamp

796-720-I 690

Ring

30-8 a

Press-in of side

- spherical bushing

07281-02169

Clamp

796-720-I 690

Ring

07281-01919

Clamp

Removal of cylinder head nut Expansion of piston ring Blade lift cylinder Blade tilt and ripper lift cylinder Ripper tilt cylinder

_E 5 -z % % ym + z

g ? z

Nature of work Removal of pin plug of lubricated track link

Symbol

Parts No.

791-646-7531 I

Cleaning of pin of lubricated truck link

791-660-7460

Part Name

I I

Remover

Brush

Remarks

I I

’

For washing pin I

791-646-7900

Push tool

For lage plug

791-932-I 1 IO

Push tool

For small plug

Installation of seal of lubricated track link

791-632-I 030

Push tool

For F3 type seal

Air tightness check of lubricated track link

791-601-I 000

Oil pump Ass’y

Filling of lubricated track link with oil

791-646-8002

Lubricator

Installation of pin plug of lubricated track link

791-601-I 000

oil pump assembly I

Track link remover

790-434-I 1 IO

Adapter

790-434-l 610

buide

195-32-61210

Bolt

I I

0101 O-51 440

1Bolt

790-101-1102

1 I

I Shoe bolt may be used

I Pump

I ’

790-I 01-4300

I Cylinder

1150tons

791-685-9510

I Frame

791-685-9520

I Frame

791-685-9530

1Rod

791-685-9550

1Nut

791-685-9560

1Bolt

790-434-I I 20

I Adapter

I I I I I I

1 1 1 1 4 ’

I I I I I I

0101 O-51 030

1Bolt

1 I

04530-I 2030

I Eye bolt

790-101-1102

I Pump

790-I 01-4300

Cylinder

791-685-9540

Rod

791-685-9550

Nut

791-685-9510

Frame

791-685-9520

Frame

I 1 I I 1 I

150 tons

30-9 0

Nature of work

Track link remover

Track link Installer

30-10 0

Symbol

Parts No.

Part Name

Remarks

Nature ofwork

Symbol

PartsNo.

Part Name

Remarks

Q'ty

791-685-9510

Frame

791-685-9520

Frame

791-685-9530

Rod

791-685-9540

Rod

791-685-9550

Nut

791-685-9560

Bolt

791-126-0150

Adapter

01010-51030

Bolt

791-685-9620 1Extension

791-680-5550

1Guide

790-434-1140

IAdapater

791-680-9630

1Adapter

790-101-1102

~Pump

I I I

1 1 1

I I I

790-101-4300

s1 E

Track link Installer

790-434-1160 791-685-9510 791-685-9520

Frame

791-685-9530

7 -

791-685-9540

Rod

791-685-9550

Nut

791-685-9560

Bolt

791-126-0150

Adapter

790-434-1150

Guide

790-434-1120

Adapter

01010-51030

Bolt

790-434-1160

Guide

790-101-1102

Pump

I I

1 I 1 I

790-101-4300

Cylinder

790-101-1102

Pump

790-101-4200

Puller

1150tons

30tons

30-11 0

Nature of work

Track link remover & installer

30-12 0

Symbol

Parts No.

Part Name

o’tv

Remarks

791-680-9801

Remover & installer

KIT For lubricated type

790-I 01-l 102

Pump

790-I 01-4200

Puller

30 tons

790-I 01-4300

Cylinder

150 tons

REMOVAL OF STARTING MOTOR ASSEMBLY Disconnect the cable from the negative (-) A terminal of the battery. Disconnect wiring (1) and (2). Disconnect wiring connector (3). Remove starting motor assembly (top) (4). Remove

starting

motor

assembly

(bottom)

(5).

INSTALLATION OF STARTING MOTOR ASSEMBLY . Carry out installation in the reverse order to removal.

30-l 3 @

REMOVAL Serial

OF ALTERNATOR

ASSEMBLY

No. : 10001 - 10167

Drsconnect the cable from the negative minal of the battery.

Disconnect

Remove

adjustment

Remove

fan belt cover (3).

Remove

mounting

Remove

belt (5).

Remove

alternator

wiring

ter-

(I 1. bolt (2).

bolt and nut (4). a assembly

(6).

F19703003

INSTALLATION OF ALTERNATOR ASSEMBLY Serial l

No. : 10001 - 10167 Carry out installation removal.

in the reverse order to

pq *

Adjust the alternator belt tension. For details, see TESTING AND ADJUSTING.

30-14 @

REMOVAL

OF ALTERNATOR

ASSEMBLY

Serial No. : 10168 and up

ADisconnect the cable from the negative minal of the battery.

(-1 ter-

1. Disconnect wires (I) and (2). 2. Loosen mounting bolts (3) of alternator assembly. 3. Loosen locknut (4), then rotate adjustment nut (5) and remove V-belt (6). 4. Remove bolts (7) and (31, then remove alternator assembly (8) together with belt cover. a

INSTALLATION OF ALTERNATOR ASSEMBLY Serial No.: 10168 and up -

Carry out removal.

installation

in the

reverse

order

Adjusting tension of alternator belt * Adjust the tension of the alternator belt. For details, see TESTING AND ADJUSTING.

30-14-l @

REMOVAL

OF ENGINE OIL COOLER ASSEMBLY

Drain cooling

water.

Remove adiabatic covers (I), (21, and (3). * The adiabatic covers are installed to Serial No. 10168 and up.

Remove

turbocharger

Remove

torque

converter

oil cooler

connector

engine

oil cooler

assembly

(3).

Serial No. : 10168 and UD

outlet tube (I).

(2). 5.

Remove

INSTALLATION OF ENGINE OIL COOLER ASSEMBLY .

Carry out installation removal.

Refilling with water * Add water to the specified level from filter port, and run the engine to circulate the water through the system. Then check the water level again.

in the reverse order to

30-l 5 @

REMOVAL

OF TORQUE CONVERTER

OIL COOLER ASSEMBLY

No . : 10001 - 10167

Serial

1. Drain cooling water. 2. Remove cover (1). 3. Disconnect heater hose (2). 4. Remove

engine oil cooler drain plug assem-

bly (3). 5. Disconnect torque converter and outlet hoses (4) and (5). 6. Remove tor (6).

torque

converter

oil cooler

inlet

oil cooler connec-

7. Remove torque converter oil cooler assembly (7). &I kg

Torque converter oil cooler assembly: 75 kg

F19703004

INSTALLATION OF TORQUE CONVERTER OIL COOLER ASSEMBLY Serial l

No . : 10001 - 10167

Carry out installation removal.

in the reverse order to

Refilling with water * Add water to the specified level from filler port, and run the engine to circulate the water through the system. Then check the water level again.

30-l 6 @

REMOVAL Serial 1. 2. 3. 4. 5. 6. 7. 8. 9.

OF TORQUE CONVERTER

OIL COOLER ASSEMBLY

No.: 10168 and up

Remove engine underguard. Drain coolant. Open engine right side cover (I) and remove side cover (2). Remove side covers (3), then remove side cover stay. Remove water inlet tube (4). Remove water outlet tube (5). Disconnect oil inlet hose (6). Disconnect oil outlet hose (7). Sling torque converter oil cooler assembly (81, remove mounting bolts, then lower assembly to remove. &I kg

Torque

converter

CED01240

oil cooler assembly : 75 kg

INSTALLATION OF TORQUE zs CONVERTER OIL COOLER ASSEMBLY Serial

No . : 10168 and up

Carry out removal.

Refilling with water Add water to the specified level, and run the engine to circulate the water through the system. Then check the water level again.

installation

in the

reverse

order

30-l 6-1 8

REMOVAL Serial

OF FUEL INJECTION

PUMP ASSEMBLY

No. : 10001 - 10167

Close the fuel supply valve.

Disconnect

4 fuel supply hoses (1).

Disconnect

fuel control

Remove

Disconnect

Remove

injection

pump coupling

Remove

coupling

bolts (7).

Remove

fuel injection

pump assembly

(8).

L%kg

Fuel injection

pump assembly:

a 30 kg

lubrication

rod (2).

tubes (3) and (4).

6 fuel injection

tubes (5).

cover (6).

zs INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY Serial .

No . : 10001 - 10167

Carry out removal.

installation

in the

reverse

order

a w

Sleeve

nut:

22.1 2 2.5 Nm i2.25 + 0.25 kgm} w

Fuel injection mounting bolt: 53.9 f 19.6 Nm I5.5 = 2.0 kgm} Adjust the fuel injection timing. For details, see TESTING AND ADJUSTING.

30-17 8

REMOVAL Serial

OF FUEL INJECTION

PUMP ASSEMBLY

No. : 10168 and up

1. Open engine left side cover (I), then remove side covers (2) and (31, and side cover stay. 2.

Close fuel supply valve.

Remove bracket (4), oil level gauge control rod (6).

Disconnect

Remove lubrication tubes (8) and (9), and boost compensator tube (IO).

Disconnect

Remove

Loosen mounting bolts (13) at drive shaft end and remove 4 pump mounting bolts (14).

Remove fuel injection gether with coupling. r+ kg

(51, and fuel m

4 fuel hoses (7).

6 delivery

coupling

tubes (II).

cover (12).

Fuel injection

pump

assembly

pump assembly

(15) tom

: 30 kg

INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY Serial .

No. : 10168 and up

Carry out installation removal.

* *

reverse

order

Adjust the fuel control rod. For details, see TESTING AND ADJUSTING, Adjusting fuel control linkage.

Adjust the injection timing. For details, see TESTING AND ADJUSTING, Adjusting fuel injection timing. Bleed the air from the fuel circuit.

30-l 7-l @

in the

CED01332

ROMOVAL Serial

OF WATER PUMP ASSEMBLY

No. : 10001 - 10167

1. Drain cooling water. 2. Remove torque tor (1).

converter

oil cooler connec-

3. Remove water tube (2). 4. Remove water pump assembly (3).

INSTALLATION OF WATER PUMP ASSEMBLY Serial

No . : 10001 - 10167

Carry out installation der to removal.

Refilling with water * Add water to the specified level from

in the reverse

or-

filter port, and run the engine to circulate the water through the system. Then check the water level again.

30-18 @

REMOVAL

OF WATER PUMP ASSEMBLY

Serial No. : 10168 and up

z z

Drain coolant.

Open engine right side cover (I), then remove side covers (2) and (3), and side cover stay.

Remove torque (4) and (5).

converter

Remove

water

tube (6).

Remove

water

pump

oil cooler connectors

assembly

(7).

INSTALLATION OF WATER PUMP ASSEMBLY

CED01507

Serial No.: 10168 and up . .

Carry out removal.

installation

in the

reverse

order

Refilling with water Add water to the specified level, and run the engine to circulate the water through the system. Then check the water level again.

30-l 8-1 @

REMOVAL

OF TURBOCHARGER

ASSEMBLY Serial

Remove adiabatic covers (II, (2), and (3). + The adiabatic covers are installed to Serial No. 10168 and up.

Remove

Disconnect

Remove

turbocharger

outlet tube (3).

Remove

turbocharger

assembly

(4).

Turbocharger

assembly:

30 kg

r&lkg

intake connector turbocharger

No. : 10168 and up

(1). inlet hose (2).

‘-

CEDOl939

INSTALLATION OF TURBOCHARGER ASSEMBLY . Carry out installation in the reverse order to removal.

a * m

Fit the gasket with the TOP mark facing up. Mounting bolt: 49.0 = 4.9 Nm I5 + 0.5 kgm}

30-19 @

REMOVAL OF NOZZLE HOLDER ASSEMBLY

1. Remove exhaust pipe. (Only for No. 4 to 6.) &

Exhaust pipe: 30 kg

2. Remove radiator top cover and 4 engine side covers at top on left and right. (Only for No. 4 to 6.) * For No. 1 - 3, remove only the top left engine side cover. 3. Lift off hood (3). (Only for No. 4 to 6.) Pl kg

Hood:

85 kg

4. Disconnect Komaclone tube. Lift off air cleaner assembly (1). (Only for No. 4 to 6.) & kg

Air cleaner assembly:

35 kg

5. Remove cover (2). (Only for No. 1 to 3.) 6. Remove cover (3). (Only for No. 4 to 5.) 7. Remove Komaclone tube (4), then bracket (5). (Only for No. 6.)

remove

8. Remove clamp, then remove fuel pipe (6). (Only for No. 2 to 6.) m * For No. 1, disconnect.

injection

9. Disconnect spill connection (8).

remove

10.

hose

(7),

then

Remove cylinder head cover (9).

11. Remove nozzle holder assembly (IO).

INSTALLATION OF NOZZLE HOLDER ASSEMBLY l

Carry out removal

installation

in the

reverse

order

m m

Sleeve

nut: 22.05 + 2.45 Nm I2.25 +. 0.25 kgm)

Cylinder head cover mounting bolt: 31.85 + 2.45 Nm i3.25 + 0.25 kgm}

Nozzle holder mounting bolt: 26.95 + 2.45 Nm I2.75 2 0.25 kgm} Tighten the nozzle holder mounting bolts uniformly. Set the nozzle holder with the match mark facing the front of the engine, then install.

* *

30-20 @

REMOVAL

OF CYLINDER HEAD ASSEMBLY

1. Drain coolant. 2. Remove exhaust

pipe.

Exhaust pipe : 30 kg r&l 3. Rikove radiator top cover, then and right engine side covers. 4. Lift off hood. Hood : 85 kg &I Komaclone 5. DLiconnect cleaner assembly (1). r&Ikg

6. 7. 8. 9.

Air cleaner

tube,

assembly

remove

and

4 left

lift off

air

: 35 kg

Remove intake connector (2). Remove cover (3). Remove intake connector (4). Disconnect flange (5) of Komaclone

tube.

r: 4

2 z

Serial No. : 10168 and UD 10. Remove adiabatic covers (371, (38), and (39). * The adiabatic covers are installed to Serial No. 10168 and up.

11. Disconnect turbocharger inlet hose (6). 12. Remove turbocharger outlet tube (7). 13. Remove muffler drain tube (8).

and exhaust mani14. Sling muffler, turbocharger, fold as an assembly, the lift off muffler, turbocharger, and exhaust manifold assembly (9). a &I kg

15. 16. 17. 18. 19.

Remove Remove Remove Remove Remove

Muffler, turbocharger, assembly: 160 kg

exhaust

manifold

cover (IO). 6 injection pipes (II). Komaclone tube (12). inlet tube (13). turbocharger bracket (I 4).

20. Disconnect wiring connector (15). 2 hoses (16), and move 21. Disconnect (17) down. 22. Remove 2 tubes (18), then remove resistor (19). 23. Remove breather (20).

fuel filter corrosion

Serial No. : 10168 and up

tube (40) at in24. Disconnect boost compensation take manifold end. tube is installed to The boost compensation * Serial No. 10168 and up.

30-22 @

25. Using eyebolt sembly (21).

el kg

remove

Intake manifold

as-

manifold

intake

m assembly

: 50 kg

26. Remove spill tube (22) and connection (23). In the case of No. 5 and 6, disconnect wiring * connector (24) and ground connection (25), then remove bracket (26).

/hV 27. Using forcing screws 0,

I’

17MFQ2214

remove head cover (27). m

/-\

28. Remove rocker arm assembly (28). loosen the locknut, then loosen + ment screw 2 or 3 turns.

17MF02215_

m the adjust-

30-23

29. 30. 31. 32.

Remove Remove Remove Remove

push rod (29). crosshead (30). flange (31). nozzle holder assembly

(32).

m 33. Remove rocker arm housing. 1) Remove pin (33), the use a bar to lever pipe (34) and move it. 2) Remove mounting bolts, then remove rocker arm housing (35).

34. Using eyebolts 0, bly (36). r+ k’d

30-24 8

Cylinder

remove

cylinder

head assembly

head assemm

: 40 kg

INSTALLATION OF CYLINDER HEAD ASSEMBLY .

Carry out removal.

installation

in the

reverse

order

@ -i 1 w .

Exhaust manifold mounting bolt : 1st step: 0 - @: 49 2 9.8 Nm 6 = 1 kgm1 2nd step: @I,@: 88.2 d 9.8 Nm {9 2 1 kgm} m -@: 110.3 + 12.3 Nm ill.25 c 1.25 kgm} Mounting bolt (2 places marked *) : Anti-friction compound (LM-P)

Sleeve

17MF02216

nut : 22.1 = 2.5 Nm I2.25 + 0.25 kgm}

m m l

Intake manifold mounting bolt : 1st step: 0 - @: 24.5 + 4.9 Nm I2.5 r 0.5 kgm1 2nd step: @I - 8: 63.7 f 9.8 Nm (6.5 + 1.0 kgml

a w

Cylinder

head cover mounting bolt : 31.9 + 2.5 Nm I3.25 2 0.25 kgm}

Clean the oil holes of the mounting bolts before installing. Check that the ball of the adjustment screw is fitted properly into the socket of the push rod. Adjust the valve clearance. For details, see TESTING AND ADJUSTING, Testing and adjusting valve clearance. Rocker arm assembly mounting bolt : 98 = 4.9 Nm {IO 2 0.5 kgm} Locknut : 67.7 + 9.8 Nm I6.9 r 1 kgm}

Adjust

I I 17MF02217

M the crosshead

as follows.

1) Loosen the locknut and turn back the adjustment screw.

2) Press down lightly with a finger on the top of the crosshead and screw in the adjustment screw. w Locknut: 39.2 c 5.9 Nm (4 f 0.6 kgm} w

Flange mounting bolt : 27 z 2.5 Nm I2.75 d 0.25 kgm1

Rocker arm housing mounting bolt : 98.1 +. 4.9 Nm {IO f 0.5 kaml

30-25 @

* * * * *

If any rust of more than 5 mm square is found on the shaft or the thread of the bolt, replace the head bolt with a new bolt. Be careful to check that there is no dirt or mounting surface of the dust on the cylinder head or inside the cylinder. Check that the grommet does not come out when installing the gasket. Tighten the cylinder head mounting bolts 2 hand, then tighten in the - 3 turns by order given in the diagram. After tightening, make one punch mark on the bolt head to indicate the number of times it has been tightened. . If any bolt already has five punch marks, do not reuse it. Replace it with a new bolt. ro1, Mounting bolt : Anti-friction compound (LM-P) QEI Cylinder head mounting bolt :

6162F311

Serial No. : 10001 - 10167 1st step : 77.5 2 14.7 Nm I7.9 = 1.5 kgm} 2nd step : 230.5 + 14.7 Nm (23.5 2 1.5 kgm} 3rd step : 382.5 r 14.7 Nm I39 f 1.5 kgm} Final tightening torque: 495.2 + 14.7 Nm j50.5 + 1.5 kgm}

Serial No. : 10168 and up

Make

cylinder

marks on head and

bolt

1st step : 98.1 2 9.8 Nm {IO + 1 kgm} 2nd step : 186.3 z 4.9 Nm I19 f 0.5 kgm} 3rd step : Make marks with paint on the bolt and head, then tighten bolt a further 60”t’zZ.

Refilling with water Add water to the specified level, and run the engine to circulate the water through the system. Then check the water level again.

Tighten

bolt

SO’;!5’ DBD03028

30-25-l @

REMOVAL OF FUEL TANK ASSEMBLY

1. Remove rear cover (1). 2. Close 2 fuel valves (2). 3. Disconnect hose (3). 4. Remove hose mount brackets (4) and (5) with hoses still installed. Disconnect wiring connector

(6).

Remove side cover at left side of cab. ’ 17MF02218

Disconnect hose (8). Lift off tank (9). * Be careful that the hose bracket does not get caught when lifting off. & kg

Fuel tank assembly:

1,150 kg (When tank is full)

liti

INSTALLATION OF FUEL TANK ASSEMBLY l

Carry out installation removal.

I 30-26 8

in the reverse order to

198FO2412

I z

TURNING OVER RADIATOR AND FRONT GUARD ASSEMBLY

1. Drain cooling water. 2. Disconnect radiator outlet tube (I), move it to side. 3. Remove radiator top cover. 4. Disconnect ground connector (3).

connection

(2)

and

5. Disconnect aeration hose (4). 6. Disconnect (5).

radiator

7. Disconnect hose radiator sub-tank.

inlet tube

(6) between

of connector

radiator

and

8. Sling radiator and front guard assembly, then disconnect left and right brackets (7) and cap. Lower radiator and front assembly slowly, and secure radiator and front assembly (9) with wire (8).

INSTALLATION OF RADIATOR AND FRONT GUARD ASSEMBLY l

Carry out installation removal.

in the reverse order to

Refilling with water * Add water to the specified level from filler port, and run the engine to circulate the water through the system. Then check the water level again.

I97FO302

30-27 0

REMOVAL OF RADIATOR ASSEMBLY

1. For details,

see TURNING OVER RADIATOR AND FRONT GUARD ASSEMBLY.

2. Remove left and right bottom mounting brackets. 3. Sling radiator assembly, then remove left and right top caps (2). 4. Raise radiator assembly slowly, then remove radiator assembly (3). * Be careful not to damage the core when removing the assembly. I9 kg

Radiator assembly:

INSTALLATION ASSEMBLY l

Carry out installation removal.

30-28 0

350 kg

OF RADIATOR

in the reverse order to

I97FO3023

REMOVAL OF RADIATOR GUARD ASSEMBLY

Lower the work equipment ground.

completely

to the

1. Sling blade lift cylinder, and remove cap (1) and shim (2) of piston rod. m * Check the number and thickness of the shims, and keep in a safe place. 2. Run engine, and retract piston rod of blade lift cylinder fully. * After disconnecting the blade cylinder, install it to the lock pin on the body to hold it in position.

3. Drain cooling water. 4. Remove radiator outlet hose (3).

5. Remove exhaust pipe. & kg

Exhaust pipe: 30 kg

6. Remove radiator right side covers.

top cover

and 6 left and

7. Lift off hood. g H f15 z

& kg

Hood:

85 kg

8. Remove cover, and disconnect 2 blade hoses (4). g

Operate the control levers several times to release the remaining pressure in the hydraulic piping.

9. Disconnect aeration hose (5) at radiator end. 10. Disconnect end.

radiator

inlet hose (6) at radiator

11.

Disconnect 2 cooler hoses (7).

12.

Disconnect wiring connector (8).

30-29 @

Serial

Serial No. : 10001 - 10167

No. : 10001 - 10167

nut (9), adjustment then push tension pulley, and remove fan m belt (IO) from pulley. Be careful when pushing the tension pul+ ley, as the pulley will rotate.

13. Loosen fan belt tension

'162Fl40

Serial No. : 10168 and UD Serial

No. : 10166 and up

13. Loosen tension of tension pulley (91, and a remove fan belt (IO). Ir Using a chain block, pull in the direction shown in the diagram on the right to loosen the tension of the tension pulley belt.

IO CEDOl944

14. Remove lock bolt (I 1). 15. Sling radiator guard assembly, pull out rear pin (12). Ir Repeat the operation in the same order on the opposite side. If pin (12) is stiff, disconnect the track * and use tool A to remove pin (12).

16. Using tool A, pull out front pin (13). J, Repeat the operation in the same on the opposite side.

30-30 @

order

17. Lift off radiator guard assembly (14) slowly. * Be extremely careful not to damage the core when removing. &I kg

Radiator

guard

assembly

: 2400 kg

INSTALLATION OF RADIATOR GUARD ASSEMBLY . Carry out installation in the reverse order to removal.

Adjust so that the play at the spherical portion in the axial direction is within 0.5 mm, and check that it rotates smoothly. Standard shim thickness C : 4 mm

197F381

Bleed the air from the cylinder. For details, see TESTING AND ADJUSTING.

Adjust the fan belt tension. For details, see TESTING AND ADJUSTING.

30-3 1 8

REMOVAL ADisconnect terminal

OF ENGINE ASSEMBLY

the cable from of the battery.

1. Drain coolant. 2. Remove exhaust

the negative

(-1

pipe.

Exhaust pipe : 30 kg &I radiator top cover and left and right 3. Rikove side covers. 4. Lift off hood. Hood : 85 kg &I 2 cab front steps and intake port 5. Rihove cover. 6. Disconnect starting motor wiring (1). 7. Remove cover (2). 8. Remove 2 connectors (3) of torque converter oil cooler. 9. Disconnect radiator outlet hose (4).

Serial

No.

: 10001

- 10167

Serial No . : 10001

- 10167

nut (5) and remove fan IO. Loosen adjustment a belt (6) from pulley. Be careful when pushing the tension pul* ley, as the pulley will rotate.

Serial

No.

: 10168

and

Serial No. : 10168 and up

10. Loosen tension pulley (5) and remove fan belt (6). Using a chain block, pull in the direction * on the right to shown in the diagram loosen the tension of the tension pulley belt.

CEDO1945

30-32 @

11. 12. 13. 14. 15.

Disconnect radiator inlet hose (7). Disconnect aeration hose (8). Remove 2 covers (9). Disconnect 2 air conditioner hoses (IO). Disconnect wiring connector (I I).

16. 17. 18. 19.

Disconnect Disconnect Disconnect Disconnect

fuel control rod (12). 2 fuel hoses (13). ground wire (14). 2 wiring connectors (15).

Disconnect Komaclone cleaner assembly (16).

el kg

Air cleaner

tube, and lift off air

assembly

: 35 kg

21. Remove 2 battery cables (17). 22. Disconnect fuel control intermediate 23. Disconnect wiring connector (19).

rod (18).

24. Disconnect 25. Disconnect 26. Disconnect

2 air conditioner hoses (20). 2 heater hoses (21). 2 ELPC valve hoses (22).

27. Remove clamp (23) of receiver move receiver tank to left. 28. Lift off bracket (24). r&lkg

tank,

then

Bracket : 65 kg

29. Remove damper 30. Lift off universal

level gauge joint (26).

(25). m

17MF02239

m 31. Lift off engine assembly (27). + When removing the engine assembly, check that all wiring and piping has been disconnected, and use a lever block to prevent interference with any parts, and lift off with the front slightly raised. Be particularly careful to make sure that the front mount does not hit the radiator guard mount. &I kg

30-34 (EC

Engine assembly

: 3,000 kg

17MF02239

INSTALLATION ASSEMBLY

OF ENGINE

in the reverse order to

Carry out installation removal.

Adjust the fan belt tension For details, see TESTING AND ADJUSTING.

m w

Universal joint mounting bolt : 110.3 f 12.3 Nm III.25 f 1.25 kgm)

Engine mount cap mounting bolt : 926.7 + 103 Nm I94.5 f 10.5 kgm}

Refilling with water Add water to the specified level, and run the engine to circulate the water through the system. Then check the water level again.

30-34-l 8

REMOVAL OF DAMPER ASSEMBLY

1. Using transmission underguard (1). L+lkg

Underguard:

jack

remove

rear

360 kg

2. Remove drain plug and drain damper. : Damper: Approx. 2.1 e u

oil

from

3. Sling universal joint (2), then remove mounting bolts, and remove universal joint. m I98FO245

4. Remove oil level gauge guide (3). 5. Remove mountino bolts and holder (4). . ,. then remove coupling T5). 1#21

3 ’ I

6. Remove retainer (6).

17MF02242

17MF02243

Sling damper cover (7), remove mounting bolts, then screw in 3 forcing screws and m remove. the guide bolt approx. 200mm) A Set so that the damper cover will not come (Q =

out suddenly. & kg

Damper cover: 60 kg

8. Using eyebolts 0, sling damper assembly (8), then remove mounting bolts and lift off. m

A PI kg

Set the forcing screws (a = approx. 200mm) so that the damper cover will not come out suddenly. Damper assembly:

17MF02244

17MF02245

75 kg

9. Remove bearing (9) from flywheel.

17MF02246

30-35 0

INSTALLATION

Carry out installation removal.

OF DAMPER ASSEMBLY

in the reverse order to

Universal joint mounting bolts: 11.25 + 1.25 kgm

N~I&

Holder mounting bolt thread: Thread tightener

Holder mounting bolt: 28.25 + 3.25 kgm

(LT-2)

Install damper cover (7) as follows. 1) Using guide bolt (n = 200mm), set the damper cover in position. 2) Using tool B, press fit bearing.

Use a guide bolt (Q = approx. 200mm) position the damper assembly.

Fill 50% of the clearance at the hatched portion in the diagram with grease (G2-U) (approx. 11 g).

Refilling with oil * Add-engine oil to the specified level, and run the engine to circulate the engine oil through the system. Then check the water level again.

30-36 0

17MF02247

DISASSEMBLY

OF DAMPER ASSEMBLY

Disassembly of damper assembly

1. Set damper assembly to block 0. 2. Remove mounting nut (I), then using forcing screws 0, remove flange (2).

17MF02249

17MF02250

6. Remove shaft (3).

4. Remove rubber (4). 5. Using forcing screws from body (6).

remove

flange

(5)

5 17MF02251

6 17MF02252

6. Remove seal (7) from flanges (2) and (5).

Disassembly of damper cover assembly

7. Remove bearing cover (IO).

(8) and

oil seal

(9) from

8. Remove oil seal (11) from retainer (12).

17MF02255

30-37 0

ASSEMBLY OF DAMPER ASSEMBLY

Assembly of damper assembly Flange

1. Install seal (7) to flanges (2) and (5). *

Install the seal so that the lip is facing the inside as shown in the diagram.

Seal

17MF02256

2. Align bolt holes and install flange (5) to body (6). H-XI&

Flange mating surface: Gasket sealant

11 1

17MF02257

(LG-4)

A Check that there are no dents, rust, oil, grease, or water on the mating surface, then coat both the faces of the flange and body with gasket sealant.

17MF02258

3. Set flange and body assembly then set shaft (3) in position.

to block 0, Shaft

4. Assemble rubber (4). a

When assembling the rubber, coat the whole surface of the rubber, the outside circumference of the shaft, and the inside circumference of the body with grease (G2-LI).

After assembling the rubber, fill the clearance between the shaft and body (16 places) approx. 30% with grease (G2-LI) (approx. 190s).

!ara

Body 17MF02259

17MF02260

5. Install flange (2). &

Flange mating surface: Gasket sealant

(LG-4)

A Check that there are no dents, rust, oil, grease, or water on the mating surface, then coat both the faces of the flange and body with gasket sealant. 6. Tighten mounting nut (1).

17MF02261

30-38 0

Assembly of damper cover assembly

7. Using push tool 0, retainer (12). a *

Oil seal press-fitting surface: Gasket sealant

(LG-1)

Coat the inside surface of the retainer thinly with gasket sealant, and wipe off any sealant that is squeezed out. Lip of oil seal: Grease (G2-LI)

8. Using push tool 0, cover (IO).

9. Using push tool 0, cover (10). &I?s *

press fit oil seal (11) to

press fit bearing

17MF02262

17MF02263

17MF02264

(8) to

press fit oil seal (9) to

Oil seal press-fitting surface: Gasket sealant

(LG-1)

Coat the inside surface of the cover thinly with gasket sealant, and’wipe off any sealant that is squeezed out.

&I?+

Lip of oil seal: Grease (G2-LI)

30-39 0

1. Draining oil Hydraulic tank: Approx. 95 e Power train unit: Approx. 120 Q 2. Remove fuel tank assembly. For details, see REMOVAL ASSEMBLY.

OF FUEL TANK

3. Remove floor frame assembly. For details, see REMOVAL OF FLOOR FRAME ASSEMBLY. C17MF02266

4. Sling universal joint assembly (2), then remove mounting bolts, and lift off universal joint assembly. m 5. Remove control lever bracket (3) from frame, and move it towards power train unit assembly. 6. Disconnect 2 connectors of wiring (4). 7. Disconnect torque converter cooler hose (5). 8. Disconnect hydraulic oil sensor connector, and remove tube (6). 9

wiring

Disconnect 3 hoses (7).

10. Disconnect 5 ripper circuit hoses (8) at valve end, and move them towards side frame. 11. Disconnect hose (9) between ripper Hi valve at valve end.

pump

and

12. Disconnect pin puller hoses (IO). 13. Remove fuel hose clamps, (11) to side.

and move hoses

14. Remove mount bolt (12) and mount cap (13). m 15. Loosen clamp (14), and move it to outside. m 16. Using forcing screws 0, remove cover (15). 17. Using forcing screws 0, pullout shaft (16). * If the shaft does not come out, use jack 0 to move the sprocket backwards or forwards and adjust to a position where the shaft will come out.

18. Lift off power train unit assembly (17). * Be sure to disconnect all wiring and piping before removing the power train unit assembly. kg C?l

Power train unit: 3,600 kg

I98FO2467

I96FO2469

I96FO2470

INSTALLATION

Carry out installation removal.

in the reverse order to

Universal joint:

Mounting bolts: 94.5 + 10.5 kgm

Mount cap: 94.5 f

11.25 f

1.25 kgm

10.5 kgm

Clamp the peaked portion of the coupling seal securely, and assemble so that the clamp threaded portion is parallel to the seat surface of the cap mount. m

OF POWER TRAIN UNIT ASSEMBLY

Housing clip: 0.675 f

0.175 kgm

Refilling with oil * Add oil to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again.

30-42 0

DISCONNECTION

OF POWER TRAIN UNIT ASSEMBLY

Remove power train unit assembly. For details, see REMOVAL OF POWER TRAIN UNIT ASSEMBLY.

1. Set power train unit assembly (1) on block 0. 2. Remove steering control cables (2) together with bracket. 1111 3. Remove transmission together with bracket. 4. Disconnect (5).

control m

cables . (3)

3 rods (4), and remove

bracket

5. Remove clamps (6) of central pressure detecting hose at 4 places, disconnect 9 hoses, then remove hose bracket assembly (7). * Before disconnecting the hoses, mark with tags to show their mounting positions. 6. Disconnect wires (8) at connectors, clamps, then remove wiring.

remove

7. Remove pin puller hose (9).

17MF02278

8. Sling hydrualic pump (9), remove mounting bolts, then remove pump assembly (9) together with hose. C?kg

35 kg

Hydraulic pump assembly:

9. Remove scavenging pump remove oil filler pipe (11).

piping (IO), then

10. Sling filter assembly

(12), remove bolts, then remove filter assembly.

mounting

11. Sling power train pump and strainer assembly (13), disconnect strainer pipe (14) and clamp bracket (15) of pipe, and remove mounting bolts, then remove pump and strainer assembly (13). & kg

Pump, strainer assembly:

12. Lift off mount bracket (16). & kg

Mount bracket:

55 kg

150 kg

13. Sling scavenging pump (17), remove mounting bolts, then remove pump assembly. & kg

Scavenging

14. Disconnect

clamp,

pump assembly: and remove

40 kg

gauge

tube

(16). 15. Disconnect hose (19). 16. Support center of transmission (height: 500mm).

with block @

17. Sling oil pan (20), remove 4 mounting bolts at bottom and 15 mounting bolts at top, then remove brackets (21) and (22), and oil pan (20). &I kg

Oil pan: 110 kg

18. Sling PTO and torque converter assembly (23), remove mounting bolts, then remove PTO and torque converter assembly (23). lf41 I+ kg

30-44 0

PRO, torque converter assembly: 600 kg

Using a lever block, raise the assembly horizontally, and disconnect it from the transmission.

19. Sling transmission assembly (24), remove mounting bolts, then remove transmissin assembly (24) from steering case assembly (25). Transmission

assembly:

950 kg

& kg Sr Use a lever block, and lift off horizontally from the steering case assembly.

17MF02282

CONNECTION OF POWER TRAIN UNIT ASSEMBLY l

Carry out connection disconnection.

in the reverse order to

m g E 5

Bend the cotter pin securely. )xJ Bend the cotter pin securely. m w

Rotating part of PTO boss: Grease (G2-LI)

Using a lever block, raise the PTO and torque converter assembly horizontally, align it with the spline on the shaft at the steering case side, and install.

30-45 0

DISCONNECTION

OF PTO, TORQUE CONVERTER ASSEMBLY

1. Remove coupling assembly (1). 2. using forcing assembly (2).

screws 0, m 112)

remove

3. Remove shims (3). A Check the number and thickness Sims, and keep in a safe place. 4. Remove (5). m

snap ring (4), then remove

retainer

of the

spacer

5. Remove mounting bolts, then using eyebolts 0, sling PTO assembly. 6. Using forcing screws 0, bly (6). m & kg

PTO assembly:

I-

17MF02283

remove PTO assem300 kg

6 30-46 0

17MF02285

17MF02286

CONNECTION OF PTO, TORQUE CONVERTER ASSEMBLY

Carry out connection disconnection.

in the

reverse

order

Adjust the clearance between the taper roller bearings as follows. 1) Set retainer assembly to housing, and tighten 6 mounting bolts to 1 kgm in turn. 2) Using thickness gauge, measure clearance a between retainer and housing. * When measuring, measure at 4 places (A. . . B. C. D) around the circumference. and take the average value as clearance a. 3) Selecting shim thickness * Shim thickness = Clearance a (0 to +O.O5mm) * The shims are a divided type, so check the number of shims and make sure that the shim thickness is the same on the left and right. j, Standard shim thickness t = 0.15, 0.20, 0.5 4) Assemble selected shim thickness, then tighten retainer assembly to specified torque. w

Mounting bolt: 6.75 f

Retainer

17MF02287

Remova; tap

D \

0 /

\ B

0.75 kgm

Assemble the shim as shown in the diagram on the right so that it does not come at the position of the retainer removal tap.

RerAoval tap

I98FO2487

Removal tap A

Lip of oil seal: Grease (G2-LI)

&I&

O-ring:

Grease (G2-LI)

Check that the snap ring is fitted securely in the groove. Rknoval

tap

I98FO2488

When assembling the PTO assembly, coat the P portion of the shaft with anti-friction compound (LM-P).

30-47 0

DISASSEMBLY

OF TORQUE CONVERTER ASSEMBLY

1. Torque converter assembly Set the torque converter assembly (1) to tools C. 2. Torque converter valve assembly Remove mounting bolts, then using eyebolts 0, remove valve assembly (2). * Remove the 6 mounting bolts that are marked in black.

3. Draining oil Remove drain plug (3) at 2 places and drain oil from pump case. * After draining the oil, tighten the drain plug. m

Plug: 1.15 f

17MF02289

17MF02288

17MF02290

0.15 kgm

4. Lockup clutch, drive case assembly 1) Leaving 2 mounting bolts in place, remove mounting bolts (4). Set so that input shaft is at top, then remove remaining mounting bolts. remove off lockup 3) Using eyebolts 0, clutch and drive case assembly (5).

17MF02291

4) Disassemble lockup clutch and drive case assembly as follows. i) Remove mounting bolts, then using forcing screws 0, remove input shaft (6). ii) Remove snap ring (7), then remove plate (8).

17MF02294

30-48 0

f: 5

iii) Set the clutch housing side facing down, and set block 0 to turbine. iv) Using forcing screws 0, disconnect press-fitting portion of bearing, then remove turbine (9).

v) Remove mounting bolts, then using eyebolts 0, remove housing and piston assembly (10). * When removing, the piston will fall out, so support it by hand. vi) Remove piston (11) from housing (12). vii) Using push tool 0, remove bearing (13) from housing (12).

17MF02296

197F.316

I96FO2497

I96FO2496

197F318

viii) Remove 2 discs (14) and 1 plate (15) from drive case (16) in turn. * Keep the disk and plate in a flat place to prevent distortion.

197F319

5. Stator 1) Remove snap ring (17), then remove stator assembly (18).

17MF02297

30-49 0

2) Remove snap ring (19), then remove race (20) from stator (21). 3) Remoe snap ring (22) from stator (21).

I 98FO2502

I99FO2500

6. Pump assembly 1) Remove pump assembly (23).

17MF02298

2) Remove

mounting bolts, then remove retainer (24). 3) Tap with a plastic hammer, and remove bearing and guide assembly (25) from pump. 4) Using push tool 0, from guide (27).

remove

bearing

2,5

(26)

17MF02299

17MF02300 __-I

7. Stator clutch housing Remove mounting bolts, them remove stator clutch housing (28).

17MFfl7?.1ll

30-50 0

8. Spring Remove spring (29).

9. Discs, plate Remove 2 discs (30) and 1 plate (31) in turn. A Keep the disc and plate in a flat place to prevent distortion.

do $1 IO.

17MF02302

Pin Remove pin (32).

11. Piston Remove piston (33). 12. Gear Remove (35).

snap

ring (34), then

remove

gear

17MF02303

13. Stator shaft, shaft assembly 1) Remove mounting bolts (36).

17MF02304

2) Tap stator shaft and shaft assembly (37) with a plastic hammer to remove from case (38). * When removing the stator shaft assembly, set the case in the condition shown in the diagram. 3) Remove snap ring (39). 4) Remove snap ring (40). 5) Using push tool @, remove shaft assembly (41) from stator shaft assembly (42).

30-51 0

6) Disassemble shaft assembly as follows. i) Remove snap ring (43), then remove inner race (44). ii) Remove collar (45). iii) Remove bushing (46) from shaft (47).

,\ 47

\ //////////////y//////////;//

I 17MF02307

7) Disassemble stator shaft assembly as follows. i) Remove snap ring (48). ii) Using push tool @I, remove bearing (49) from stator shaft (50).

14. Case Remove case (38) from tool c.

I98FO25

30-52 0

ASSEMBLY OF TORQUE CONVERTER ASSEMBLY

Clean all parts, and check for dirt or damage.

Put a few drops of engine oil on the rotating parts of the fearings, and rotate them several times.

Check that the snap ring is fitted securely in the groove.

Coat the seal ring thinly with grease (GPLI).

1. Case Set case (38) to tool C.

5 z

t 2. Stator shaf’t assemblv 1) Assemble stator shaft assembly as follows. i) Using push tool, press fit bearing (49). and secure with snap ring (48). ii) Install seal ring to stator shaft (50).

I98FOZ5

17MF02310

2) Install snap ring (39). 3) Tap stator shaft assembly (42) with a plastic hammer, and press fit bearing portion to case.

17MF02311

30-53 0

3. Shaft assembly 1) Assemble shaft assembly as follows. i) Install bushing (46). * Expand fit the bushing. ii) install collar (45). * Install the collar with the chamfered portion of the outside diamediameter facing down. iii) Using push tool, press fit inner race (44), and secure with snap ring (43). iv) Install seal ring to shaft (47).

2) Install shaft assembly (41). jr Using 2 guide bolts (Thread dia. = IOmm, Pitch = 1.25mm, Length = 60mm), align the oil hole and intall the shaft assembly. 3) Tighten mounting bolts temporarily. 4) Install snap ring (40). 5) Tighten mounting bolts (36) fully. a

Mounting bolt:

Mounting bolt: 6.75 f

Thread tightener (LT-2) 0.75 kgm 17MF02312

4. Gear Fit gear (35) and secure with snap ring (34). 5. Piston 1) Install seal ring to case. 2) Fit seal ring and install piston (33). * Make sure to assemble the seal ring facing in the correct direction. Assemble with the side taking the pressure facing the case as shown in the diagram.

Side.receiving

pressure

17MF02313

6. Pin Remove pin (32).

30-54 0

17MF02304

I?---

17MF02303

7. Discs, plate install 2 discs (30) and 1 plate (31) in turn.

8. Spring Install spring (29).

17MF02302

9. Stator clutch housing Align with dowel pin and fit stator clutch housing (28), then tighten with mounting bolts. j, Make sure that the spring is fitted securely in the piston and housing hole. rr\-

Mounting bolt:

Thread tightener (LT-2)

Mounting bolt: 11.25 f

1.25 kgm

z ;;

10. Pump assembly 1) Using push tool 0, guide (27).

install bearing (26) to

17MF02314

2) Set bearing and guide assembly (25) in pump, then using push tool, press fit bearing portion. * When assembling the bearing and guide assembly, align the guide and pump oil holes. 3) Fit retainer (24), and tighten with mounting bolts. * When installing the retainer, align the retainer and pump oil holes. Thread tightener (LT-2)

fi-

Mounting bolt:

Mounting bolt: 6.75 k 0.75 kgm

17MF02315

17MF02316

30-55 0

4) Install pump assembly (23). When installing the pump assembly, * be extremely careful not to damage the seal ring assembled to the shaft.

17MF02298

11. Stator assembly 1) Install snap ring (22) to stator (21). 2) Fit race (20) to stator (21) and secure with snap ring (19).

3) Fit stator assembly snap ring (17).

(18) and secure with

12. Lockup clutch, drive case assembly 1) Assemble lockup clutch and drive assembly as follows. i) Set turbine (9) to block @,.

case

ii) Using eyebolts 0, to turbine.

30-56 0

set drive case (16)

17MF02297

7MF02317

iii) Install 2 discs (14) and 1 plate (15) in turn.

iv) Install seal ring to housing. v) Fit seal ring to piston (II), and set in housing (12). * When installing, be extremely careful not to damage the seal ring. vi) Using eyebolts 0, fit housing and piston assembly (IO) and tighten with mounting bolts. j, When installing, support the piston by hand to prevent it from falling out, and set it in position in the drive case. Mounting bolt: Thread tightener Mounting bolt: 11.25 f

17MF02318

(LT-2)

1.25 kgm

I96FO2497

196FO2496

vii) Using push tool 0, press fit bearing (13). viii) Fit plate (8) and secure with snap ring (7).

17MF02319

17MF02320

ix) Using eyebolts 0, fit input shaft (6) and tighten with mounting bolts. TV?-

Mounting bolt: Thread tightener

Mounting bolt: 11.25 k 1.25 kgm

(LT-2) 6

x) Install seal ring to input shaft.

17MF02321

30-57 0

2) Using eyebolts 0, set lockup clutch and drive case assembly (5) to pump. A Install a guide bolt (Thread dia. = 1 Omm, Pitch = 1.5mm, Length = 60mm) to the drive case, align the position of the drain plug, and set to the pump. 3) Tighten mounting bolts (4). N-C&

Mounting bolt: Thread tightener

Mounting bolt: 5.5 + 0.5 kgm

(LT-2)

13. Torque converter valve assembly Fit gasket, and using eyebolts 0, install valve assembly (2). * Tighten the mounting bolts uniformly in turn. m

Mounting bolt: 5.0 f

0.5 kgm

14. Torque converter assembly Remove torque converter assembly tool c.

(1) from

30-58 a

17MF02288

DISASSEMBLY

OF PTO ASSEMBLY

1. Idler gear assembly 1) Using eyebolts 0, sling PTO assembly. 2) Remove mounting bolts, then remove plate (1).

17MF02322

3) Face torque converter side down, and set PTO assembly on block. 4) Remove lubrication tube. 5) Remove mounting bolts, then using forcing screws 0, remove shaft assembly (2).

6) Remove plug, then using forcing screws 0, remove bearing (3).

7) Remove spacer (4). 8) Remove idler gear assembly (5) and bearing (6) from bottom.of PTO case.

;

17MF02324

17M:2326

9) Remove outer race (7). IO) Remove snap ring (8).

17MF02326

17MF02327

30-59 0

2. Cover assembly 1) Remove mounting bolts, then using forcing screws 0, remove cover assembly (9).

2) Using

puller

(IO). 3) Using puller 0, gear (12).

remove

gear

assembly

remove bearing (11) from

3. Cover assembly 1) Remove mounting bolts, then using forcing screws 0, remove cover assembly (13).

D--13---

17MF02329

2) Using puller 0, remove bearing (14). 3) Remove mounting bolts, then remove gear (15).

I98FO253

30-60 a

l98FO2532

4) Using push tool 0, remove boss assembly (17) from cage (16). 5) Using forcing screws 0, remove bearing (19) from boss (18).

17MF02330

17MF02331

4. Scavenging pump drive gear 1) Using eyebolts 0, sling PTO assembly. 2) Remove mounting bolts, then remove drive gear (20).

17MF02332

5. Boss 1) Remove snap ring (21) 2) Using push tool, remove boss (22) from bearing pressfitting portion.

17MF02333

3) Remove snap ring (23). 4) Using push tool, remove bearing (24).

30-61 0

Bearing, race assembly 1) Using push tool, remove bearing and race assembly (25).

17MF02336

2) Remove outer race (26).

27 26

7. Sleeve Remove sleeve (27) from PTO case.

17MF02337

30-62 0

ASSEMBLY

OF PTO ASSEMBLY

* *

Clean all parts, and check for dirt or damage. Put a few drops of engine oil on the rotating parts of the bearings, and rotate them several times. j, Check that the snap ring is fitted securely in the groove.

1. Sleeve 1) Face torque conerter side down, and set PTO case on block. 2) Install sleeve (27) to PTO case. * Expand fit the sleeve. 2. Bearing race assembly * Use the bearing and spacer as a set. 1) Using push tool @, press fit outer

race

(26). 17MF02338

8 z

2) Set race (28) to press, then using push tool 0, press fit bearing (29). 3) Assemble spacer (30). 4) Usng push tool 0, press fit bearing (31).

Press

-7///////////y///////

17MF02339

5) Assemble bearing and race assembly (25). * Assemble the bearing and race assembly with the lip of the race at the bottom. 6) Assemble spacer (32). 7) Using push tool ($9, press fit outer

race

(33).

17MF02340

30-63 0

3. Boss 1) Using eyebolts 0, sling PTO assembly. 2) Using push tool, press fit bearing (24) and secure with snap ring (23). 3) Using a plastic hammer, press fit boss (22) to bearing from inside of case.

17MF02342

-22

17MF02341

4) Secure with snap ring (21). 17MF02333

4. Scavenging pump drive gear Install drive gear (20) and tighten with mounting bolts. AI’+m

Mounting bolt: Thread tightener

(LT-2)

Mounting bolt: 6.75 I!I 0.75 kgm

17MF02332

5. Cover assembly 1) Set boss (18) to press, and using push tool @, press fit bearing (19). 2) Using push tool @, press fit boss assembly (17) to cage (16).

30-64 0

3) Install gear (15), and tighten with mounting bolts. 0. m

Mounting bolt: Thread tightener

(LT-2)

Mounting bolt: 11.25 f 1.25 kgm

4) Set cover assembly to press, then using push tool 0, press fit bearing (14).

5) Face torque converter side down, and set PTO assembly on block. fit O-ring and cover 6) Using eyebolts, assembly (13), then tighten with mounting bolts. * Set the cover assembly to the case, and tap uniformly with a plastic hammer to press fit it. /(i7,

O-ring:

Grease (G2-LI)

02344

6. Cover assemblv Set gear (12j to press, using push tool 0, press fit bearing (11). Press fit gear assembly (10). * Press fit the gear assembly with the spling portion on the inside of the gear at the top.

17MF02345

17MF02346

Using eyebolts, fit O-ring and cover assembly (9), then tighten with mounting bolts. * Set the cover assembly to the case, and tap uniformly with a plastic hammer to press fit it. AXA-.

O-ring:

Grease (G2-LI)

30-65 0

7. Idler gear assembly * Match the production number and set number on the inside and outside of the bearing and the spacer to make sets when assembling. 1) Install snap ring (8). 2) Using push tool, press fit outer race (7). 3) Set idler gear (5) to bottom of PTO case.

17MF02327

17MF02326

4) Set shaft to press, and using push tool 0, press fit bearing (3).

1 I98FO2549

I 5) Using bolts 0, fit O-ring and align shaft assembly (2) with idler gear, and assemble temporarily. * Set the shaft assembly to the case, and tap uniformly with a plastic hammer to press fit it. Leave approx. 5 mm space to make it easier to assemble the spacer and bearing. H-X&-

O-ring:

Grease (G2-LI)

6) Using eyebolts, turn over PTO assembly. 7) Assemble spacer (4).

30-66 0

17MF02349

8) Using copper bar, press fit bearing (6).

17MF02350

9) Fit plate (1) and tighten with mounting bolts. &IL

Mounting bolt: Thread tightener

(LT-2)

Mounting bolt: 11.25 f 1.25 kgm m sling PTO assembly and eyebolts, Using 10) tighten shaft assembly fully. 11) Fit gasket and install lubrication tube. 8. Measuring 1) After completing the assembly, check the backlash between the idler gear and the and gear drive pump train power hydraulic pump drive gear. 2) When measuring, put the probe of the dial gauge at right angles against the face of the gear tooth at the tip of the being gear Hold the gear. idler in place and measure the measured readling when the idler gear is moved backwards and forwards. * Standard value for backlash: 0.204 -0.516 mm * Measure at three or more places on diametrically opposite sides.

17MF02351

30-67 0

DISASSEMBLY

OF TORQFLOW TRANSMISSION

ASSEMBLY

Keep the disc and plates in a flat place to prevent distortion.

1. Transmission assembly Set transmission assembly (1) to tool Dl.

I97FO3OU

2. Plate Remove nut, then remove with sleeve (3). 3. Cover Remove (4).

mounting

plate (2) together

bolts, then remove

4. Charging pump assembly Remove mounting bolts charging pump assembly seat.

cover

(5), then remove (6) together with

5. Lubrication valve assembly Remove mounting bolts, then remove lubrication valve assembly (7).

6. Case Remove mounting bolts, then use forcing screws 0 to remove case (18). * When removing the case, use a chain block and lift the case off slowly.

17MF02354

30-68 a

7. Input shaft, No. 1 carrier assembly A Make match marks on each plate and the housing. 1) Remove tie bolt (9). 2) Using forcing screws 0, disconnect inpu shaft and No. 1 carrier assembly (IO), use eyebolts 0 to remove. A Screw in the forcing screws uniformly to disconnect the No. 1 carrier assembly.

3) Disassemble input shaft and No. 1 carrier assembly as follows. . Disassembly of input shaft assembly i) Remove snap ring (11, then remove No. 2 sun gear (12). ii) Remove snap ring (13). iii) Set input shaft and No. 1 carrier assembly to block 0, then tap with copper hammer to remove input shaft assembly (14).

17MF02357

17MF02358

17MF02359

iv) Set input shaft assembly (14) to press, and remove bearing (15).

v) Remove spacer (16). vi) Using push tool, remove No. 1 sun gear (17) and spacer bearing (18).

30-69 0

vii) Set spacer bearing on block 0, then use push tool to remove bearing (19) from spacer (20). viii) Set spacer bearing on block 0, then use push tool to remove bearing (21) from spacer (20).

17MF02363

17MF02364

Disassembly of No. 1 carrier assembly i) Remove inside snap ring (22). ii) Set No. 1 carrier assembly on block, then use push tool @ to remove No. 1 carrier assembly (24) from plate (23).

I97FO3077

I97FO3076

SI 2

iii) Remove spacer (25) from No. 1 carrier assembly (24). 25,

I97FO3076

iv) Remove

snap

ring

(26)

from

plate

(23). v) Using push tool 0, (27).

remove

bearing

i3 I97F0307E

30-70 0

I 97FO308

vi) Remove snap ring (28), then remove collar (29). vii) Pull out shaft partially, remove ball (30), then remove shaft (31). j, Be careful not to lose the ball, and keep it in a safe place.

17MF02365

I97FO3083

viii) Remove gear (32) and thrust washer (33) from carrier, then remove bearing (34) from gear.

/“’ 17MF0236E

8. Spring Remove spring (35). 9. No. 1 discs, plates, springs Remove springs (36), discs (37), and plates (38) in turn. 10. No. 1 ring gear Remove No. 1 ring gear (39). 11. No. 1 housing assembly Using eyebolts 0, remove No. 1 piston (40) together with No. 1 housing (41).

17MF02367

30-71 0

12. Spring Remove spring (42). 13. No. 2 discs, plates. springs Remove springs (43), discs (44), and plates (45) in turn. 14. Torque pins Remove torque pins (46).

17MF02368

15. No. 2, 3 carrier assembly 1) Using eyebolts @, remove No. 2 and 3 carrier assembly (47) together with ring gear. Ir Sling the carrier, then insert a bar in the ring gear holes and lever the carrier to remove it.

17MF02369

17MF02370

197FO3085

2) Disassemble No. 2 and 3 carrier assembly as follows. i) Remove ring (48). ii) Pull out shaft partially, remove ball (49), then remove shaft (50). * Be careful not to lose the ball, and keep it in a safe place.

iii) Remove gear (51) and thrust washer (52) from carrier, then remove bearing (53) from gear. * The ring is held in position by the internal pushing force, so do not disassemble carrier and ring gear (54).

30-72 0

16. No. 2 ring gear Remove No. 2 ring gear (55).

17MF02371

17. No. 2, No. 3 housing assembly Using eyebolts 0, remove No. 2, 3 housing (57) together with No. 2 piston (56).

17MF02372

18. No. 3 piston Remove No. 3 piston (58).

17MF :02373

19. Spring Remove spring (59). 20. Guide pin Remove guide pin (60) 21.

No. 3 discs, plates, springs Remove springs (61), discs (62) and plates (63) in turn.

If& EG

17MF02374

30-73 a

22.

Plate Using eyebolts 0, remove plate (64).

MF02375

23.

No. 4 discs, plates, springs Remove springs (65), discs (66), and plates (67) in turn.

24. Torque pins Remove torque pins (68).

I 25.

No. 4 housing assembly Using eyebolts 0, remove No. together with No. 4 housing (70).

26. Collar Remove (71).

mounting

piston

bolts, then remove

collar

17MF02376

17MF02377

27.

17MF02378

No. 5 clutch assembly 1) Using eyebolts @I, sling No. 5 clutch assembly (72), then tap bottom of output shaft with a copper hammer to remove.

30-74 CD

17MF0237S

2) Disassemble .

No. 5 clutch assembly as follows. Disassembly of No. 4 carrier assembly i) Remove snap ring (73), then remove No. 3 sun gear (74). ii) Remove bearing and collar (75). iii) Set bearing and collar on block 0, then use push tool‘to remove bearing (76) from collar (77).

-197F030&3 11 ‘d

17MF02380

17MF02381

iv) Using eyebolts @, remove No. 4 carrier assembly (78) together with No. 4 sun gear (79). v) Remove No. 4 sun gear (79). vi) Remove hub (80). A Be careful not to damage the seal ring when removing. vii) Remove snap ring (81), then remove collar (82).

17MF02382

17MF02383

------lI

17MF02384

17MF02385

viii) Remove shaft partially, remove ball (83), then remove shaft (84). A Be careful not to lose the ball, and keep it in safe place. ix) Remove gear (85) and thrust washer (86) from carrier, then remove bearing (87) from gear (85).

30-75 a

x) Remove snap ring (88). xi) Using push tool, remove bearing (89). * The ring is held in position by the internal pushing force, so do not disassemble carrier and No. 3 ring gear (90).

89 /

I l

17MF02388

17MF02389

Disassembly of output shaft, housing assembly i) Remove mounting bolts, use forcing screws @I to disconnect output shaft and housing assembly (91), then use eyebolts @I to remove. A Screw the forcing screws in uniformly to disconnect the output shaft and housing assembly.

17MF02390

ii) Remove springs (92), discs (93), and plates (94) from drum (95) in turn.

17MF02391

17MF02392

iii) Set output shaft and housing assembly in press, and using push tool @, remove housing assembly (96) from output shaft assembly (97). * Set block @ in position to prevent the housing assembly from falling out.

I97FO3

30-76 0

IO5

iv) Set housing assembly (96) to press, then use tool D2 to compress spring. * Operate the press slowly and push the spring down uniformly. v) Remove snap ring (98). then remove retainer (99), spring (IOO), and piston (101).

17MF02393

(

17MF02394

vi) Remove snap ring (102), then using push tool, remove bearing (103).

197F03106

197FO3107

vii) Remove snap ring (104), then remove bearing (105) from output shaft. viii) Remove snap ring (106), then remove bearing (107) from output shaft.

I97FO3

28. Snap ring Remove snap ring (108). 29.

I OE

108

Bearing Using push tool, remove bearing (109).

30. Collar Remove (110).

mounting

bolts, then remove

31. Case Remove case (11) from tool Dl.

collar

17MF02395

17MF02396

30-77 0

ASSEMBLY

* *

ASSEMBLY

Clean all parts, and check for dirt or damage. Put a few drops of engine oil on the rotating parts of the bearings, and rotate them several times. Coat the sliding surfaces of all parts with engine oil before installing. Install the piston seal ring with the side receiving the pressure facing the housing, coat it with grease (G2-LI), and install it uniformly so that it does not move to one side. N-^-\~~

OF TORQFLOW TRANSMISSION

Rotation seal ring: Fix in position with grease (G2-LI), and be extremely careful that it does not get caught when assembling.

Side receiving

I-

pressure

l97F337

Check that the snap ring is fitted securely in the groove. Make match marks on each plate and the housing when disassembling.

1. Case Set case (111) to tool Dl. 2. Collar 1) Install seal ring to collar. 2) Fit collar (110) and tighten with mounting bolts. j, Install the seal ring so that the side receiving the pressure faces down.

cc2

17MF02397

3. Output shaft assembly Using push tool, press fit bearing (105) and secure with snap ring (104). Set output shaft to press, then using push tool 0, press fit bearing (109). Install seal ring to output shaft. Using eyebolts, set output shaft assembly (97) to case, then using push tool @ press fit bearing portion. 17MF02398

30-78 0

5) Install snap ring (108). 6) Fit collar (71) an tighten bolts. /?L

with

mounting

Mounting bolt: Thread tightener

(LT-2)

Mounting bolt: 6.75 f 0.75 kgm

17MF02400

4. No. 5 clutch assembly 1) Assemble No. 5 clutch assembly as follows. Assembly of No. 4 clutch assembly l i) If No. 3 ring gear and No. 4 carrier are supplied as individual parts, use tool D3, and with ring (112) compressed, set No. 3 ring gear (90) on No. 4 carrier, then tap No. 3 ring gear with a plastic hammer to assemble. j, Check that the ring is fitted securely in the groove. lS;Fd3I

ii) Using push tool, press fit bearing and secure with snap ring (88).

1511

--__

17MF02401

(89)

17MF02402

bearing (87) to gear (85), iii) Assemble then fit thrust washers (86) to both ends and set to carrier. iv) Fit ball (83) and press fit shaft (84). * Check that the gear rotatessmoothly.

b/acg$d 83

17MF0236;

17MF02366

30-79 a

v) Install seal rng to collar. vi) Install collar (82) and secure with snap ring (81). * Align the collar with the dowel pin, and tap with a plastic hammer to install. vii) Install seal ring to hub. viii) Install hub (80) to No. 4 carrier assembly (78).

17MF02385

Assembly of housing assembly i) Using eyebolts 0, set drum No. 4 carrier assembly.

17MF02403

(95) to

17MF02404

ii) Install discs (93), springs plates (94) in turn. * No. of discs: 5 Sr No. of plates: 4 * No. of springs: 5

(92),

and

17MF02405

17MF02406

iii) Using push tool, press fit bearing (103), and secure with snap ring (102).

197FO31

30-80 0

iv) Install seal ring to piston. v) Set piston (IOI), spring (IOO), and retainer (99) to housing. * Set the 3 springs as shown in the diagram. vi) Set housing assembly (96) in press, then using tool D2, compress spring and secure with snap ring (98). * Operate the press slowly and press the spring down uniformly.

17MF02407

17MF02393]

vii) Using eyebolts @, fit housing assembly (96) and tighten with mounting bolts. ,?_

Mounting bolt: Thread tightener

(LT-2)

Mounting bolt: 18 f 2 kgm

viii) Install seal ring to housing.

17MF02408

Using eyebolts @I, set No. 5 clutch assembly (72) to output shaft.

Using push portion.

tool

press

fit

17MF02379

17MF02409

bearing

30-81 0

5. No. 4 sun gear Install No. 4 sun gear (79). 6. Bearing, collar 1) Set collar (77) on block 0, then using push tool, press fit bearing (76).

cd4

17MF02410

17MF02412

17MF02411

2) Install bearing and collar (75). * Install with the collar lip at the top. 7. No. 3 sun gear Fit No. 3 sun gear (74) and secure with snap ring (73). 8. No. 4 housing assembly 1) Fit seal ring to No. 4 piston, and set in No. 4 housing. 2) Using eyebolts @I, align with dowel pin, and install No. 4 piston (69) together with No. 4 housing (70). * Knock in the area around the dowel pin with a plastic hammer until there is no clearance at the contact surface. 9. Torque pins Install torque pins (68). * Length of torque pin: 162 mm

_--.

17MFr-17377 L

10. No. 4 discs, plates, springs Install plates (67), discs (66), and springs (65) in turn. * No. of discs: 3 A NO. of plates: 3

17MF02376

30-82 0

11. Plate Using eyebolts 0, align with dowel pin and install plate (64). * Knock in the area around the dowel pin with a plastic hammer until there is no clearance at the contact surface.

12. No. 3 discs, plates, springs Install discs (62), springs (61), and plates (63) in turn. h No. of discs: 3 * No. of plates: 2

13. Guide pin Install guide pin (60). 14. Spring Install spring (59). j, Free height of spring:

91 mm

0” z z

17MF02374

15. No. 2,3 housing assembly 1) Install seal rings to No. 2 piston and No. 3 piston. 2) Set No. 2 piston (56) and No. 3 piston (58) to No. 2 and 3 housing (57). * Tie the No. 3 piston and housing with thin wire.

56 \

58’

17MF02413

3) Using eyebolts 0, align with dowel pin and install No. 2 piston (56), No. 2 and 3 housing (57), and No. 3 piston (58) as one unit. * Knock in the area around the dowel pin with a plastic hammer until there is no clearance at the contact surface.

30-83 0

16. No. 2 ring gear Install No. 2 ring gear (55). * Install with the teeth cut on the inside facing up.

17. Sleeve If sleeve (113) has been removed, install to bolt holes marked % in diagram below with slit at bottom.

17MF02371

Slit

17MF02415

18. No. 2,3 carrier assembly 1) Assemble No. 2 and 3 carrier assembly as follows. i) If ring gear and No. 2, No. 3 carrier are supplied as individual parts, use tool D4, and with ring (114) compressed, set ring gear (54) on No. 2, 3 carrier, then tap ring gear with a plastic hammer to assemble.

ii) Assemble bearing (53) to gear (51), then fit thrust washers (52) to both ends and set to carrier.

50 53

30-84 0

__-__ iii) Fit ball (49) and press fit shaft (50). * Check that the gear rotates smoothly. iv) Install ring (48). v) Install seal ring to No. 2 and 3 carrier assembly.

i97FO3085

17MF02370

2) Using_ eyebolts @, install No. 2 and 3 carrier assembly (47) together with ring gear.

17MF02417

3) Using portion

push tool @, press fit bearing of No. 2 and 3 carrier assembly.

17MF02418

19. Torque pins install torque pins (46). * Length of torque pin:

199 mm

20. No. 2 discs, plates, springs Install discs (44), springs (43), and plates in turn. * No. of discs: 5 A No. of plates: 4 21. Spring Install spring (42). A Free height of spring:

70 mm

(45)

7MF02368

30-85 0

22. No. 1 housing assembly 1) Fit seal ring to No. 1 piston and set to No. 1 housing. 2) Using eyebolts 0, align with dowel pin and install No. 1 piston (40) together with No. 1 housing (41). * Check that the spring is fitted securely in the piston and the housing hole. * Knock in the area around the dowel pin with a plastic hammer until there is no clearance at the contact surface. I97FO305

23. No. 1 ring gear Install No. 1 ring gear (39). * Install with the inside teeth facing up. 24. No. 1 discs, plates, springs Install plates (38), discs (37), and springs (36) in turn. * No. of discs: 5 * No. of plates: 5 25. Spring Install spring (35). * Free height of spring: 66 mm

17MF02367

26. Input shaft, No. 1 carrier assembly 1) Assemble input shaft and No. 1 carrier assembly as follows. l Assembly of No. 1 carrier assembly i) Assemble bearing (34) to gear (32), then fit thrust washers (33) to both ends and set to carrier.

17MF02366

ii) Fit ball (30) and press fit shaft (31). * Check that the gear rotates smoothly. iii) Fit collar (29) and secure with snap ring (28).

I97F03083

30-86 0

17MF02365

iv) Using push tool, press fit bearing (27) in plate (23), and secure with snap ring (26). v) install seal ring to plate. vi) Install spacer (25) to No. 1 carrier assembly (24).

i4 17MF02419

I97FO3078

vii) Set plate (23) to No. 1 carrier assembly (24), then using push tool @, press fit bearing portion. viii) Secure with inside snap ring (22).

197FO31

1811

I97F03076

ix) Install No. 1 sun gear (17). x) Using push tool, press fit bearings (21) and (19) to spacer (20).

17MF02420

17MF02421

1 i’MF02422

xi) Using push tool CD, press fit spacer bearing (18). xii) Set spacer (16) in position.

17MF02423

17MF02361

30-87 0

Assembly of input shaft assembly i) Using press, press fit bearing (15) to input shaft. ii) Press fit input shaft assembly (14) to No. 1 carrier assembly, and secure with snap ring (13).

197FO31

17MF02424

iii) Fit No. 2 sun gear (12) and secure with snap ring (11). iv) Install seal ring to No 1 carrier assembly.

17MF02357

2) Using eyebolts 0, align with dowel pin and set input shaft and No. 1 carrier assembly (10) in position. j, Lower slowly and set in position so that the tip of the input shaft does not hit the bearing. * Tap the input shaft with a plastic hammer to press fit the No. 2 carrier and bearing portion.

17MF02425

17MF02426

3) Tighten 4 tie bolts (9) uniformly. 4) Tighten remaining tie bolts (9). w

Tie bolt: 26.5 f 1.5 kgm

5) Install seal ring to input shaft.

17MF02427

30-88 0

28. Air check Using tool D5, check stroke of each piston. * Air pressure: 5 - 6 kg/cm* Unit:

Piston

Standard stroke

6.6 3

4.2

4.7

6.0

17MF02428

29. Case Fit O-ring, then fit case (8) and tighten with mounting bolts. * Lower the case slowly with a chain block.

17MF02429

30. Output shaft bearing 1) Using push tool, press fit bearing (107) to output shaft, then secure with snap ring (106).

17MF02430

31.

Lubrication valve assembly Fit O-ring, then install lubrication valve assembly (7), and tighten with mounting bolts.

32. Control valve assembly Fit O-ring, then install control valve assembly (6) together with seat, and tighten mounting bolts (5). Y-X~

Mounting bolt: Gasket sealant (LG-1)

Mounting bolt: 5 f 0.5 kgm

17MF02353

30-89 a!

33. Cover Fit gasket, then fit cover (4) and tighten with mounting bolts. * Remove plug (115), and align the position of the lever and yoke of the spool. 34.

Plate Fit gasket, then fit plate (2) together sleeve (3), and tighten with nut.

35. Transmission assembly Remove transmission &sembly Dl.

with

I (1) from tool

30-90 a

I97FO3044

DISASSEMBLY

OF STEERING CASE ASSEMBLY

Steering valve assembly Remove mounting bolts, then using shackle 0, remove valve assembly (1).

Clutch, brake assembly Using tool E, sling clutch and brake assembly, remove mounting bolts, then remove clutch and brake assembly (2). * When removing the clutch and brake assembly, be careful not to damage the discs and plates. * Remove the clutch and brake assembly on the opposite side in the same way.

17MF02433

3. Shafts Remove left and right shafts (3). 4. Lubrication tubes Remove lubrication tubes (4) and (5).

I96FO2646

17MF02434

17MF02435

17MF02436

5. Pipes * When removing the pipes, be careful not to damage the O-rings. 1) Remove left and right pipes (6). 2) Remove pipe (7).

6. Seat Remove mounting bolts, then using eyebolts 0, remove seat (8)

17MF02437

7. Input shaft 1) Remove snap ring (9). 2) Remove input shaft (10). 8. Transfer, gear housing assembly 1) Install guide bots 0 to steering case. 2) Using forcing screws 0, pull out housing assembly. 3) Using shackle 0, remove housing assembly (11). 9. Cage 1) Turn over steering case so that R.H. cage is at top. 2) Remove mounting bolts, and using forcing screws, remove bearing cage (12), then remove shim. * Check the number and thickness of the shims, and keep in a safe place. 3) Remove outer race (13) from bearing cage.

17MF02438

17MF02439

17MF02440

17MF02441

13 /

17MF02443

30-92 0

17MF02442

4) Remove mounting bolts, then eyebolts 8, remove cage (14).

using

ed 10. Bevel gear, shaft assembly 1) Using eyebolts, remove shaft assembly (15).

bevel

gear

==Q-h=J

17MF02444

and

2) Assemble bevel gear and shaft assembly as follows. i) Remove nut and pull out reamer bolt, then remove bevel gear (16). ii) Using puller 0, remove bearings (17) and (18) from shaft (19).

17MF02445

11. Cage 1) Turn over steering case. 2) Remove mounting bolts, and using forcing screws, remove bearing cage (20), then remove shim. * Check the number and thickness of the shims, and keep in a safe place. 3) Remove outer race (21) from bearing cage. 17MF02446

17MF02449

7MF02448

30-93 0

ASSEMBLY OF STEERING CASE ASSEMBLY

*Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. 1. Cage Using push tool, press fit outer race (21) in bearing cage.

17MF02449

Assemble shim, then install bearing cage (20), and tighten with mounting bolts. * Standard shim thickness: 2mm m

Mounting bolt: 18 f

2 kgm

MF02449

2. Bevel gear, shaft assembly 1) Assemble bevel gear and shaft assembly as follows. i) Set shaft (19) in press, and using push tool @, press fit bearing (18). ii) using push tool @I, press fit bearing (17).

17MF0244

17MF02451

iii) Set bevel gear (16) to shaft, then fit reamer bolt and tighten with nut. QZT

Nut: 18 + 2 kgm

17MF02452

30-94 0

2) Turn over so that R.H. cage of steering case is at top. 3) Using eyebolts, install bevel gear and shaft assembly (15).

17MF02445

3. Cage 1) Using eyebolts @, fit cage (14) and tighten with mounting bolts. QF

Mounting bolts: 18 f

2 kgm

2) Using push tool, press fit outer race (13) to bearing cage.

17MF02444

17MF02443

3) Assemble shims, then fit bearing cage (12) and tighten with mounting bolts. * Standard shim thickeness: 2mm m

Mounting bolt: 18 f

2 kgm 17MF02442

4. Adjusting preload Put push-pull scale @ in contact with tip of bevel gear teeth, and measure rotating torque of bevel gear shaft. * Standard value for rotating torque: 2.2 2.8 kg * Rotate the bevel gear 2 or 3 truns before measuring the rotating torque. * If the value is not within the standard range, adjust as follows. If torque is too HIGH, INCREASE shim thickness If torque is too LOW, DECREASE shim thickness

30-95 0

5. Transfer, gear housing assembly 1) Install guide bolts @ in steering case. 2) Fit O-ring, then using shackle 0, set housing assembly (11) to steering case, and tighten with mounting bolts. w

Mounting bolt: 18 + 2 kgm

17MF02454 -_6. Adjusting

tooth contact,

backlash

1) Adjusting

backlash Put the probe of dial gauge 0 in contact with the tip of the bevel gear teeth at right angles. Hold the bevel pinion in position, and read the measurement when the bevel gear is moved forward and backward. Sr Standard value for backlash: 0.3 - 0.4mm * Measure at least six points diametrically opposite around the gears. I96FO2664

If the result of the inspection shows that the correct backlash is not being obtained, adjust as follows.

If backlash is too small Adjust shim at bevel pinion side to move bevel pinion in direction A; or adjust shim at bearing cage of bevel gear shaft to move bevel gear in direction B.

Backlashis small

I97F342

Backlashis large

l97F343

If backlash is too large Adjust shim at bevel pinion side to move bevel pinion in direction A; or adjust shim at bearing cage of bevel gear shaft to move bevel gear in direction B. * When adjusting the shim at the bearing cage of the bevel gear shaft, do not change the preload of the bearing. Adjust by moving shims from one side to the other. Always keep the same total thickness of shims.

30-96 0

2) Checking tooth contact Testing i) Coat the tooth face of the bevel pinion (minimum). red lead lightly with Rotate the bevel gear forward and backward and inspect the pattern left on the teeth. ii) Tooth contact should be checked with no load on the bevel pinion. It should be in the center of the tooth height. The tooth contact pattern should be located 20 to 50% from the small end “d”, and should cover 30 to 75% of the length of the tooth. In addition, there should be no strong “a” or contact at the addendum dedendum “b” (tip or root of the gear teeth) or at the big end “c” and small end “d”. If the gears are adjusted to this pattern, the tooth contact will be correct when load is applied. a: Addendum b: Dedendum C: Big end d: Small end

I97F344

e: Width contact f: Center of tooth contact

Adjustment If the result of the inspection shows that the correct tooth contact is not being obtained, adjust again as follows: i) If bevel pinion is too far from center line of bevel gear. Contact is at the small end of the convex tooth face of the bevel gear and at the big end of the concave tooth face. Procedure and adjustment l Adjust the thickness of the shims at the bevel pinion to move the bevel pinion in direction A. Adjust the shim thickness at the bearing cage of the bevel gear shaft to move the bevel gear in direction B. Check the tooth contact pattern and backlash again. ii) If bevel pinion is too close to center line of bevel gear. Contact is at the small end of the concave tooth face of the bevel gear and the big end of the convex tooth face. Procedure for adjustment l Adjust the thickness of the shims at the bevel pinion to move the bevel pinion in direction A. Adjust the shim thickness at the bearing cage of the bevel gear shaft to move the bevel gear in direction B. Check the tooth contact pattern and backlash again. * When adjusting the bevel gear to the right or left, do not change the preload of the bearing. Adjust by moving shims from one side to the other. Always keep the same total thickness of shims.

I97F345

I97F346

fl A l97F347

30-97 0

7. Input shaft 1) Assembly input shaft (10) in case. 2) Secure with snap ring (9).

17MF02439

8. Seat Fit O-ring, then using eyebolts 0, install seat (8), and tighten with mounting bolts.

9. Pipes /-“~

O-ring: When installing coat the o-rings grease (G2-LI).

the pipes, thinly with

1) Fit O-rings to both ends, and install pipe (7). 2) Fit O-rings to both ends, and intall pipe (6).

17MF02435

10. Lubrication tubes Fit gaskets and install lubrication and (5).

tubes

(4)

17MF02434

30-98 0

11. Clutch, brake assembly Fit O-ring, then using tool E, set clutch and brake assembly (2) in steering case, and tighten with mounting bolts. w

Mounting bolt: 18 + 2 kgm installing the lcutch and brake When assembly, be careful not to damage the discs and plates. Install the clutch and brake assembly on the opposite side in the same way.

12. Shafts Install left and right shafts (3). * Procedure for installing shaft 1) Remove plug (22), and screw in bolts (Thread Dia. = 14mm, Pitch = 2.0mm, Length = 90mm) to pull in piston and release brake. 2) Fit right shaft, then rotate bevel gear and install left shaft.

z : ‘0 13. Steering valve assembly Fit gasket, then using shackle 0, assembly (1).

install valve

30-99 0

DISASSEMBLY

OF STEERING CLUTCH, BRAKE ASSEMBLY

Keep the discs and plates in a flat place to prevent distortion.

DISCONNECTION ASSEMBLY

1. Plate Remove (1).

mounting

OF CLUTCH BRAKE

bolts, then remove

plate

bolts, then remove

plate

2. Collar Remove collar (2). 3. Plate Remove (3).

mounting

Sleeve 1) Using forcing (4). 2) Using puller 0, sleeve.

screws

remove

remove bearing

sleeve (5) from

5. Clutch, brake assembly 1) Turn over clutch and brake assembly. 2) Using eyepbolts 0, disconnect clutch assembly (6) and brake assembly (7).

17MF02458

17MF02459

30-100 0

DISASSEMBLY

OF CLUTCH ASSEMBLY

6. Clutch stopper Remove mounting stopper (8).

bolts, then remove clutch /

10 /

7. Discs, springs, plates Remove discs (9), springs (10) and plates (11) in turn. * No. of discs: 8 No. of plates: 8 17MF02460

17MF02461

8. Torque pins Remove torque pins (12). 9. Clutch hub Remove mounting bolts, then using eyebolts Q, remove clutch hub (13).

12 17MF02462

17MF02463

17MF02464

I98FO2675

17MF02465

17MF02466

Plate 1) Remove mounting bolts, then using forcing screws 0, remove plate (14). 2) Remove outer race (15) from plate.

11. Bearing cage assembly 1) Remove bearing cage assembly (16). 2) Disassemble bearing cage assembly as follows. i) Remove mounting bolts, then remove plate (17). ii) Remove nut (18). iii) Remove bearing (19), spacer (20), and bearing (21) from cage (22).

30-101 0

12. Spacer Remove spacer (23). 13. Clutch cage 1) Using eyebolts

23 0,

remove

clutch

cage 24

(24).

17MF02468

17MF02467

2) Using puller, remove outer race (25).

17MF02469

14. Piston Remove piston (26). 15. Belleville springs Remove Belleville springs (27). A No. of Belleville springs: 2

16. Brake hub 1) Turn over clutch housing 2) Remove mounting bolts, then using eyebolts @I, remove brake hub (28) from clutch housing (29). 3) Remove bearing (30) from brake hub (28).

30-l

17MF02470

17MF02471

17MF02472

DISASSEMBLY

OF BRAKE ASSEMBLY

17. Brake stopper Remove mounting stopper (31).

bolts, then remove

brake

18. Discs, springs, plates Remove discs (32), springs (33), and plates (34) in turn. * No. of discs: 8 No. of plates: 7 A Keep the discs and plates in a flat place to prevent distortion.

17MF02473

17MF02474

19. Torque pins Remove torque pins (35).

20. z z z

Brake cage 1) Remove mounting bolts, then using eyebolts 0, remove brake cage (36).

17MF02475

2) Using puller, remove outer race (37). 38 /

21.

Piston Remove piston (38).

17MF02477

22.

Belleville springs Remove Belleville springs (39). * No. of Belleville springs: 3

23.

Outer race Using push tool 0, remove outer race (40).

17MF02478

17MF02479

30-103 0

ASSEMBLY OF STEERING CLUTCH, BRAKE ASSEMBLY

Clean all parts, and check for dirt or damage. &II&

Seal ring: Grease (G2-LI)

Coat the mating surface of the disc and plate with engine oil.

ASSEMBLY

OF BRAKE ASSEMBLY I98FO2690

1. Outer race Using push tool @, install outer race (40). 2. Belleville springs Install Belleville springs (39). * Install the Belleville springs as shown the diagram below.

17MF02480

17MF02481

1. Piston Fit seal ring and install piston (38).

17MF02478

17MF02482

4. Brake cage 1) Using push tool 0, press fit outer race (37). 2) Using eyebolts, fit seal ring, install brake cage (36) and tighten with mounting bolts. w

Mounting bolt: 11.25 + 1.25 kgm

5. Torque pins Install torque pins (35).

17MF024.83

30-104 0

6. Brake hub Using eyebolts 0, set brake hub (28) in brake housing.

7. Discs, springs, plates Install plates (34). springs (33) and discs (32) in turn. * No. of discs: 8 No. of plates: 7

17MF02484

17MF02474

8. Brake stopper 1) Fit stopper (31), then tighten with mounting bolts. m

Mounting bolt: 18 -I 2 kgm

Check that the springs are fitted securely on the torque pins, then tighten the clutch stopper. 2) After installing brake stopper, use eyebolts 0 to remove brake hub (28).

2 z 0’

Assembly

17MF02485

17MF02486

17MF02487

17MF02488

of clutch assembly

9. Brake hub 1) Using push tool @I, press fit bearing (30) to brake hub (28). 2) Using eyebolts, set brake hub (28) to clutch hosing (29), then tighten with mounting bolts. m

Mounting bolt: 18 f

2 kgm

10. Belleville springs 1) Turn over clutch housing. 2) Install Belleville springs (27). * Install the Belleville springs as shown in the diagram below.

17MF02489

11. Piston Fit seal ring and install piston (26).

I96FO2660

17MF02470

30-105 0

12. Clutch cage 1) Using push tool, press fit outer race (25). 2) Assemble spacer (23). 3) Using eyebolts 0, install clutch cage (24).

-lr

( 3

17MF02490

17MF02468

17MF02466

17MF02465

I98FO2675

17MF02491

17MF02463

17MF02462

13. Bearing cage assembly 1) Assemble bearing cage assembly as follows. i) Using push tool, pres fit bearing (21) to cage (22). ii) Install spacer (20). iii) Using push tool, press fit bearing (19). iv) Tighten nut (18). v) Install plate (17), then tighten with mounting bolts. m

Mounting bolt: 2.5 + 1 kgm

2) Press fit bearing cage assembly (16). * Tap the cage assembly with a plastic hammer to press fit.

14. Plate 1) Using push tool, press fit outer race (5). 2) Install plate (14), then tighten with mounting bolts. w

Mounting bolt: 11.25

1.25 kgm

15. Clutch hub Using eyebolts 0, install clutch hub (13) and tighten with mounting bolts. m

Mounting bolt: 5.5 k 2 kgm

16. Torque pins Install torque pins (12).

30-l

17. Discs, springs, plates Install plates (II), springs (10) and discs (9) in turn. A No. of discs: 8 No. of plates: 8 18. Clutch stopper Install clutch stopper (8), then tighten with mounting bolts. A Check that the springs are fitted securely on the torque pins, then tighten the clutch stopper. m l

Stopper mounting bolt: 18 f

Connection assembly

2 kgm

11 17MF02461

17MF02460

of clutch, brake

19. Clutch, brake assembly Using eyebolts 0, set brake assembly position on clutch assembly (6).

(7) in

8 z z

‘6

17MF02492

20. Sleeve 1) Using push tool 0, press fit bearing (5) in sleeve. 2) Fit O-ring and seal ring, then set sleeve (4) in clutch and brake assembly.

17MF02494

21.

Plate Install plate (3), then tighten with bolts. m

mounting

Mounting bolt: 6.75 + 0.75 kgm

22. Collar Install collar (2). 23.

Plate Install plate (I), then tighten with mounting bolts. I98F02667

30-107 0

DISASSEMBLY

OF TRANSFER GEAR HOUSING ASSEMBLY

1. Transfer gear housing assembly Set transfer gear housing assembly on block. 2. Lubrication tube Remove lubrication block.

tube

(1) together

with

3. Bearing cage assembly 1) Remove bearing cage assembly (2). 2) Using push tool 0, remove bearing (3).

17MF02496

17MF02495

4. Drive gear 1) Remove drive gear (4). 2) Using puller 0, remove inner races (5) on both sides of drive gear.

17MF02497

17MF02498

5. Lubrication tube 1) Turn over transfer gear housing assembly. 2) Remove lubrication tube (6). 6. Pinion, housing assembly 1) Remove mounting bolts, then using eyebolts 0, remove pinion and housing assembly (7). 2) Remove shim (8). * Check the number and thickness of the shims, and keep in a safe place. l96FO2698

17MF02499

3) Disassemble pinion and housing assembly as follows. i) Remove mounting bolts, then using forcing screws 0, remove cover (9). ii) Remove holder (10).

17MF02500

30- 108 0

17MF02501

iii) Set pinion gear assembly in press, then using push tool 0, remove pinion gear (11). * When removing the pinion gear, support the bottom of the pinion gear securely with a wooden block. iv) Remove bearing cage assembly (12).

17MF02502

4 Using push tool @, remove outer race (13), bearings (14), and (15), collar (16) and outer race (17). * Keep the bearings and collar as a set. vi) Remove spacer (18) from driven gear (19).

198FO2703 (

198Fl318

vii) Remove holder (20). viii) Using puller 0, pull out inner race (21), From pinion gear.

17MF02503

17MF02504

7. Bearings 1) Using push tool @, remove bearing (22). 2) Using puller, remove bearing (23).

30-l 09 0

ASSEMBLY OF TRANSFER GEAR HOUSING ASSEMBLY

+ Clean all parts, and check for dirt or damage. Coat the sliding surfaces engine oil before installing.

of all parts with

1. Bearings 1) Using push tool @I, press fit bearing (23). 2) Turn over case, then using push too, press fit bearing (22).

17MF02506

2. Pinion, housing assembly 1) Assemble pinion and housing assebly as follows. i) Press fit inner race (21) to pinion gear. ii) Install holder (20). @E Mounting bolt: 28.25 + 3.25 kgm

iii) Set driven gear (19) and spacer (18) to pinion gear (11). iv) Using push tool, press fit outer race (17). v) Assemble bearing (15), collar (16), and bearing (14). vi) Using push tool, press fit outer race (13). * Use the bearings and collar as a set.

I SSFO2705

vii) Set bearing cage assembly (12) on pinion gear, then using push tool @, press fit bearing cage assembly.

17MF02508

30-110 0

viii) Install holder (10). w

Mounting bolt: 28.25

+ 3.25 kgm

10 17MF02501

ix) Fit O-ring, then install cover (9) as follows. l Tighten cover mounting bolts temporarily in the order shown in diagram on right. (Approx. 5 kgm) l Check clearance A between cover and cage, and check that it is as follows. Clearance A: 0.48 f 0.27 mm * Check that the variation around the whole circumference is less than 0.05 mm. Check also that the bearing is completely press fitted and is not at an angle. l After checking the above, tighten the mounting bolts of cover (9) in the order shown in the diagram on the right. w

17MF02509A

17MF02851

Mounting bolt: 6.75 + 0.75 kgm

7MF02852

2) Assemble shim (8). * Standard shim thickness: 2mm 3) Fit O-ring, then using eyebolts 0, pinion and housing assembly (7).

install

3. Lubrication tube Fit gasket and install lubrication tube (6).

30-111 0

4. Drive gear 1) Turn over transfer gear assembly. 2) Using push tool 0, press fit inner races (5) to both sides of drive gear. 3) Set drive gear (4) in case.

17MFO2497

I98F02707A’

5. Bearing cage assembly 1) Using push tool 0, press fit bearing (3). 2) Install bearing cage assembly (2). 6. Lubrication tube Fit gasket and O-ring, and install lubrication tube (1).

30-112 0

17MF02510

17MF02495

)

REMOVAL OF TORQUE CONVERTER VALVE ASSEMBLY

1. Remove floor plate.

2. Disconnect connector (1). 3. Disconnect 4 pressure detection hoses (2). 4. Remove valve assembly (3).

I-/

INSTALLATION

k-F19802211

OF TORQUE CONVERTER VALVE ASSEMBLY

Carry out installation removal.

in the reverse order to

Mounting bolt: 5.0 f

0.5 kgm

30-113 0

DISASSEMBLY

OF TORQUE CONVERTER VALVE ASSEMBLY

1. Disassemby

1) 2) 3) 4)

of lockup valve Remove solenoid valve assembly (1). Remove cover (2), then remove spring (3). Remove cover (4), then remove piston (5). Pull out spool (6).

2. Disassembly of torque converter relief valve 1) Remove cover (7), then remove spring (8). 2) Remove cover (9), then remove valve (IO), spring (II), and valve (12). 3) Pull out spool (13). 3. Disassembly of main relief valve 1) Remove cover (14), then remove shim (15) and spring (16). 2) Remove cover (17), then remove valve (18), spring (19), and valve (20). 3) Pull out spool (21). of stator clutch modulation 4. Disassembly valve 1) Remove cover (22), then remove piston (23), and spring (24). 2) Remove ring (25) from body. 3) Remove cover (26), then remove valve (27), spring (28). and valve (29). 4) Pull out spool (30). 5) Remove shim (31) from spool. of lockup clutch modulation 5. Disassembly valve 1) Remove cover (32), then remove piston (33), and spring (34). 2) Remove ring (35) from body. 3) Remove cover (36), then remove valve (37), spring (38), and valve (39). 4) Pull out spool (40). 5) Remove spool (41) and shim (42) from spool (40).

30-114 0

17MF02511

30-l 15 0

ASSEMBLY OF TORQUE CONVERTER VALVE ASSEMBLY

Clean all parts, and check for dirt or damage. Coat the‘ sliding surfaces of all parts with engine oil before installing. Assemble valves (39) and (37), (29) and (27), (20) and (18), and (12) and (10) in the direction show in the diagram so that the valve with the hole in the center is on the inside of the spool.

Assembly of lockup valve 1) Assemble spool (6). 2) Assemble piston (5) to cover (4), then fit O-ring and insall cover. 3) Assemble spring (3). 4) Fit O-ring and install cover (2). 5) Fit O-ring and install solenoid valve assembly (1).

1. Assemblv of lockuD clutch modulation valve II Set shim (42) on spool (41), then assemble to spool (40). 2) Assemble spool (40). 3) Assemble valve (39), spring (38) and valve (37) to spool, then fit O-ring and install cover (36). 4) Assemble ring (35) to body. 5) Assemble spring (34). 6) Assemble piston (33) to cover (32), then fit O-ring and install cover. 2. Assembly of stator clutch modulation valve 1) Assemble shim (31) to spool (30). 2) Assemble spool (30). 3) Assemble valve (29), spring (28) and valve (27) to spool, then fit O-ring and install cover (26). 4) Assemble ring (25) to body. 5) Assemble spring (24). 6) Assemble piston (23) to cover (22), then fit O-ring and install cover. 3. Assembly of main relief valve 1) Assemble spool (21). 2) Assemble valve (20), spring (19) and valve (18) to spool, then fit O-ring and install cover (17). 3) Assemble spring (16). 4) Assemble shim (15) to cover (14), then fit O-ring and install cover. 4.

Assembly of torque converter relief valve Assemble spool (13). Assemble valve (12), spring (11) and valve (10) to spool, then fit O-ring and install cover (9). Assemble spring (8). Fit O-ring and install cover (7).

30-116 0

-o-_u

-0

T -/27

REMOVAL OF TRANSMISSION

CONTROL VALVE ASSEMBLY

1. Remove operator’s seat (1). 2. Remove suspension with turntable. & kg

assembly

(2) together

Suspension, turntable assembly: 60 kg

3. Remove operator’s seat bottom cover (3). 4. Disconnect brake rod (4). 1111 * Remove the clamp, then move the steering control cable to the side.

17MF02513

5. Disconnect 4 wiring connectors (5). 6. Disconnect control cables (6). 1111 7. Remove cover (7) together with sleeve.

Iy21

8. Remove inspection plug (8). 9. Remove tube (9), then using forcing screws, remove control valve cover (10). Iy31 10. Remove 4 bolts (II), assembly (12). m

then

remove

valve Q

17MF02514

17MF025:j

E 0

INSTALLATION OF TRANSMISSION CONTROL VALVE ASSEMBLY l

Carry out installation removal.

in the reverse order to

Kl Bend the cotter pin securely. El a

Sleeve O-ring:

Grease (G2-LI)

Check through the plug hole in the cover that the lever and yoke are meshed, then tighten the mounting bolts. When installing the cover, if the dowel pin portion does not go in when it is tapped vvith a plastic hammer, remove the cover, correct the meshing of the lever and yoke, then install again.

Mounting bolt: 5.0 f 0.5 kgm

30-117 0

DISASSEMBLY OF TRANSMISSION 1. Disassembly

of modulating valve, quick return valve, reducing valve 1) Remove snap ring (6), then remove retainer (7), spring (9), shim (8), valves (5), (4), and (2), and spring (3). 2) Remove snap ring (lo), then remove stopper (11) and spool (12). 3) Remove snap ring (13), remove stopper (14), then remove valves (15) and (17), spring (16), spool (18), shims (19) and (20), and springs (21) and (22). 4) Remove cover (1) then remove vlave (23).

CONTROL VALVE ASSEMBLY

2. Disassembly of directional valve 1) Remove spool (24). 2) Remove spool (25).

valve,

speed

17MF02518

30-118 0

ASSEMBLY OF TRANSMISSION

CONTROL VALVE

Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.

1. Assembly of modulating valve, quick return valve, reducing valve l)Assemble valve (23), and install cover (1). 2)Fit springs (22) and (21), shims (20) and (19), and spool (18), then fit valve (17), spring (16). and valve (15), and secure with stopper (14) and snap ring (13). * Standard shim thickness: 1 .Omm 3) Fit spool (12). and secure with stopper (11) and snap ring (10). 4) Fit valve (2). spring (3). and valves (4) and (5), then fit spring (9) and shim (8). and secure with stopper (7) and snap ring (6). * Standard shim thickness: 2.5 mm 2.

Assembly of directional 1) Install spool (24). 2) Install spool (25).

valve, speed valve

30-119 0

REMOVAL OF STEERING CONTROL VALVE ASSEMBLY

1. Remove fuel tank assembly. For details, see REMOVAL ASSEMBLY. 2. Disconnect cable.

2 yokes

OF FUEL TANK

(1) of steering

control

3. Disconnect brake rod (2). m 4. Disconnect 2 pin puller hoses (3). 5. Disconnect 4 pressure detection hoses (4). 6. Remove steering valve assembly (5). m

el kg

Steering valve assembly:

55 kg

17MF02520

INSTALLATION OF STEERING CONTROL VALVE ASSEMBLY l

Carry out installation removal.

in the reverse order to

Bend cotter pin securely.

1121 m w

30-l 20 0

Mounting bolt: 11 + 1.5 kgm

DISASSEMBLY OF STEERING CONTROL VALVE ASSEMBLY 1. Disassembly of check valve 1) Remove block (1). then remove spring (2). 2) Remove snap ring (3), then remove seat (4) and check valve (5) from valve body (6). 2. Remove lever case from valve body (6). 3. Remove bolts (8), then remove spring (9) and shim (10). 4. Remove 3 seat mounting remove seat (12).

bolts

(II),

then

5. Disassembly of clutch shaft assembly 1) Remove shaft assembly (13) from body (6). 2) Remove nuts (14) and (15), then remove guide (16), spring (17) and guide (18) from shaft (19). 6. Disassembly of brakes shaft assembly 1) Remove brake shaft assembly (20) from body (6). 2) Remove nuts (21) and (22), then remove cylinder (23), guide (24), spring (25) and guide (26) from shaft (27). 7. Disassembly of clutch valve Remove plug (28), then remove shim (29), spring (30), piston (31) and valve (32) from body (6). 8. Disassembly of brake valve Remove plug (33), then remove shim (34), spring (35), valve (36) and piston (37) from body (6).

ASSEMBLY OF STEERING CONTROL VALVE ASSEMBLY *

Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.

1. Assembly of brake valve Assemble piston (37), valve (36), spring (35) and shim (34) in body (6), then fit O-ring and install plug (33). * Shim thickness: 6 X 0.5 mm 2. Assembly of clutch valve Assemble valve (32), piston (31), spring (30) and shim (29) in body (6), then fit O-ring and install plug (28). * Shim thickness: 2 X 0.5 mm 3. Assembly of brake shaft assembly 1) Set guide (26), spring (25), guide (24) and cylinder (23) in shaft (27), then install nuts (22) and (21). 2) Assemble brake shaft assembly (20) in body (6). 4. Assembly of clutch shaft assembly 1) Set guide (18), spring (17) and guide (16) in shaft (19), then install nuts (15) and (14). 2) Assemble shaft assembly (13) in body (6). 5. Fit O-ring and set seat (12) in postion, then tighten mounting bolts (11). 6. Set shim (IO) and spring (9) in position, then install bolts (8). * Shim thickness: 1 X 1.0 mm 7. Fit gasket and install lever cases (7) to valve body (6). 8. Assembly of check valve 1) Set seat (4) and check valve (5) in body (6), and install snap ring (3). 2) Set spring (2) in body (6), then fit O-ring and install block (1).

30-122 a

z ? z

31 30

iSSFl324

30-123 0

SCAVENGING

PUMP ASSEMBLY

1. Drain oil : u Power train oil: Approx. 120 Q 2. Open inspection cover of under cover. * Hold the inspection cover securely, then remove the bolts and open the cover. 3. Remove pump outlet tube (1). 4. Disconnect pump inlet tube (2). 5. Remove 4 pump mounting remove pump assembly (3). & kg

Pump assembly:

bolts,

then

40 kg

INSTALLATION OF SCAVENGING PUMP ASSEMBLY l

Carry out installation in the reverse order to removal Refilling with oil Add oil to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again.

30-124 0

17MF02521

REMOVAL OF POWER TRAIN PUMP ASSEMBLY

1. Remove left and right engine side covers, then remove left step cover (1) and cab front cover (2). 2. Disconnect 2 air conditioner hoses (3). 3. Sling torque converter and transmission oil strainer (4), disconnect 4 connecting bolts holding to pump, then remove strainer. 4. Remove 2 pump mounting bolts, install guide bolts 0 (Dia. = 12 mm, pitch = 1.75 mm, length = 200 mm), and sling pump assembly (5). 5. Remove remaining 2 pump mounting bolts, raise pump assembly (5) and pull out to remove. f=GzL

Power train pump assembly:

40 kg

17MF02524

8 z! b

INSTALLATION OF POWER TRAIN PUMP ASSEMBLY l

Carry out installation in the reverse order to removal. Refilling with oil Add oil to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again.

30-l 25 0

REMOVAL OF FINAL DRIVE ASSEMBLY

1. For detail, see REMOVAL OF TRACK SHOE ASSEMBLY 2. Using jack 0 (50 ton) and ripper, jack up machine and set stand 0 (height: approx. 700 mm) under equalizer bar and rear of chassis.

A Set the stand securely in position

3. Drain oil from final drive case. : u Final drive case: Approx. 43 Q (Each side) 4. Remove covers (I), (2).

5. Remove cover (3). 6. Using bolts 0, pull out shaft (4) until point where spline comes out. * If the shaft will not come out, move the sprocket backwards or forwards, and adjust to a position where the shaft will come out. 7. Leaving 2 or 3 mounting bolts at top from 8 mounting bolts (5) on inside and 17 on outside, remove mounting bolts. 8. Remove 3 mounting bolts of final drive case cover, then set tool F and lever block (l/2 t), and sling final drive assembly (6).

9. Remove remaining mounting bolts, then move to outside and remove from case. * Operate a lever block and twist with a bar to keep the clearance at the mating surface of the case and final drive case assembly uniform when removing. & kg lO.Remove

30-126 0

Final drive case assembly: shaft (4).

1950 kg 17MF02530

17MF02531

INSTALLATION

Carry out installation removal.

Y-ZIL @Z l

OF FINAL DRIVE ASSEMBLY

in the reverse order to

Mounting bolt: Thread tightener

(LT-2)

Mounting bolt: 135 I!I 15 kgm

Refilling with oil * Supply engine oil to the specified from filler port.

level

Final drive case: Approx. 43 P (Each side)

30-127 0

DISASSEMBLY

OF FINAL DRIVE ASSEMBLY

1. Cover 1) Set final drive assembly on block @ (height: approx. 50 mm). 2) Remove mounting bolts (1) and (2), then using eyebolts 0, remove cover (3).

17MF02532

17MF02533

17MF02534

17MF02535

2. Hub 1) Remove plate (4). 2) Lift off hub (5).

g b _

3. Sprocket, drum assembly 1) Remove mounting bolts (6), then remove holder (7). 2) Using eyebolts 0, sling sprocket and drum assembly (8). 3) Using tool Gl, remove sprocket and drum assembly together with bearing (9).

I97F359

30-128 0

4) Disassemble the sprocket and drum assembly i) Set sprocket and drum assembly on block (height: 100 mm). ii) Remove flooting seal (IO). * Keep the floating seal in a safe place to protect it from damage.

17MF02538

iii) Remove mounting bolts, then remove seal (11). iv) Remove outside drum mounting bolts (12).

17MF02539

17MF02540

17MF02541

17MF02542

v) Remove mounting bolts (13) and (14), then using eyebolts 0, remove cover (15).

vi) Remove mounting bolts, then remove seal (16). vii) Remove inside drum mounting bolts (17).

17MF02543

17MF02544

30-129 0

viii) Lift off inside drum (18).

ix) Using eyebolts 0, remove inner drum assembly (19) from outside drum (20). x) Remove outer race (21). xi) Weld plate of tool G2 around whole circumference of rubber bushing, then set tool G2 as shown in diagram below, and pull out rubber bushing (22).

I98FO2722

198Fl412

17MF02545

22mm

, Section A-P

, 17MF02546 4. Wear guard Remove mounting guard (23).

bolts, then remove

17MF02546

wear

17MF02547

30-130 0

5. Cover assembly 1) Remove mounting bolts (24), then using eyebolts @, remove cover assembly (25).

17MF02550

17MF02549

2) Disassemble cover assembly as follows. i) Remove mounting bolts, then remove floating seal cage (26). ii) Remove floating seal (27). A Keep the floating seal in a safe place to protect it from damage.

------In 1

17MF02551

17MF02552

iii) Remove spacer (28). iv) Remove bearing (29).

17MF02553

v) Turn over cover, and remove plate (30). vi) Lift off ring gear (31).

17MF02554

17MF02555

30-l 31 0

6. Carrier assembly 1) Using eyebolts 0, remove carrier assembly (32). 2) Set carrier assembly on block (height: 100 mm), and disassemble as follows. i) Remove spacer (33).

17MF02556]1

17MF02557

ii) Using puller 8, remove outer race (34).

17MF02558

iii) Remove mounting bolts, then remove holder (35). iv) Using tool G3, remove shaft (36). v) Remove gear (37), bearing (38), and spacer (39). vi) Remove outer race (40) from gear.

30-132 0

38 17MF02561

17MF02562

7. Sun gear, shaft assembly 1) Remove sun gear and shaft assembly (41).

17MF02563

2) Disassemble sun gear and shaft assembly as follows. il Remove mounting bolts, then remove plate (42). ii) Using puller 0, remove bearing (43).

-I

17MF02564

17MF02565

iii) Remove mounting bolts, then remove plate (44). iv) Using push tool 09, remove sun gear (45) from shaft (46).

@ /

17MF02566

%02567

17MF02569

8. Hub, shaft assembly 1) Remove 18 mounting bolts (47) of shaft. 2) Remove 2 mounting bolts of gear, then using eyebolts 0, remove hub and shaft assembly (48).

30-133 0

3) Disassemble hub and shaft assembly as follows. i) Remove mounting bolts, then remove holder (49). ii Using tool G4, remove hub assembly (50) and bearing (51) from shaft assembly (52).

17MF02570

iii) Remove spacer (53), then remove bearing (54) from shaft (55). iv) Remove outer race (56) and gear (57) from hub (58).

17MF02572

17MF02573

17MF02574

17MF02575

9. Cage assembly 1) Remove mounting bolts, then using eyebolts 0, remove cage assembly (59). 2) Remove shim (60). * Check the number and thickness of the shims, and keep in a safe place.

3) Disassemble cage assembly as follows. i) Using puller 0, remove outer race (61). ii) Remove oil seals (62) and (63).

I98F02738 L

30-134 0

I97F50

10. Gear assembly 1) Remove gear assembly (64).. 2) Using puller 03, remove beaiing gear (66).

(65) from ..

17MF02i?7

17MF02576

11. Outer race, oil seal 1) Using puller 0, remove outer race (67). 2) Remove oil seals (68) and (69) from case (70).

I97F502

I98FO274

30-l 35 0

ASSEMBLY OF FINAL DRIVE ASSEMBLY

Wash all parts, then dry them, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.

1. Oil seal, outer race 1) Using push tool 03, 0, install oil seal (69). (69). A Set the upper oil seal with the pressure side facing up, and the lower oil seal with the pressure side facing down, and install. a

Lip of oil seal: Grease (G2-LI)

Press-fitting surface of oil seal: Gasket sealant (LG-5)

17MF02578

A Coat the inside surface of the case thinly with gasket sealant, and wipe off any gasket sealant that is squeezed out. -68

17MF02579

2) Using push tool @, press fit outer

race

(67).

17MF02580

2. Gear assembly 1) Using push tool @, press fit bearing (65) to gear (66). 2) Set tool G5 to case, and install gear assembly (64). * Do not remove tool 65 until the cage is installed.

65 17MF02581

30-136 a

I97F405

3. Cage assembly 1) Assemble cage assembly as follows. i) Using push tools @J and 0, install oil seals (63) and (62). * Set the upper oil seal with the pressure side facing up, and the lower oil seal with the pressure side facing down, and install. /F’~

Lip of oil seal: Grease (G2-LI)

Press-fitting surface of oil seal: Gasket sealant (LG-5) 17MF02582

Coat the inside surface of the case thinly with gasket sealant, and wipe off any gasket sealant that is squeezed out.

17MF02583

ii) Using push tool @, press fit outer race (61).

17MF02584

2) Using eyebolts 0, set cage (59) to case, then tighten 6 mounting bolts. w *

Mounting bolt: 1.5 kgm Rotate the gear and tighten uniformly, then remove tool G5 installed at Step 2-2).

30-l 37 0

gauge 0, as shown in 3) Using thickness diagram, measure clearances 6E and 6F between cage @ and case @ 6 of shim to be inserted 4) Set thickness according to table below.

I99FO274511

@M easurement

Measurement

30-138 0

position

17MF02ii6

5) Assemble shim (60) set in Item 4), and tighten cage mounting bolts. w

Mounting bolt: 11.25 k 1.25 kgm

17MF02587

4. Hub, shaft assembly 1) Assemble hub and shaft assembly as follows. j, The bearing connecting the hub and shaft is a set, so match the match symbols and production numbers on the inner and outer races and inner race spacer when assembling.

of inner race spacer (ex: K-3)

17MF02588

i) Install gear (57) to hub (58). QZK

Mounting bolt: 28.25 f 3.25 kgm ii) Using push tool 0, press fit top and bottom outer races (55) to hub (58).

5-S 17MF02589

17MF02590

17MF02591

17MF02592

iii) Using push tool 0, press fit bearing (54) to shaft (55). iv) Assemble spacer (53).

30-139 0

4 Set hub assembly (50) to shaft assembly (52), then using tool G6, press fit bearing (51). * Rotate the hub when press fitting the bearing.

r----r

17MF02593

17MF02594

vi) Install holder (49). m-

Mounting bolt threaded portion: Thread tightener (LT-2)

Mounting bolt: 28.25 + 3.25 kgm

17MF02595

2) Using eyebolts 0, raise hub and shaft assembly (48), then fit O-ring and set to case. 3) Tighten 18 mounting bolts (47) of shaft.

17MF02569

17MF02568

5. Sun gear, shaft assembly 1) Assemble sun gear and shaft assembly as follows. i) Press fit shaft (46) to sun gear (45). ii) Install plate (44).

17MF02596

30-140 0

17MF02566

iii) Using push tool @, press fit bearing (43). iv) Install plate (42).

17MF02597

2) Set sun gear and shaft assembly hub.

17MF02564

(41) to

6. Carrier assembly 1) Assemble carrier assembly as follows. The planetary gear bearing is a set, so match the match symbols and production numbers on the inner and outer races and inner race spacer when assembling.

I Match symbol of inner or outer races 1-11

Match symbol of inner or outer races

17MF02598

Install ring and spacer to gear, then using push tool 0, press fit top and bottom outer races (40).

30-141 0

ii) Assemble spacer (39) and bearing (38) to gear (37), and set to carrier. * Set the direction of assembly of the gear as shown in the diagram.

17MF02600

iii) Using tool G7, press fit shaft (36). * Align the position of the bearing and spacer holes, and press fit the shaft slowly. iv) Install holder (35). * After tightening the bolts, check that the gear rotates smoothly. w

17MF02562

17MF02560

Mounting bolt: 56 f 6 kgm

v) Using push too 8, press fit outer race (34). vi) Assemble spacer (33).

17MF02557

2) Using eyebolts 0, set carrier assembly (32) to shaft assembly. * When installing the carrier assembly, be careful not to damage the bearing.

17MF02556

30-142 0

7. Cover assembly 1) Assemble cover assembly as follows. i) Raise ring gear (31), and set to cover. ii) Install plate (30). * install the plate with the chamfered portion on the outside.

17MF02554

17MF0255E

iii) Using tool G8, press fit bearing (29). iv) Install spacer (28).

v) Using tool G9, install floating seal (27) to cage. * When installing the floating seal, remove all grease and oil from the O-ring and surface in contact with the O-ring, then dry before installing. * After installing the floating seal, check that the angle of the seal is within 1 mm. vi) Fit O-ring and install floating seal cage (26). * Install cork plugs in the trimming bolt holes. * Install the floating seal cage with the notched portion at the bottom as shown in the diagram.

17MF02602

17MF02603

Gs 17MF02604

17MF02605

30-143 0

2) Fit O-ring, then using eyebolts

set

cover assembly (25) to case. 3) Tighten mounting bolts (24). w

Mounting bolt: 56 f 6.0 kgm

17MF02550

17MF02549

8. Wear guard Install wear guard (23). Mounting bolt: 94.5 k 10.5 kgm

17MF02547

9. Sprocket, drum assembly 1) Assemble sprocket and drum assembly as follows. i) Using push tool 0, press fit rubber bushing (22) in inner drum. * If thembushing is stiff and will not go in, press fit with a press. * Press fit the busing until the end face of the inner drum and the end face of the busing are flush as shown in the diagram. Bushing

Inner drum I

17MF02607

17MF02608

Y-XI&

Press fitting portion of bushing: anti-friction compound (LM-P)

ii) Install top and bottom outer races (21). * Expand fit the outer race.

30-144 a

iii) Using eyebolts 0, raise inner assembly (19), then lower slowly and set on outside drum (20).

I-----

17MF02545

iv) Install inside drum (18). * Align the dowel pins of the outside drum and inner drum when installing. xCL

Mounting surface: Gasket sealant (LG-6)

I98FO2722

4 Tighten

inside

drum

mounting

bolts

(17). KCL

Mounting bolt threaded portion: Thread tightener (LT-2)

Mounting bolt: 80 f 10 kgm

vi) Install seal (16). /(il\,

Seal mounting surface: Gasket sealant (LG-6)

17MF02544

17MF02543

17MF02542

17MF02541

vii) Fit O-ring to inner drum, then using eyebolts 0, set cover (15) in position, and tighten mounting bolts (14) and (13). w

Mounting bolt (14): 28.25 f 3.25 kgm

Install cork plugs in the trimming bolts holes.

x) Turn over sprocket and drum assembly and set on block, then tighten outside drum mounting bolts (12). a

Mounting bolt threaded portion: Thread tightener (LT-2)

Mounting bolt: 80 + 10 kgm

xi) Install seal (7). RQIL

Seal mounting surface: Gasket sealant (LG-6) 17MF02540

17MF02539

xii) Using tool G9, install floating seal (10). * Remove all the grease from the O-ring and O-ring contact surface, and dry before installing. * After installing the floating seal, check that slope of the seal is less than 1 mm.

17MF02610

2) Using eyebolts 0, set sprocket and drum assembly (8) to cover. * Check that there is no dirt or dust on the sliding surface of the floating seal, then coat thinly with engine oil. 3) Using tool G8, press fit bearing (9). * When press fitting the bearing, rotate the sprocket and drum assembly.

&G&&g 17MF02611

I97F365

30-146 0

4) Fit holder (7) and tighten (6).

mounting

bolts

Mounting bolt: 28.25 + 3.25 kgm

10. Hub 1) Sling hub (3) and install. 2) Install plate (2). w

Mounting bolt: 11.25 I!T1.25 kgm

17MF02535

17MF02534

17MF02533

17MF02532

I h

& 0

11. Cover Using eyebolts 0, install cover tighten mounting bolts (2) and (1).

(3),

then

AT?--

Mounting surface: Gasket sealant (LG-5)

Mounting bolt: 28.25 + 3.25 kgm

30-147 0

REMOVAL OF TRACK FRAME ASSEMBLY

1. For details,

see REMOVAL

OF TRACK SHOE

ASSEMBLY. 2. Using jack (70 ton), raise the machine and set standard 0 (height: approx. Im) under the equalizer bar case. 3. Remove cover (1). 4. Remove holder (2). 5. Remove pivot shaft mounting bolts (3).

198F02753

I9gF62754

6. Remove mounting bolts of pivot shaft inside cover (4), and disconnect cover. 7. Remove pin (5). m * Sling the track frame assembly, then remove the lock plate, and knock out the pin. 8. Lift off track frame assembly (6). 1121 * Use a chain block on the inside of the idler yoke and adjust to keep horizontal so that the track frame assembly does not slope to the left. * The oil inside the pivot chamber will leak out, so put a container under it to catch the oil. & kg u

Track frame assembly: Pivot chamber:

Approx.

4500 kg 12~

m !I -0

INSTALLATION OF TRACK FRAME ASSEMBLY l

Carry out installation removal.

in the reverse order to

Pin: Grease (G2-LI)

Pivot shaft: Anti-friction

w l

Plug: 15 f

compound

(LM-P)

3 kg

Refilling with oil * Add engine oil to the pivot case to the specified level. For details, see INSTALLATION OF EQUALIZER BAR ASSEMBLY.

30-148 0

I98FO2757

REMOVAL OF IDLER YOKE ASSEMBLY 1. Remove track shoe assembly. For details, see REMOVAL OF TRACK SHOE ASSEMBLY. 2. Remove scrapers (I), (2), (3), and (4) from side face of idler. 3. Remove idler assembly. For details, see REMOVAL OF IDLER ASSEMBLY. 4. Drain oil from spring chamber. + Drain the oil with a pump. 6 5. 6.

Spring

chamber

: Approx.

Remove idler yoke top cover (5). Disassemble yoke assembly (including idler bogie as follows. I) Loosen idler yoke mounting bolts (6) gradually in turn on diagonally opposite sides. m * Wrap cloth around the chrome plated portion to protect the chrome plated portion from being hit and damaged by the tool. A To prevent danger, never stand in front of the yoke assembly. The recoil spring inside the recoil cyling der is applying a pushing force of 363 kN (37 tons) on the yoke, so be careful not to loosen the mounting bolts suddenly. Loosen the mounting bolts gradually until clearance a between the flange of the recoil cylinder and idler yoke assembly is 8 - 12 mm. 2)

CLD01059

75 ~2

Flange

Plated

bushing

DLD02846

When the bolts are loosened, the torque will suddenly drop. Check that the spring is not applying any pushing force on the mounting bolts, then remove all bolts. If the torque increases (the pushing force * of the spring is applied) during the loosening operation, stop the loosening operation and disassemble as follows.

If the torque does not drop during Step 2) deAhscribed above, and the torque when the bolts are loosened remains large, there is probably damage to recoil spring set bolt (91, or nut (IO) at the tip of the shaft has fallen off, so there is danger that the yoke assembly may fly off to the front. For this reason, disassemble as follows.

CLD01062

30-148-l 0

When disconnecting the yoke assembly and reA coil cylinder assembly, do not stand in front of the yoke assembly or behind the recoil cylinder assembly until safety has been confirmed and the recoil spring assembly has been removed. i)

ii)

Prepare the following parts. 791-730-1110 Bolt @ (x6): 01580-12722 Nut @ (x6): Washer @ (x6): 01643-32780 Remove

6 bolts marked

(use again)

%, then install bolts

CKD01063

0, nuts@, and washers @ listed in Step i). * Check that dimension L is less than 361 sr

mm. Screw in bolts @ until they contact bottom of the yoke thread.

remaining iii) Remove marked %_).

12 bolts

(those

the Yoke

not

iv) Hold bolts @ with a wrench to prevent them from turning, then loosen 2 nuts @ simultaneously on opposite sides. * Be careful not to let the load bea,r on only one bolt.

OK002847

When recoil spring is fully extended and torque has completely dropped in loosening direction of nut 0, remove bolt 0. * When clearance b is approx. 165 mm, the spring is fully extended.

CLD01065

Remove

idler yoke (7) from

recoil cylinder

(8). 8

30- 148-2 0

INSTALLATION

OF IDLER YOKE

in the

Carry out removal.

installation

reverse

order

Spring chamber : Approx. 75 4? Ir When using waste oil, use oil that does not include mercury, alkali or any other dangerous substance.

m Sr

Bolt (6): 1324 i. 147 Nm (135 2 15 kgm) If the recoil spring holder nut has come off or fallen out, assemble again. OF RECOIL see ASSEMBLY For details, SPRING ASSEMBLY.

30-148-3 0

REMOVAL OF RECOIL SPRING ASSEMBLY 1.

Remove track shoe assembly. For details, see REMOVAL OF TRACK SHOE ASSEMBLY.

Drain oil from spring chamber. * Drain the oil with a pump. &

Spring chamber

Remove

idler top cover (1).

Remove

trunnion

(2).

Trunnion

: 56 kg

& kg 5.

: Approx.

75 .t

17MF02855

Remove outside cover (3) and inside cover (4). * Remove the inside and outside covers.

17MF02618

m Remove pins (5). * Using tool H, remove the inside and outside pins.

17MF02619

Remove idler and recoil spring assembly (6). Ir Using a lever block, keep the assembly horizontal, and be careful not to damage the oil seal at track frame (7) end. & kg

Idler, recoil spring assembly

: 1500 kg

i-&’

,(-y

17MF02620

Remove recoil cylinder assembly (6). a * Disconnect recoil cylinder assembly from idler yoke assembly (9) as follows. 1) Put idler yoke assembly (9) in contact with ground, then raise recoil cylinder assembly (8). Sr When doing this, check that there is no damage to the weld of recoil spring case +

(8). Wrap cloth around the chrome plated portion to protect the chrome plated portion from being hit and damaged by the tool.

Loosen idler yoke mounting bolts (IO) gradually in turn on diagonally opposite sides. ~TO prevent danger, never stand in front of the idler yoke assembly or behind the recoil cylinder assembly. AThe recoil spring inside the recoil spring case is applying a pushing force of 363 kN (37 tons) on the yoke, so be careful not to loosen the mounting bolts suddenly. Loosen the mounting bolts gradually until clearance a between the flange of the recoil cylinder and idler yoke assembly is 8 - 12 mm. When the bolts are loosened, the torque will suddenly drop. Check that the spring is not applying any pushing force on the mounting bolts, then remove all bolts. * If the torque increases (the pushing force of the spring is applied) during the loosening operation, stop the loosening operation and disassemble as follows.

CLD01067

Plated

bushing

DLD02848

CLD01069

glf

the torque does not drop during Steps 2) and 3) described above, and the torque when the bolts are loosened remains large, there is probably damage to recoil spring set bolt (19), or nut (20) at the tip of the shaft has fallen off, so there is danger that the yoke assembly may fly off to the front. For this reason, disassemble as follows.

30-150 0

a When disconnecting

the yoke assembly and recoil cylinder assembly, do not stand in front of the yoke assembly or behind the recoil cylinder assembly until safety has been confirmed and the recoil spring assembly has been removed. i)

Prepare the following parts. Bolt @ (x6): 791-730-I 110 Nut @ (x6): 01580-12722 (use again) Washer @ (x6): 01643-32780

Remove 6 bolts marked %, then install bolts 0, nuts 0, and washers @ listed in Step i). Check that dimension L is less than 361 * mm. Screw in bolts (I) until they contact the * bottom of the yoke thread. not iii) Remove 12 bolts (those remaining marked a). ii)

CKD01063

iv) Hold bolts 0 with a wrench to prevent them from turning, then loosen 2 nuts @ simultaneously on opposite sides. Be careful not to let the load bear on * only one bolt. DKD0.2847 J

and When recoil spring is fully extended torque has completely dropped in loosening direction of nut 0, remove bolt 0. When clearance b is approx. 165 mm, * the spring is fully extended.

CLD01071

Remove

ring (11).

CLD01072

10. Remove adjustment cylinder (12). * Pump in grease from lubricator push out piston assembly (13).

(141, and

CLD01073

CKD01074

Disassembly of piston assembly a i) Remove wear ring (15) from piston assembly, then remove snap ring (16), and remove packing (17).

11. Remove

recoil spring assembly

&I kg

Recoil spring assembly

30-150-2 0

(18).

: 400 Kg

CLD01075

INSTALLATION OF RECOIL SPRING ASSEMBLY

Carry out removal.

installation

in the

reverse

order

Spring chamber: Approx. 7% When using waster oil, use oil that does not include mercury, alkali or any other dangerous substance.

When installing the pin, align the center of the idler and recoil spring cylinder with a bar, and install.

& w

Mounting

bolt (IO): Therad tightener (LT-2) Tightening torqe of bolt (IO): . Top mounting bolt (IO bolts): 1324 +_ 147 Nm (135 +_ 15 kgm) . Bottom mounting bolt with plate (8 bolts)” 1564 + 172 Nm (159.5 f 17.5 kgm) If the recoil spring holding nut has fallen off, see ASSEMBLY OF RECOIL SPRING for assembling.

Pump in grease as follows to prevent air from collecting inside the cylinder. 1) Fill inside of cylinder with approx. 75cc of grease (each side). 2) Set cylinder drain hole facing up, then loosen lubricator (14). lubricator (14) to specified 3) Tighten torque. m Lubricator: 73.5 f 14.7 Nm (7.5 f 1.5 kgm)

30-150-3 0

DISASSEMBLY OF RECOIL SPRING ASSEMBLY 1.

Set recoil spring assembly (I) in tool 0. The spring is under high installed load, a so be careful to set it correctly. * Installed load of spring: 388.3 kN (36.9 tons)

CLD01077

Apply hydraulic pressure spring, then remove lock nut (3).

slowly to compress plate (2) and remove

Release tension

gradually

Remove rear pilot (8) from

hydraulic of spring.

pressure

pilot (5), spacer spring (4).

0 2

and relieve

(61, bolt

(7), and 3

CL001078

ASSEMBLY ASSEMBLY

OF RECOIL SPRING

1. Assemble pilot (8), bolt (7), spacer (61, and rear pilot (5) to spring (4), then set in tool 0. The spring is under high installed load, so be careful to set all parts correctly.

Apply spring,

hydraulic pressure slowly to compress and set so that installed length of spring

~!$$dl~r$~.a

: 1078 mm

CL001079

30-150-4 5

-1

CKD01080

Fit nut (3), then install lock plate (2). Sr When securing the recoil spring mounting nut, make a clearance of 0 - 1.0 mm between lock plate (2) and nut (31, then bring lock plate (2) and bolt (7) into tight contact, and secure in position. * Purpose of making clearance I) If the nut is screwed in a small amount and nut (3) protrudes beyond bolt (71, lock plate (2) may bend and lock bolt (8) may fall off. 2) If the nut is screwed in too far, the load of the spring will always be applied to the set bolt, and the set bolt will break.

TClearance

O-1.

Omm

DKD02849

Gradually release hydraulic pressure to completely relieve tension of spring, then remove recoil spring assembly (1) from tool 0.

30-151 0

REMOVAL OF IDLER ASSEMBLY 1.

For details, see REMOVAL OF TRACK SHOE ASSEMBLY. 2. Remove inside and outside covers (I) and (2) (2 each). a ATo prevent danger, never stand in front of the idler yoke assembly. 3.

Sling the idler assembly (31, and remove (4), then remove the idler assembly (2). Idler assembly:

INSTALLATION ASSEMBLY .

/GJ

350 kg

17MF02630

OF IDLER ‘02631

Carry out removal. w

cap

installation

Mounting

in the

reverse

order

bolt of front cover (I): 549.1 = 58.8 Nm I56 + 6 kgm)

Tighten the idler cap mounting bolts in the order @+@I+@ After tightening, check that clearance a at the bottom of the cap is 0 mm. & Cap mounting bolt: Thread tightener (LT-2) Q~EI Cap mounting bolt: 1,324 f 147 Nm (135 t 15 kgm}

30-152 @

DISASSEMBLY

OF IDLER ASSEMBLY

1. Remove plug and drain oil. : u Idler: Approx. 1.5 P 2. Set idler assembly (1) on block 0. 3. Remove mounting screws 0, remove seal guide (2).

bolts, then using forcing retainer (3) together with

4. Turn over idler assembly (4), remove mounting bolts, then using eyebolts 0, remove shaft (4) together with retainer. 5. Using puller 0, remove seal guide together with retainer (6) from shaft.

(5)

6. Remove seal guides (2) and (5) from retainers (3) and (6).

2-5 \

17MF02635

17MF02636

17MF02637

17MF02638

17MF02639

7. Remove floating seals (7) and (8) from seal guides (2) and (5), and retainers (3) and (6). * Keep the floating seals in a safe place to protect them from damage.

2.5’

8. Remove bushing (9) from idler (10).

17MF02640

ASSEMBLY OF IDLER ASSEMBLY

Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.

1. Set tool J, to idler (IO), and press fit bushing (3). A When press fitting the bushing, center it with a plastic hammer, then press fit with a puller. * Press fit the bushing so that the distance from the end face of the idler to the top face of the bushng is 15 f Imm.

2. Using tool J,, install floating seal (8) to retainers (3) and (6). 3. Fit O-ring, install retainer with mounting bolts.

(3), then

tighten

4. Using eyebolts 0, set idler (IO) on shaft (4). j, Set a block (approx. 140mm) under the idler. 5. Turn over idler assembly. j, Tie the shaft with wire to prevent it from falling out. 6. Fit O-ring, install retainer with mounting bolts.

(6), then

tighten

17MF02644

17MF02&

7. Using tool J,, install floating seal (7) to seal guides (2) and (5). 8. Fit O-ring to seal guide.

J3 17MF02646

30-154 0

9. Set tool J, to idler, and press fit seal guide (2). * Press fit the seal guide so that distance “a” from the end face of the shaft to the top face of the seal guide is 96 f 0.2mm. j, Turn over the idler assembly, and repeat the same procedure to press fit seal guide (5).

J2 /

10. Add gear oil through oil filler to the specified level.

Idler: Approx.

Plug: 21 f

1.5 Q

5 kgm

30-155 0

REMOVAL OF TRACK

1. For details, see REMOVAL ASSEMBLY. 2. Remove retainer (1).

OF TRACT SHOE

3. Remove track roller guard (1).

52 *

Track roller guard inside: 85 kg

Track roller guard outside:

90 kg

If the mounting bolts cannot be removed, use a power wrench to remove them.

i 4. Start the engine, then operate the blade and ripper levers, and raise the machine. After raising the machine, set the block on A the track shoe, and lock the work equipment layer and brake pedal. 5. Remove track roller assembly (2). 1131 * Set tool K under the track roller assembly, then remove the track roller assembly. I3 kg

Track roller assembly:

120 kg

INSTALLATION OF TRACK ROLLER ASSEMBLY l

Carry out installation removal.

in the reverse order to

Retainer mounting bolt: Thread tightener

(LT-2)

Retainer mounting bolt: 56 f

6 kgm

1121 *

Assemble the guard tension bolt with the head on the inside.

& a

Guard tension bolt: Thread tightener

(LT-2)

Guard mounting bolt: Thread tightener

(LT-2)

Guard tension bolt: 94.5 *

10.5 kgm

Guard mounting bolt: 94.5 f

10.5 kgm

m * *

Assemble so that the oil plug is on the outside of the machine. Install the dowel pin only on the oil plug side.

& N

30-156 n

Roller mounting bolt: Thread tightener

(LT-2)

Roller mounting bolt: 94.5 k 10.5 kgm

17MF02649

DISASSEMBLY

OF TRACK ROLLER ASSEMBLY

1. Remove plug, and drain oil. : Track roller assembly: u

Approx.

14 P

2. Set track roller assembly (1) on block 0. 3. Remove mounting bolts, then using forcing screws 0, remove seal guide (2) together with retainer (3) from shaft.

4. Turn over track roller asembly, and remove 0, bolts, then using eyebolts mounting remove shaft (4) together with retainer. 5. Using press, remove seal guide (5) together with retainer (6) from shaft. 6. Remove seal guides (2) and (5) from retainers (3) and (6).

17MF02654

g 3 z

17MF02639

7. Remove floating seals (7) and (8) from seal guides (2) and (5) and retainers (3) and (6). * Be careful not to damage the floating seals, and keep in a safe place.

17MF02656

8. Remove bushing (9) from roller (10).

17MF02657

ASSEMBLY OF TRACK ROLLER ASSEMBLY

Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.

1. Set roller (IO) in press, then use tool L, to press fit bushing (9). * When press fitting the bushing, center it with a plastic hammer, then press fit with a press. * Press fit the bushing so that the distance from the end face of the roller to the top face of the bushing is 15 * Imm. 17MF02659

17MF02660

2. Set shaft (4) to roller. 3. Using tool L,, install floating seal (8) to retainers (3) and (6). 4. Fit O-rings, install retainers (3) and (6), then tighten with mounting bolts.

17MF02661

17MF02662

5. Using tool L,, install floating seal (7) to seal guides (2) and (5). 6. Fit O-ring to seal guide.

7. Using tool L,, press fit seal guide (2). * Press fit the seal guide so that distance “a” from the end face of the shaft to the top face of the seal guide is 69 k 0.2mm. * Turn over the track roller assembly, and repeat the same procedure to press fit seal guide (5). 8. Add gear oil through oil filler to the specified level. Q

Track roller: Approx.

1.4 P 1

30-158 0

Plug: 21 f

5 kgm

17MF02665

REMOVAL OF CARRIER ROLLER ASSEMBLY

1. Track tension Loosen track tension. * For details, see SHOE ASSEMBLY.

REMOVAL

TRACK

2. Carrier roller assembly (1) m A Using a jack, raise the track shoe so that the carrier roller assembly can be removed.

INSTALLATION OF CARRIER ROLLER ASSEMBLY l

Carry out installation removal.

in the reverse order to

When installing the carrier roller to the support, leave a clearance as shown in the diagram.

&I&

Support mounting bolt: Thread tightener

(LT-2)

30-l 59 0

OF CARRIER ROLLER ASSEMBLY

DISASSEMBLY

1. Remove plug and drain oil. : Carrier roller assembly: Approx. 0 7e u 2. Set carrier roller assembly on block 0. 3. Remove

mounting

bolts, then remove

cover

(2). 4. Remove ring (3).

a 17MF02667

17MF02666

17MF02669

17MF02670

17MF02671

17MF02672

17MF02613

17MFO2614

5. Using tool M,, remove nut (4). 6. Using puller 0, remove press-fitting portion of seal guide, then use eyebolts to remove bearing (5) together with roller (6).

I 7. Remove outer races (7) from roller. 6. Using puller 0, remove seal guide (8) together with bearing (9) from shaft. 9. Remove floating seal (IO) from seal guide (8).

I-L---J

17MF02675

10. Using push tool 0, remove seal guide (11). 11. Remove

floating

seal (12) from

seal guide

(11).

30-l

ASSEMBLY OF CARRIER ROLLER ASSEMBLY

Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.

1. Using push tool 0,

press fit bearing (9).

2. Using push tool 0, press fit outer race (7).

3. Set roller (6) and bearing (5) on shaft. 4. Using push tool 0, press fit bearing (5) on shaft. * Rotate the roller when press fitting the bearing. Press fit the bearing until the rotation of the bearing becomes slightly heavy.

. 17MF02679

17MF02678

Using tool M,, tighten nut (4) at IO kgm. * After tightening the nut, if the nut hole and the shaft hole are not aligned, align in the direction of loosening the nut. 6. Install ring (3).

17MF02669

17MF02668

7. Fit O-ring, install cover (2), then tighten with mounting bolts.

17MF02680

30-l 61 0

8. Using tool M,, install floating seal (10) to seal guide (8). 9. Fit O-ring, then align with dowel pin and install seal guide (8).

17MF02681

10. Using tool M,, install floating seal (12) to seal guide (11). 11. Using tool M,, press fit seal guide (11). * Press fit the seal guide so that distance “a” from the end face of the shaft to the top face of the seal guide is 159.75 f 0.2mm.

si$&& ,I

’

‘11 17MF02683

17MF02685

12. Add gear oil through oil filler (1) to the specified level. * Rotate the roller when adding the oil. Q

Carrier roller: Approx.

Plug: 21 f

30-162 0

5 kgm

0.7 e

17MF02682

CHECKING BEFORE REMOVAL OF TRACK SHOE ASSEMBLY aln

some cases, it may be extremely dangerous to remove the track shoe assembly. To prevent danger, carry out the following checks before removing the track shoe assembly. Checks before starting I) Loosen the lubricator at the adjustment cylinder, release the grease, then move the machine backward and forward a short distance, and check that the track tension is relieved. If the track tension is not relieved and the track shoe assembly remains tense, there may be an abnormality inside the track frame (the recoil spring case is broken, the recoil spring set bolt is broken, or the nut at the end of shaft has fallen off). Never loosen the lubricator more than g one turn.

REMOVAL OF TRACK SHOE ASSEMBLY (NORMAL) CA ;

If CHECKING BEFORE REMOVAL OF TRACK SHOE ASSEMBLY shows that there is no abnormality, do as follows. 1. Set master link in position. + Set a block (height: approx. 400 mm) so that the master link is approx. 600 mm from the ground at the front. m 2. Relieve track shoe tension. Never loosen lubricator (I) more than one a turn. * If the track is not relieved by loosening the lubricator, move the machine backwards and forwards. *

3. 4.

Remove mounting bolts of track shoe (2) and a master link (3). Raise tip of master link, move machine towards rear slowly, and lay out track shoe assembly (4).

CLD01083

CLD01084

30-163 z

REMOVAL OF TRACK SHOE ASSEMBLY (WHEN THERE TRACK FRAME)

ABNORMALITY

INSIDE

When CHECKING BEFORE REMOVAL OF TRACK SHOE ASSEMBLY shows any abnormality, do as follows. If there is any abnormality inside the track frame, a there is danger that the track shoe assembly may spring back when it is removed or that the idler may spring out when the track shoe assembly is removed. This may lead to serious injury, so remove the track shoe assembly as follows. a If there is any interference or abnormal catching around the idler assembly, examine carefully and remove the problem before starting. 1. Remove work equipment assembly. For details, see REMOVAL OF WORK EQUIPMENT ASSEMBLY. 2. Loosen lubricator (I) of adjustment cylinder, then move machine backwards and forwards to release grease. m Never loosen the lubricator more than one a turn. * Check that all the grease has been removed. 3.

Drive slowly forward to put track shoe at idler end in contact with large block @ or a wall (if another large bulldozer of the same capacity as the machine being repaired is available, put in contact with the blade). Stop machine when recoil spring bends and slack is formed in track shoe assembly, then apply brake. When doing this, set so that master link is between idler and front carrier roller. For safety reasons, fit a lever block between carrier roller support and link. Remove shoe (4), then disconnect master link 11 (5). ABe extremely careful to ensure safety when disconnecting the track shoe. Move machine towards rear slowly and lay out track shoe assembly.

30-l 63-1 &

CLD01085

INSTALLATION OF TRACK SHOE ASSEMBLY . Carry out installation in the reverse order to removal.

* m___ t

When adjusting the track shoe tension, dimension a to 25 + 5 mm.

set

Tighten the shoe bolts in the order shown in the diagram. 6 Mounting bolt : Anti-friction compound (LM-P) m Mounting bolt (master bolt) Initial torque : 490.3 + 49.0 Nm (50 ? 5 kgm) Tightening angle : 180 k 10”

------GO1048

DKD00282

30-163-2 5,

This section describes only for the lubricated A track link. Shoe (master link portion) Set the track assembly on a flat floor with the shoe facing up, then remove the shoe bolt at the master link, and remove the shoe. A Do not use an impact wrench when loosening the master link bolt.

F6164026

Disassembly into l/4 parts Because of the weight of the track assembly, if the l/2 assembly is too large and there are problems with disassembly and assembly work, divide into l/4 assemblies. Shoe (regular link portion) Raise the track assembly and set it on the floor with the shoe facing up, then use a shoe bolt impact wrench to remove the shoes. * When moving the track assembly, be careful not to damage the master link portion. * If a gas cutter has to be used to remove the shoe nut, to prevent deterioration of the seal due to the heat, keep the temperature of the seal portion below 80°C. and take action to prevent welding spatter from entering the gap between the links. Draining oil Before disassembling the link assembly, drain the oil from inside the pin and take precautions so that the link press does not become dirty with oil. * Before disassembling, if it is judged that it is necessary to rebuild the track as a dry type track, the following work need not be carried out. 1) Set the link assembly on a flat floor with the large plug side facing up, then chamfer the burrs on the end face of the pin with a grinder. * If the track is disassembled with burrs still at the end face of the pin, the pin press fitting hole of the link will be scratched, and this will cause leakage from the pin press-fitting portion after rebuilding. 2) Using a drill (elOmm), make a hole in the large plug, then remove the large plug. * If any dirt or deteriorated oil is stuck to the pin hole, drill through with a longer drill to remove it. When doing this, be careful not to damage the oil hole.

30-164 0

Burrs

Chamfer

F 19802241

3) After removing the large plug, use a baby grinder (angle of grinder tip: 45” - 60’7, and chamfer the pin hole so that the plug is not damaged when the plug is knocked in. 4) Turn over the link assembly so that the small plug side is facing up, remove the burrs at the end face of the pin with a grinder, then use tool W to knock the small plug to the inside. j, If the small plug hole is blocked with burrs, grind with a grinder until the hole can be seen completely. 5) Using a drill (olOmm), plug hole.

chamfer

the small

6) Blow with comressed air to remove the metal particles when draining the oil inside the pin or removing the burrs, then wash the link assembly with high-pressure water or steam.

5. Dissasembly of link 1) Set the link assembly on a link press, then hit with a hammer so that the bushing and jaw are in tioht contact. * If the linktread and outside diameter of the bushing are worn, adjust the height of the shoe or guide plate, and center the disassembly jig with the pin and bushing center to prevent damage to the link hole when disassembling. * If the centering is not carried out the link hole may be properly, damaged, the pin may break, or the bushing may crack during disassembly. 2) Operate the left cylinder and remove the left link and pin and bushing press-fitting portion at the same time. * Check the removal force of the pin and bushing, and use this value as reference to judge if it is possible to obtain the necessary pin and bushing press-fitting force when turning and reassembling. * Do not push the disassembly jig inside more than is necessary as the spacer may break.

F 19802245

Left disassembly

jig

Jaw

Right disassembly jig

9802248

30-165 a

3) Return the left cylinder, then operate the right cylinder and remove the right link and pin and bushing press-fitting portion at the same time. 4) Return the right cylinder, remove the left and right links, pins, bushings, and spacers, then feed the following set for one link assembly into the jaw. To decide if the seal can be used again, carry out inspection when the seal is still installed to the link, so do not remove the seal from the link. If oil is remaining, this can be used as a guide line for reuse of the seal, so mark such links or seals. If the end face of the bushing and seal surface are damaged, it will cause oil leakage, so be extremely careful when handling.

6. Inspection Check the following items to determine if the part can be reused as a lubricated track or as a grease-filled track. Carry out a comprehensive check to determine if the link assembly can be rebuilt as a lubricated track or as a grease-filled track. making judgements about reuse A When of parts, see Shop manual “Guidance for Reusable Parts”. Check the pins, bushing, links and spacers visually for damage, and carry out a color check or use a flaw detector to check of being parts that are suspected damaged. Any part that is cracked must not be used again, so scrap it. Check the external appearance of the seal and the end face of the bushing visually to determine if they can be used again. * If only the bushing is replaced with a new part, the worn or damaged part of the seal lip contacts the end face of the bushing directly, so it may not be able to carry out its sealing function. For this always replace the seal reason, together with the bushing, or rebuild as a grease-filled track.

30-166 a

Fl 980224

F19802248

3) Using calipers, measure spacer thickness a and overall length b of the sliding portion of the bushing and spacer. Check if it is possible to obtain the specified seal mounting dimension when reassembling. j, If the amount of wear of the spacer and bushing is greater than the specified amount, the assembly precision of the seal portion cannot be guaranteed, so replace with new parts, or rebuild as a grease-filled track. 4) Using a micrometer, cylinder gauge, and calipers, measure the outside diameter of the pin and the inside diameter of the bushing at the worn portion, and judge if the parts can be used again. j, If the amount of wear is greater than the specified amount, there will be play during travel, and it will also cause the oil to become dirty, so replace with new parts or rebuild as a grease-filled track. * For details of the dimensions when making judgement, see MAINTENANCE STANDARDS.

ll a

F19802249

Fl9802250

5) Using a micrometer and cylinder gauge, measure the outside diameter of the pin and bushing press-fitting portion, and the inside diameter of the pin and bushing press-fitting portion of the link to determine if the permitted interference can be obtained. However, when rebuilding as a lubricated track, check the standard interference for the pinand link. * If the permitted interference can not be obtained, replace with new parts or replace with an oversize part. * For details of the dimensions when making judgement, see MAINTENANCE STANDARDS.

A198022521

30-167 0

I I

F 19802253

A PRECAUTIONS FOR STORAGE To prevent rust of the counterbore portion of the link, leave the seal installed to the link and be careful not to damage the seal lip during storage. Coat the pin and bushing press-fitting portion, shoe mating surface, and master link mating surface of the link with rust prevention oil to prevent rust. Coat the whole circumference of the pins, bushings, and spacers with rust prevention oil to prevent rust, and be particularly careful not to damage the end face of the bushing during storage.

30-168 0

1. WHEN REBUILDING

AS LUBRICATED

1. Preparatory work 1) Washing seal assembly l Machines equipped with F3 type seals Remove the seal assembly from the link, then separate into the seal ring and load ring, and clean the parts. * The seal ring and load ring deteriorate easily when brought into contact with cleaning agent (trichlene, etc.), so wash the parts quickly. After cleaning, wipe the parts with a clean cloth to remove all the cleaning agent. l

Machines eqipped with W7 type seals For seals that are to be reused, leave the seal installed to the link, and do not wash it.

TRACK

Load ring

Seal ring

F 19802254

2) When reusing the pin, chamfer the corner of the end face smooth with a grinder. Remove any protruding parts stuck to the press-fitting portion with a grinder. * If the corner of the end face has become sharp due to wear, there will be scuffing when press fitting and this will cause oil leakage.

3) Make a mark on the end face at the small plug end to show the direction of the side hole (hole in the radial direction) in the pin when assembling. * When rebuilding the pin, assemble in the same direction as when the part is new (side hole on the link tread side).

Make a mark to show

30-169 a

4) If the link, pin, bushing, or spacer are dirty, wash them. Remove any protruding parts stuck to the link and bushing with grinder. * These parts easily rust, so wash them immediately before assembly. * Use tool X to wash the pin hole. A Do not polish or carry out any other treatment of the end face of the bushing as this causes the oil leakage. 5) Use tool Y to knock the large plug into the pin. 9 Insert plug into hole in guide through plug insertion window. (Coat the plug with oil.) ii) Push bar by hand and insert the plug as far as it will go. iii) Push plug with bar, and push guide itself against pin. iv) Hit in bar with a hammer. *

Dimension “a” to knock in the plug from end face of pin: 11 k 2 mm

A If there is no more place to chamfer at the pin hole because of wear, use a baby grinder (angle of grinder tip: 45 - 60”) to carry out chamfering. * Coat the outside circumference of the plug with G0140B and knock in the smaller diameter part first.

17MF02805

6) Installation of seal assembly l Machines equipped with F3 type seal Clean the link counterbore, then use tool KA to push the seal in fully to the bottom.

Machines equipped with W7 type seal When reusing the link and replacing the seal with a new part, clean the link counterbore, then push the seal in fully to the bottom.

30-170 0

If there is oil stuck to the link counterbore and seal assembly, the seal will rotate and its sealing performance will drop, so do not coat with oil. In addition, be careful not to let oil get into the counterbore portion of the seal when pushing in.

Remove all oil and grease fro

Y Direction to push in

F19802259A

Remove all oil and grease from shaded area

5% u

F 19802260

7) In order to keep the protrusion of the pin and bushing constant and the installation dimensions of the steel within the specified value during assembly, adjust the press-fitting jig dimensions of the link press For details of the standard dimensions, see PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS.

F19802261

To leave a small space for the pin when assembling, ensure that the dimension (dimension a’) is greater than dimension “a” at the pin pushing portion of the left press-fitting jig. When assembling in order @ left link press fitting, @ right link press fitting, provide the extra space.for the pin on the right press-fitting jig.

F 19802262

If the end face of the pin (portion P) or the end face of the link (portion 0, R) are worn, add the amount of wear to the standard dimension when adjusting the dimension of the press-fitting jig so that the amount of protrusion of the left and right pin and bushing is uniform. 8) Adjust the relief pressure of the link press to make sure that the pushing force of the press does not exceed the specified value. * If the pushing force is too strong, excessive force will be brought to bear on the spacer, and it will be pushed against the bushing. This will cause the spacer to break or will cause abnormal wear between the spacer and bushing end face. * If the interference at the press-fitting portion is different from when the part is new, as when reusing a pin or bushing, measure several of the press-fitting portions, and use the value below to determine the set pushing force according to the average interference. * Set pushing force of pin and bushing: 150 ton Set pushing force k 1.8 X average pushing force (Adjust the relief pressure of link press to fix the set pushing force)

I-

F19802263

30-171 0

2. Assembly of link 1) Use a clean brush to coat the area between the pin and bushing with oil (G0140B), set in position, then set in front of the jaw of the link press. * When reusing (turning) the bushing, set the worn surface on the outside circumference of the bushing facing the shoe mounting surface of the link (facing up on the link press).

2) Set the left and right bushing end master link with the shoe mounting surface facing up, then press fit to the bushing. * When doing this, use the pin end master link as a support. * Bushing press fitting force: 10 - 35 ton

4) Turn over the master link, and check that the left and right master links have been press fitted in parallel.

30-172 0

5) Measure the amount of protrusion of the left and right bushings with a depth gauge. * Adjust the press-fitting jig for the link press so that the protrusion of the left and right bushings is uniform.

Coat whole circumference

’ F19802299

8) Set the right link in position and install the spacer to the pin. * Check that there is no dirt or dust stuck to the seal surface and bushing end face, then use a clean cloth or brush to coat with oil (G0140B). j, Wipe the spacer with a clean cloth, then install it.

\\ ’ :

”

I=19802270

30-173 0

9) Using the right jig as the receiving end and the left jig as the pushing end, press fit the pin and bushing at the same time. j, When press fitting, the seal may come off the link due to the play, so press fit smoothly. If the seal comes off the link, stop the press-fitting operation and fit the seal correctly on the link, then start the press-fitting operation again. * Pin and bushing press fitting force: 65-105ton

10) Using a fine adjustment

spacer, press fit so that the end face of the pin is in tight contact with the bottom of the receiving jig. * Adjust the depth of lthe hole in the receiving jig so that the protrusion of the left and right pins is uniform.

11) Set the left link in position and install the

spacer to the pin. * Coat with oil in the same way as when installing the right link.

12) Using the left jig as the receiving end and the right jig as the pushing end, press fit the left link. * When press fitting, be careful that the left and right seal and spacer do not come out of position. j, Provide enough space on the left jig so that the end face of the pin does not contact the bottom of the jig. * Link press fitting force: 65 - 105 ton

30-174 0

F 19802273

13) Press fit the link, spacer, and bushing so that they are each in tight contact. * It is impossible to check from outside if they are in tight contact, so control the hydraulic force of the link press and set the relief pressure to a constant value. Then apply hydraulic force and push in until this pressure is reached. For details of the setting for the relief pressure, see “Preparatory work”. links rotate * Check that neighboring together. F19802275

14) After assembling each link, use a dial gauge and pinch bar to measure the end play from the link previously assembled, to check that the link is assembled within the specified value. * If the end play does not come within 0 - 0.13mm even when applying the pushing force until the relief valve is actuated, raise the relief pressure setting gradually to adjust. * Adjust the relief pressure setting carefully and be sure not to raise the pushing force of the link press higher than necessary. Using a shoe bolt hole pitch gauge, check that the distance between the shoe bolt holes is within the standard value. * If the distance between the shoe bolt holes is greater than the specified value, disassemble and check for any abnormality, then press fit again. * If the distance between the shoe bolt holes is smaller than the specified value, and the shoe cannot be installed, the wear of the spacer or bushing end face is probably greater than the repair limit, so disassemble and replace with a new part. * If the end play is too large, the sealing performance will drop, so set the end play to a small value. 16) After assembling each link, use tool KB to remove the air from inside the pin, and check the sealing performance. * Hold the space inside the pin at a vacuum of 650 - 700 mmHg for 5 seconds and check that there is no change in pressure. If the pressure changes, disassemble and check the seal for any abnormality, then assemble again.

30-175 0

17) Assemble the pin end master link as the final link. * Check that the left and right master links are press fitted in parallel.

3. Filling with oil After completion of assembly of the link assembly, fill the pin hole with oil. 1) Using tool KC, remove the air inside the pin from the small plug hole, set to a vacuum of 650 - 700 mmHg, then fill with oil (G0140B) until the pressure is 2 - 3 kg/cm*. * In cold or extremely cold areas, instead of G01408, fill with Komatsu genuine oil (150-09-19270) which has excellent low temperature qualities. j, Be careful not to raise the oil pressure too high as this will have an adverse effect on the seal. * To determine the oil amount, set the small plug end at the top (stand the link assembly on its side), leave for 30 minutes, then charge with oil so that depth L of the space at the pin hole is within the specified value below. Specified value of L: 50 - 80 mm

G0140B

901 FOOl

2) After completion of filling with oil, use tool 2 to knock in the small plug to the specified position. j, Coat the outside circumference of the small plug with G0140B. * Knock in the plug to the depth given below. Depth to drive from end face: 7.5 f 1 mm

30-176 Co

4. Shoe (regular link portion) Set the link assembly on the bed, then use a shoe bolt impact wrench and torque wrench to install the shoe. m

Shoe bolt (regular link): Initial tightening torque: 80 + 8 kgm Tightening angle: 120 f 10

5. Connecting to make l/2 assembly Set two completely assembled portions of track on a flat surface in a straight line with the shoes facing up. Pull master link (1) at the pin end to master link (2) at the bushing end, and set at the mating surfaces. Then put shoe (3) on top, ,check that shoe bolt (4) goes in easily by hand, and connect the two parts. &III&

Mounting bolt: Anti-friction

Shoe bolt (master link): Initial tightening torque: 50 rir:5 kgm Tightening angle: 180 + 10

* *

When tightening, tighten in order 0 - 0. Do not use an impact wrench for the master link mounting bolt.

compound

(LM-P)

F6164026 F19802282

30-l 77 @

4) Use tools Y and 2 to knock the large and small plug into the pin. i) Insert plug into hole in guide through plug insertion window. (Coat the plug with oil.) ii) Push bar by hand and insert the plug as far as it will go. iii) Push plug with bar, and push guide itself against pin. iv) Hit in bar with a hammer. *

Dimension “a” to knock in the plug from end face of pin: Small plug: 7.5 If: 1 mm Large plug: 11 f 2 mm

17MF02805

If the plug is not removed from the pin during disassemlby, it can be used as it is.

5) Clean any part where outside diameter of the pin, front face of the spacer, end face or inside diameter of the bushing are dirty. 6) Coat the outside diameter of the pin and the front face of the spacer with grease. 7) Installation of seal assembly Machines equipped with F3 type seal l Clean the link counterbore, then use tool KA to push the seal in fully to the bottom. * If there is grease stuck to the link counterbore and seal assembly, the seal will rotate and its sealing performance will drop, so do not coat with grease. l

Machines equipped with W7 type seal When reusing the link and replacing the seal with a new part, clean the link counterbore, then push the seal in fully to the bottom. * If there is grease stuck to the link counterbore and seal assembly, the seal will rotate and its sealing wil drop, so do not performance coat with grease.

8) In order to keep the protrusion of the pin and bushing constant and the installation dimensions of the steel within the specified value during assembly, adjust the of the link press-fitting jig dimensions press. * For details of the standard dimensions, JIG DIMENSION see PRESS-FITTING TABLE FOR LINK PRESS. * If the end face of the pin (portion P) or the end face of the link (portions Q, R) are worn, add the amount of wear to the standard dimension when adjusting the dimension of the press-fitting jig so that the amount of protrusion of the left and right pin and bushing is uniform.

Rem from Direction to push in

F 19602259A

Remove all oil and grease from the shaded area

F19602260

a b

F19602261

30-l 79 Co

2. Assembly of link 1) Coat the area between the pin and bushing with lithium grease (G2-LI), set in position, then set in front of the jaw of the link press. * When reusing (turning) the bushing, set the worn surface on the outside circumference of the bushing facing the shoe mounting surface of the link (facing up on the link prss).

IF1 9902264

3) Using a shoe bolt hole pitch gauge, press fit until the distance between the shoe bolt holes of the left and right link is the specified value. * Use compressed air to remove all metal particles from burrs while press fitting the bushing. 4) Turn over the master link, and check that the left and right master links have been press fitted in parallel.

5) Measure the amount of protrusion of the left and right bushings with a depth gauge. jr Adjust the press-fitting jig for the link press so that the protrusion of the left and right bushings is uniform.

30-180 0

6) Feed the master link portion, then set the pin and bushing in position. * When reusing the pin, assemble so that the side hole is on the link tread side in the same way as when the part is new. If the parts are not assembled facing the specified direction, the strength may drop, so mark the direction of the side hole clearly on the end face to prevent any mistake during assembly. * If the outside diameter of the pin is worn, assemble so that the face that is not worn is on the pulling side. However, in this case, also assemble so that the side hole faces the tread surface of the link. 7) Set the left and right links in position, then operate the left and right pushing jigs to press fit the pin and bushing at the same time. * When press fitting, the seal may come off the link due to the play, so press fit smoothly. If the seal comes off the link, stop the press-fitting operation and fit the seal correctly on the link, then start the press-fitting operation again. * Set pushing force of pin and bushing: 150 ton Set pushing force k 1.8 X average pushing force (Adjust the relief pressure of link press to fix the set pushing force)

F19802284

9802285

8) Using a shoe bolt hole pitch gauge, check that the distance between the shoe bolt holes is within the standard value.

9) Assemble the pin end master link as the final link. * Check that the left and right master links are press fitted in parallel.

3. Shoe (regular link portion) Set the link assembly on the bed, then use a shoe bolt impact wrench and torque wrench to install the shoe. QE

Shoe bolt (regular link): Initial tightening torque: 80 f 8 kgm Tightening angle: 120 f 10

F 19802240

30-181 0

4. Connecting to make l/2 assembly Set two completely assembled portions of track on a flat surface in a straight line with the shoes facing up. Pull master link (1) at the pin end to master link (2) at the bushing end, and set at the mating surfaces. Then put shoe (3) on top, check that shoe bolt (4) goes in easily by hand, and connect the two parts. NC& m

Mounting bolt: Anti-friction

compound

(LM-P)

Shoe bolt (master link): Initial tightening torque: 50 f 5 kgm Tightening angle: 180 1- 10

j, When tightening, tighten in order 0 - 0. * Do not use an impact wrench for the master link mounting bolt.

30-182 0

~6164026 F19802282

PRESS-FITTING

JIG DIMENSION

TABLE FOR LINK PRESS

a6-b

Unit: mm

Jig dimension

a 4.525

30-l 84 0

k 2

2.00 Y!Y0.28

53.6

FIELD DISASSEMBLY

OF ONE LINK

section gives only the procedure for A This using the tools. For details of the procedure for disassembly or assembly, see OVERALL DISASSEMBLY (or ASSEMBLY) OF TRACK SHOE. 1. Using two bolts (2), install tool KD-1 (adapter, guide, bolt) to link (1). * It is also possible to use two track bolts for bolt (2).

2. Assemble tool KD-2 (pump, cylinder 150t) and toll KD-3 (frame, rod, adapter, bolt X 1, eyebolt), then raise the assembly and set on the track.

KD-2

KDi3

I-

Insert the rod of tool KD-4 from the cylinder end, and install with two nuts.

4. Set tool KD-5 (adapter, guide, pusher) in position, then apply hydraulic pressure and remove pin (3). When the cylinder reaches the end of its stroke, insert extension KD-5 between the adapter and guide, and repeat the operation.

F19802291

30-l 85 0

5. Set tool KD-6 (30t puller) and spacer 0 to the center of the roller tread of the link to be disassembled, then apply hydraulic pressure to the puller, open the link 5 - 6 mm and disconnect the link.

I F19802292A

30-186 0

FIELD ASSEMBLY

OF ONE LINK Press (or remover)

1. Assemble the link sub-assembly. 1) Set tool KE-1 to the end face of the link, then press fit bushing (1). * Bushing press fitting force: 10 - 35 ton

2) Set tool KE-1 to the end face of the link (pin end), then press fit pin (2). j, Set side hole of pin to the link tread side. * Pin press fitting force: 55 - 70 ton

Press (or remover) Side hole

KE-1

side I

z z

F15421167

I-

2. Set link sub-assembly connected.

(3) on the link to be

F19802294

3. Set link (4) on the opposite side, and support with tool KE-2 (guide).

KE-2

t”o\

F19802295A

30-187 0

4. Set tools KE-3 and KE-4 in the same way as for the operation to remove the pin, then use tool KE-3 (adapter, extension, guide, adapter, bolt) for press fitting the pin, and tool KE-4 (extension, guide, adapter, bolt) for press fitting the bushing, and press fit in turn. * Pin press fitting force: 55 - 70 ton A Bushing press fitting force: 10 - 35 ton

KE-4

KE13

”

F19802296A

5. Use tool KE-7 (30t puller) in the same way as when disassembling, and push open link (5) at the bushing end.

KE-7

F 19802297A

6. Set link (6) at the pin end to link (5) at the bushing end, connect with tool KE-5 (guide), then remove tool KE-7 (puller).

F19802298A

7. Set tool KE-3 at pin (7) end, then use tool KE-6 (adapter, bolt and guide) to press fit (7). AL,

Pin press fitting hole in link: Gasket sealant (198-32-l 9890)

:ylin

A Set side hole of pin to the link tread side. * Pin press fitting force: 110 - 140 ton

F19802299A

30-188 0

DISASSEMBLY

OF MASTER

LINK

1. Removal of track assembly Remove the track assembly from the chassis. 2. Separation of track Disconnect all master into four parts.

portions,

and divide

3. Removal of master link l Master pin type 1) Gas cutting of regular link Gas cut the portion marked WV , and remove @ZB . Special tool to use: Manual gas cutting torches Bus

32FO21

2) Removal of regular link Press pin (1) in the direction of the arrow with a press, remove from link (2), then remove pin (1) and link (3) at the same time from bushing (4).

32F022A

Master link type 1) Gas cutting, removal of master link at bushing end gas cut the portion EBj, then marked WV , remove move master links (5) and (6) up or down to remove them. Push pins (8) and (9) press fitted to regular link (7) with a press in the direction of the arrows to remove them. Special tool to use: 1. Manual gas cutting torches 2. Tool KF

30-l

2) Removal of master link at pin end Gas cut the portion marked WV , remove m , push pin (10) with a press in the direction of the arrow and remove from link (1I), then remove pin (IO) and link (12) at the same time from bushing (13). Special tool to use: 1. Manual gas cutting torches 2. Tool KF

32F024A

30-190 a

ASSEMBLY

OF MASTER

LINK

1. Assembly of link at bushing end 1) Using a press, press fit master link (1) at the bushing end to bushing (2). A When press fitting the left and right master links, be extremely careful to keep them parallel. * Be careful not to scratch or damage the mating surface of the master link and the end face of the bushing. Unit: b

184.15

F19802300

k 0.7

2. Assembly of link at bushing end 1) Push open the central part of the link tread with tool KE-7 as shown in the diagram. (Open approx. 10 mm at the tip of the link.)

-7 mm

17MF02806

2) Set spacer (3) and seal assembly (4) at the counterbore of the link at the connection.

32F014A

30-191 0

3) Align the pin hole and bushing hole, and connect with guide pin 0.

32FO15A

4) Remove puller KE-7, press fit pin (5) with tool KF, and install master link (1) at the bushing end. /r;\*

Pin press-fitting hole in link: Gasket sealant (198-32-l 9890) Set side hole of pin to the link tread side.

’

Press fit

32F016A

5) Install the shoe to the link at the connection. 6) After knocking in large plug (6) with tool Y, fill with oil using tool KC, then knock in small plug (7) with tool 2. fitting the left and right * When-press master links, be extremely careful to keep the left and right links parallel. (bushing end and pin end) * Be careful not to scratch or damage the mating surface of the master link and the end face of the bushing. * End play at connection (play in thrust direction of links in front of and behind pin): 0 - 0.13 mm * Be extremely careful not to get mud or dust on the tap hole mating face of the master link, bushing end face, spacer, or seal.

30-192 0

32FO18A

3. Assemblv of link at Din end 1) Set spacer (3) and’ seal assembly (4) in the counterbore of the master link.

Link

p,f

Bushing

I 32F014A

2) Pass pin (9) through bushing (8), set pin end master link (10) from the left and right, then press fit with tool KF. 3) After knocking in large plug (11) with tool Y, fill with oil using tool KC, then knock in small plug (12) with tool 2.

9’i-1 Fl gBO2301

8 H 12 5; 4) Connecting master link portion Set two completely assembled portions of track on a flat surface in a straight line with the shoe facing up. Pull master link (13) at the pin end to master link (14) at the bushing end, and set at the mating surfaces. Then put the shoe on top, and check that the shoe bolt goes in easily by hand. Mounting bolt: Anti-friction

compound

(LM-P)

Shoe bolt (master link): Initial tightening torque: 50 + 5 kgm Tightening angle: 180 + 10

32FOZOA

30-193 0

REMOVAL 1.

For details, ASSEMBLY.

Remove

OF PIVOT SHAFT TWISTING see REMOVAL

twisting

OF TRACK

seal assembly

SEAL

FRAME

(I).

1’

i_Lf

17MF0269C

INSTALLATION OF PIVOT SHAFT TWISTING SEAL l

Carry out installation removal.

in the

reverse

Using tool N, press fit twisting

bly (1). Press-fitting

* &

order

seal assem-

force: 17.6 - 31.4 kN Il.8 - 3.2 ton1 Set the distance from the end face of the shaft to the end face of the metal fitting on the inside of the seal ring to the dimension below. Dimension a: 493 * 1.0 mm Remove all oil and grease from the oil seal press-fitting surface. .. Press fitting surface Of seat: Gasket sealant (LG-6)

30- 194 @

09002981

1. For details,

see REMOVAL

OF TRACK FRAME

ASSEMBLY. 2. Remove twisting seal assembly. For details, see REMOVAL OF PIVOT SHAFT TWISTING SEAL. 3. Sling pivot shaft assembly

(1).

bolts, then using forcing 4. Remove mounting screws 0 and guide bolts 0, pull out pivot shaft assembly. &

Pivot shaft assembly:

160 kg

INSTALLATION OF PIVOT SHAFT ASSEMBLY l

Carry out installation removal.

in the reverse

marks at the top when

* mu w

Set with the match assembling.

Pivot shaft: Anti-friction Press-fitting

force:

0.1 -

order

compound

(LM-P)

2.0 ton

Pivot shaft mounting bolt: Thread tightener Pivot shaft mounting

(LT-2)

bolt: 159.5 k 17.5 kgm

30-l 95 0

REMOVAL OF EQUALIZER BAR ASSEMBLY

1. Using transmission jack, remove underguard (1) under engine and under power train. 2. Disconnect 2).

greases hoses (2) (front: 2, rear:

3. Remove stopper plate, and pull out pins (3), then remove rods (4) (front: 1, rear: 1). lfll 4. Remove (5).

mounting

5. Remove mounting (6).

bolts of left twisting

seal

bolts of right twisting seal

6. Remove right side pivot shaft covers (7) and (8). m 7. Remove holder (9), and disconnect hose (IO).

blade tilt

8. Remove plates (11) and (12). A The oil inside the pivot chamber will leak out, so put a container under it to catch the oil. : Pivot chamber: 12 e u

30-196 0

17MF02695

9. Remove

left and right pin covers

(13) and

(14). 10. Remove lock plate, then remove left and right shafts (15). m 11. Sling equalizer bar assembly and chain block. 12. Support bottom frame draulic jack (30 ton).

(16) with crane

of machine

with hy-

17MF02702

Hydraulic jack

17MF02704

17MF02701

13. Remove lock plate, then set tool 0 in position, pull out center shaft (17). m operating the hydraulic system, A When do not operate it in front of or under the puller. Operate possible. PI kg 14.

it from as far away as

Center shaft: 25 kg

Raise machine hydraulic jack.

approx.

200 mm more with

15. Operate chain block while operating crane to remove equalizer bar assembly (16). .A\ m equalizer bar assembly: 300 kg

After removing the equalizer bar assembly, do not lower the machine.

Front side

17MF02705

30-l 97 0

INSTALLATION

OF EQUALIZER

BAR ASSEMLY Oil quantity of pivot shaft

Carry out installation removal.

Mounting

in the reverse order to

bolt: Thread

Oil level

tightener

(LT-2)

112] w * &

Mounting bolt: 277.0 + 31.9 Nm I28.25 d 3.25 kgm) The stopper plate and pin stopper are in tight contact. Cover mounting bolt: Thread tightener (LT-2)

-1 I

T -

Add oil to replace the oil that leaked out from the pivot shaft chamber. (For the oil level, see the diagram on the right.)

a Serial No. : 10001 - 10127 & Outside surface of pin: Greese (G2-LI) Before installing the side shaft, align the position of flanged bushing (18) and the track frame slit, and drive in so that bushing (18) is in tight contact with faces b and c. t

Clearance d between the equalizer bar and the track frame is the same (15 5 2 mm) at the front and rear. (When checking this, check that surfaces a, b and c are in tight contact.) k Measure stepped difference A between surface e and surface f with a depth gauge, and adjust with shims so that it is 0.2 - 0.3 mm. Ir When tightening the mounting bolts of the lock plate at the rear of the machine to the specified torque 549.2 + 8.8 Nm (56 f 6 kgm), if the flanged bushing (18) rotates, tighten mounting bolts (19) of cover (14) first to a maximum of 147 Nm (15 kgm1, then tighten the lock plate to the specified torque, and tighten mounting bolt (19) again to the specified torque. QEI Mounting bolt of lock plate at rear of machine: 549.2 z 58.8 Nm {56 2 6 kgm} &

Outside

17MF02708

’ frame Track

surface of center shaft: Grease (G2-LI)

I 30-198

Slit aiea

17MF02710

Serial &

No.: 10128 and up

of pin : Grease (G2-LI) Before installing the side shaft, align flanged bushing (18) and position of slit in track frame, then drive in bushing (18) until it is in tight contact with surfaces b and c. Clearance d between the equalizer bar and the track frame must be the same (15 2 2 mm) at the front and rear. (When measuring, check that surfaces a, b, and c are in tight contact.) When tightening the lock plate mounting bolts to the specified tightening torque (549.2 r 58.8 Nm {56 f 6 kgm)), if flanged bushing (18) rotates, tighten mounting bolts (19) of cover (14) to a maximum of 147 Nm (15 kgm), then tighten the lock plate mounting bolts, and finally tighten mounting bolts (19) to the specified tightening torque. Lock plate mounting bolt: 549.2 + 58.8 Nm (56 + 6 kgm} Outside

surface

DBD02982

m &

Center shaft outside

surface : Grease (G2-LI)

30-198-l @

REMOVAL OF EQUALIZER BAR SIDE BUSHING

1. For details, see BAR ASSEMBLY.

REMOVAL

OF EQUALIZER

2. Remove seal (1).

3. Remove Ring (2).

17MF02711

4. Using tool P, pull out spherical bushing (3).

i 17MF02712

30- 199 0

INSTALLATION

OF EQUALIZER

install ring (2) on one side.

Using tool P, press fit spherical bushing (3). Direction of assembly for spherical bush* ing I) The split face of the outside ring should be horizontal as shown in the diagram. 2) The grease hole in the outer ring should be at the top and facing the inside as shown in the diagram. &

Outside surface of spherical bushing: compound (LM-P) Anti-friction

Press-fitting force: 68.6 - 133.4 kN I7 - 13.6 tons}

BAR SIDE BUSHING

17MF02713

Split face

Grease hole

side.

Install ring on poopsite

Using push tool, press fit seals (I) on both side.

Serial No. : 10001 - 10127

Inside, outside circumference of seal: Gasket sealant (LG-6)

Serial 5.

Remove equalizer bar assembly. For details, see REMOVAL OF EQUALIZER BAR ASSEMBLY.

30-200 @

No. : 10128 and up

/’

REMOVAL OF SUSPENSION

CUSHION ASSEMBLY

1. Remove equalizer bar assembly. For details, see REMOVAL OF EQUALIZER BAR ASSEMBLY. 2. Set transmission jack under machine, and remove mounting bolts, then remove cap (1) and cushion (2). m

3. Operate transmission jack slowly, and remove bolster assembly (3). 4. Remove cushion (4). m

z zb TT

02716

INSTALLATION OF SUSPENSION CUSHION ASSEMBLY l

Carry out installation removal.

a w

1jMFO2717

in the reverse order to

Mounting bolt: Thread tightener

(LT-2)

Mounting belt: 135 + 15 kgm

m *

The distance between the end face of the circular portion and the machined surface shall be dimension a. The installation dimensions shall be the same on both the left and right sides. a=30flmm

Machined

surface

17MF02719

30-201 0

REMOVAL OF SEGMENT TOOTH

1. Stop machine at position where tooth can be removed (between shoe and track frame). 2. Remove 2 covers (1). 3. Remove (2). m

mounting bolts, then remove -

tooth

IN STALLATION OF SEGMENT TC 1OTH l

Carry out installation removal.

in the reverse order to

m m

30-202 0

Tooth mounting nut: 120 + 10 kgm

REMOVAL OF HYDRAULIC PUMP ASSEMBLY

Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. 1. Drain oil : u Hydraulic tank oil: Approx 95n 2. Remove floor frame assembly. For details, see REMOVAL OF FLOOR FRAME ASSEMBLY. 3. Disconnect hydraulic connector (1). 4. Disconnect hoses (3).

suction

oil temperature

tube

wiring

(2) and 3 delivery

5. Remove mounting bolts, and lift off hydraulic pump assembly (4). &

0”

2 z

Hydraulic pump assembly:

35 kg

INSTALLATION OF HYDRAULIC PUMP ASSEMBLY l

Carry out installation in the reverse order to removal. Refilling with oil Add engine oil inside the hydraulic tank to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again.

30-203 0

REMOVAL OF BLADE LIFT VALVE ASSEMBLY

1. Drain oil. /ci7+

Hydraulic tank: Approx 95 e

2. Remove side cover of hydraulic tank. 3. Remove rod (1). 4. Disconnect pilot hose (2). 5. Disconnect tube (3). 6. Disconnect hose (4). 7. Remove blade lift valve assembly (5). * Sling the lift valve assembly, and remove the mounting bolts. /L m Blade lift valve assembly: 60 kg

INSTALLATION OF BLADE LIFT VALVE ASSEMBLY . .

Carry out installation in the reverse order to removal. Refilling with oil Add engine oil to the hydraulic tank to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again.

30-204 0

DISASSEMBLY

OF BLADE LIFT VALVE ASSEMBLY

1. Disassembly of main spool assembly Remove lever case assembly (1). Remove case (2). then remove retainer (3), plug (4) and collar (5) from case. Remove plug (6), then remove spring (7), spacer (8) and ball (9). Remove spring (IO), then remove retainer (11) and spool (12). * If there is any abnormality in the spool or body, replace the spool and body as an assembly.

2. Disassembly of demand valve assembly 1) Remove case (13), then remove spring (14). 2) Remove plate (15), then remove spool (16) and seal (17).

3. Disassembly of main relief, shuttle valve assembly 1) Remove main relief valve assembly (18). * If the adjusting screw nut is loosened and the screw turned, the set pressure will change, so do not disassemble. 2) Remove plug (19), then remove piston (20), shuttle valve spool (21) and spring (22). 3) Remove valve body (23).

4. Disassembly of suction valve assembly Remove plug (24), then remove spring (25) and valve (26). 5. Disassembly of check valve assembly Remove plug (27), then remove spring (28) and valve (29). 6. Disassembly of shuttle valve assembly Remove plug (30). then remove ball (31).

30-206 0

30-207 a

ASSEMBLY OF BLADE LIFT VALVE ASSEMBLY

Clean all parts, and check for dirt or damage. Coat the- sliding surfaces of all parts with engine oil before installing.

1. Assembly Assemble

of shuttle valve assembly ball (31), then fit O-ring and install

plug (30). Q!Z

Plug: 3.5 f0.5

Plug: 37.5 +2.5

(28), fit O-ring

kgm

3. Assembly of suction valve assembly Assemble valve (26), spring (25), fit O-ring and install plug (24). w

Plug: 52.5 +2.5

Mounting bolt: The first time 3.5 f 0.5 kgm The second time 6.75 f 0.75 kgm

Tighten the mounting bolts in order shown. 2) Assemble spring (22). shuttle valve spool (21) and piston (20), then fit O-ring and install plug (19). m

Plug: 7fl

kgm

3) Install main relief valve assembly (18). m

30-208 0

Case mounting bolt: 19 I!I 1 kgm

2) Assemble spring (14) and install (13). Mounting bolt: 19fl

kgm

6. Assembly of main spool assembly I\ Fit O-ring and install lever case assembly ‘I (1). 2) Set spool (12), retainer (11) and spring (10) in position. 3) Assemble ball (9), spacer (8) and spring (7) in case (2), then fit O-ring and install plug (6). QE

Plug: 3.5 f0.5

kgm

4. Assembly of main relief, shuttle valve assembly 1) Fit O-ring and install valve body (23). m

kgm

2. Assembly of valve assembly Assemble valve (29), spring and install plug (27).

5. Assembly of demand valve assemblv 1) Assemble seal (17) and spool (16), then fit O-ring and install case (15).

Relief valve assembly:

8.5 f 1.5 kgm

It the valve assembly has been disassembled, insall the main control valve aseembly on the machine, then turn the adjustment screw to adjust the set pressure to 210 kg/cm*.

4) Set collar (5), plug (4) and retainer (3) in case (2), then fit O-ring and install case (2).

197F371

30-209 a

REMOVAL OF BLADE TILT, RIPPER LOW VALVE ASSEMBLY

Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. 1. Drain oil. : u Hydraulic tank: Approx 95 II 2. Remove side cover of hydraulic tank. 3. Remove hydraulic tank support bracket (1).

17MF02724

17MF02725

4. Disconnect blade lift control rod (2). 5. Remove control rods (3), (4) and (5) of work equipment. * Before removing the rods, mark the position of installation. 6. Disconnect tube (6) between blade tilt-ripper low valve and blade lift valve at blade lift valve end. 7. Di$;,nrct

hoses (71, (81, (91, (IO), (1 I), (121, 1’1

Before disconnecting the hoses, mark the position of installation.

8. Sling the valve (14) assembly, the mounting bolts. &

then remove

Blade tilt, ripper low valve assembly: 54 kg

INSTALLATION OF BLADE TILT, RIPPER LOW VALVE

Carry out installation in the reverse order to removal. Refilling with oil * Add engine oil to the hydraulic tank to the specified level, and run the engine to circulate the oil through the system. Then check the water level again.

30-210 0

17MF02726

DISASSEMBLY

OF BLADE TILT, RIPPER LOW VALVE ASSEMBLY

1. Disassembly of spool assembly 1) Remove case assembly (I), then remove collar (2) from case assembly. 2) Remove joint (3). * Always loosen the joint with the spool assembled in the body. 3) Remove case (4). 4) Remove bolts (5), then remove washer (6), retainer (7), spring (8), collar (9) and retainer (IO). * Always loosen the bolts with the spool assembled in the body. 5) Pull out spool (11) from body (12). * If there is any abnormality in the spool or body, replace the spool and body as an assembly. Main relief valve assembly Remove main relief valve assembly (13). * If the cover is removed and the adjustment screw turned, the set pressure will change, so do not disassemble unless necessary. 3. Disassembly of check valve assembly Remove mounting bolts (14). then remove bar (15), seat (16), spring (17) and valve (18). 4. Disassembly of shuttle valve assembly Remove plug (19), then remove seat (20) and ball (21).

30-212 a

1'4

17MF02728

30-2 13 0

ASSEMBLY OF BLADE TILT, RIPPER LOW VALVE ASSEMBLY

Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.

1. Assembly of shuttle valve assembly 1) Assemble ball (21) in plug (19), fit O-ring, then assemble seat (20). 2) Fit O-ring and install plug assembly. m

Plug: 3.5+_0.5 kgm

2. Assembly of check valve assembly 1) Assemble valve (18) and spring (17). 2) Fit O-ring and assemble seat (16), then install bar (15) and tighten bolts (14). Main relief valve assembly Fit O-ring and install main relief valve assembly (13). QE

Main relief valve assembly: 8.5 f 1.5 kgm If the valve assembly has been disassembled, install the main control valve assembly on the machine, then turn the adjustment screw to adjust the set pressure to 210 kg/cm’.

4. Assembly of spool assembly 1) Assemble spool (11) in body (12). 2) Set retainer (IO), collar (9), spring (8). retainer (7) and washer (6) in position, then tighten bolts (5). * Always tighten the bolts with the spool assembled inside the body. m

Bolt: 3.5 f 0.5 kgm

3) Fit O-ring and install case (4). 4) Install joint (3). * Always tighten the bolts with the spool assembled inside the body. w

Joint: 6.75 f 0.75 kgm

5) Assemble collar (2) in case assembly, then fit O-ring and install case assembly (1). w

30-214 0

Mounting

bolt: 3.15 f

0.35

kgm

17MF02728

30-215 0

REMOVAL OF RIPPER HIGH VALVE

Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. 1. Drain oil : u Hydraulic tank: Approx 95 P 2. Disconnect bracket of fuel drain hose (1) from valve. 3. Disconnect 14 pipes (2), (3), and (4). 4. Remove valve assembly (5).

INSTALLATION OF RIPPER HIGH VALVE ASSEMBLY l

30-216 a

Hydraulic tank: Approx 95 P

17MF02730

DISASSEMBLY

OF RIPPER HIGH VALVE ASSEMBLY

1. Disassembly of valve assembly 1) Remove blocks (1) and (2). 2) Remove plug (3), then remove ball (4). 3) Disassembly of fixed differential pressure valve assembly. i) Remove plug (5), then remove retainer (6), spring (7) and retainer (8). ii) Pull out spool (9). * Always loosen the plug with the spool assembled inside the valve. 4) Disassembly of ripper lift high valve assembly. i) Remove plug (IO), then remove spring (11) and retainer (12). ii) Remove plug (13), then remove spring (14) and retainer (15). iii) Pull out spool (16). * Always loosen the plug with the spool assembled inside the valve. 5) Disassembly of ripper tilt high valve assembly. Repeat the procedure for disassembling the ripper lift high valve and disassemble the ripper tilt high valve. 6) Remove plug (17), then remove spring (18) and check valve (19). 7) Remove plug (20), then remove seat (21), spring (22) and valve (23).

30-218 0

i7 3

197F373

30-2 19 0

ASSEMBLY OF RIPPER HIGH VALVE ASSEMBLY

Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.

1. Assembly of valve assembly 1) Assemble valve (23), spring (22) and seal (21), then fit O-ring and install plug (20). m

Plug: 52.5 + 2.5 kgm

2) Assemble check valve (19) and spring (18), then fit O-ring and install plug (17). m

Plug: 13 f

2 kgm

31 Assembly of ripper lift high valve assembly: i) Assemble spoool (16). ii) Set retainer (15) and spring (14) on spool, then fit PO-ring and install plug (13). m

Plug: 6.75 f

0.75 kgm

iii) Set retainer (12) and spring (11) on spool, then fit O-ring and install plug (IO). m *

Plug: 6.75 f

0.75 kgm

Always tighten the plug with the spool assembled inside the valve.

4) Assembly of ripper tilt high valve assembly. Repeat the procedure for assembling the ripper lift high valve and assemble the ripper tilt high valve. of fixed differential pressure 5) Assembly valve assembly. i) Assemble spool (9). ii) Set retainer (8), spring (7) and retainer (6) on spool, and install plug (5). * Always tighten the plug with the spool assembled inside the valve. ball 6) Assemble install plug (3). m

(4). then

fit

O-ring

Plug: 3.5 + 0.5 kgm

7) Fit O-ring and install blocks (2) and (1).

30-220 0

and

197F373

30-221 0

REMOVAL OF BLADE LIFT CYLINDER ASSEMBLY

Lower the work equipment completely to the A ground. 1. Sling head end of lift cylinder assembly, and remove cap (1). m * Check the number and thickness of the shims, and keep in a safe place.

, Start engine, retract piston rod fully, tie the rod with wire to prevent it from coming out, then stop engine. *

After stopping the engine, operate the control lever several times to release the pressure in the hydraulic remaining piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

2. Disconnect hose (2). * Fit a blind plug to prevent dirt or dust from entering the piping. 3. Sling cylinder assembly (3), then remove cap m (4), then remove cylinder assembly. f+l I

Blade lift cvlinder assembly:

210 kg

INSTALLATION OF BLADE LIFT CYLINDER ASSEMBLY l

Carry out installation removal.

a l

in the reverse order to

Standard shim thickness:

Yoke:

4 mm

Grease (G2-LI)

Bleeding air Bleed the air from cylinder. For details, see TESTING AND ADJUSTING.

30-222 0

F19802231

REMOVAL OF BLADE TILT CYLINDER ASSEMBLY Lower the work equipment completely to the A ground. 1. Sling tilt cylinder assembly (I), and remove lock plate, then pull out pin (2). m Start engine, retract piston rod fully, then A stop engine. +

2. Disconnect 2 hoses (3). * Fit a blind plug to prevent dirt or dust from entering the piping. 3. Remove lock plate, and pull out pin (4), then m remove tilt cylinder assembly. * When slinging, be careful not to damage the hose with the bottom end. & kg

Blade tilt cylinder assembly: 225 kg

INSTALLATION OF RIPPER TILT CYLINDER ASSEMBLY l

Carry out installation removal.

in the reverse order to

Pin: Grease (G2-LI)

Bleeding air Bleed the air from cylinder. For details, see TESTING AND ADJUSTING.

30-223 0

REMOVAL OF RIPPER LIFT CYLINDER ASSEMBLY the work equipment completely to the A Lower ground. 1. Sling lift cylinder assembly (I), remove lock plate, then pull out pin (2) at head end. m

Start the engine and retract the piston rod fully. Stop the engine and operate the control lever several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

2. Disconnect 2 hoses (3). * Fit a blind plug to prevent dirt or dust from entering the piping. [121 3. Remove lock plate, then pull out pin (4) at bottom end and lift off cylinder assembly (1).

f=h

Ripper lift cylinder assembly:

205 kg

INSTALLATION OF RIPPER LIFT CYLINDER ASSEMBLY 0

Carry out installation removal.

in the reverse order to

Pin: Grease (G2-LI)

Bleeding air Bleed the air from cylinder. For details, see TESTING AND ADJUSTING.

30-224 0

REMOVAL OF RIPPER TILT CYLINDER ASSEMBLY

Lower the work equipment ground.

completely to the

1. Sling tilt cylinder assembly (I), remove lock plate, then pull out pin (2) at head end. m the engine and retract the piston rod A Start fully. Stop the engine and operate the control lever several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

I-

2. Disconnect 2 hoses (3). * Fit a blind plug to prevent dirt or dust from entering the piping. 3. Remove lock plate, and pull out pin. & kg

Ripper tilt cylinder assembly:

m 190 kg

z 0

INSTALLATION OF RIPPER TILT CYLINDER ASSEMBLY 0

Carry out installation removal.

in the reverse order to

Pin: Grease (GZ-LI)

RZZ+

Pin: Grease (GZ-LI)

Bleeding air Bleed the air from cylinder. For details, see TESTING AND ADJUSTING.

30-225 0

DISASSEMBLY

OF HYDRAULIC CYLINDER ASSEMBLY

(BLADE LIFT, BLADE TILT, RIPPER LIFT, RIPPER TILT CYLINDER)

1. Cylinder tube Remove cylinder tube. 2. Quick drop valve (blade lift cylinder) Remove block (I), then pull out spring (2), spacer (3), valves (4) and (5), and collar (6).

3. Piston rod assembly 0 Blade lift cylinder 1) Set cylinder assembly (7) to tool Q,. 2) Using hydraulic pump or power wrench, disconnect head assembly (8) with tool Q,. 3) Pull out piston rod assembly (9). * Put an oil pan or container under the cylinder to catch the oil.

1 l1h.iF02737 Blade tilt, Ripper lift, Ripper tilt cylinder y, Remove mounting bolts, and disconnect head assembly (10). 2) Pull out piston rod assembly (11). * Put an oil pan or container under the cylinder to catch the oil.

17MF0273P

4. Piston assemblv Blade lift cyli;der bolts, then remove mounting Remove spacer (12), and pull out valve (13). 2) Remove piston assembly (14). 3) Remove backup rings (15), and O-ring (16). 4) Remove retainer (17).

17MF02739

30-226 0

5) Disassemble the piston assembly as follows. i) Remove wear ring (18). ii) Remove piston ring (19). iii) Pull out seat (20), and valve (21).

I . 1) 2) 3) 4)

Blade tilt, ripper lift, ripper tilt cylinder bolts, then remove mounting Remove spacer (22). Pull out piston assembly (23). Remove backup ring (24) and O-ring (25). Disassembly of piston assembly i) Remove wear ring (26). ii) Remove piston ring (27).

I.8

I95FO5365

23 24

17MF02740

I95FO5364 Blade tilt

5. Head assembly 1) Remove head assembly (8) or (IO). 2) Disassemble the head assembly as follows. i) Remove O-ring (28). (only for blade cylinder) ii) Remove O-ring (29) and backup ring (36). iii) Remove packing (31). iv) Remove snap ring (32), then dust seal (33). v) Remove bushing (34).

17MF02741

Blade lift

remove Blade tilt Ripper lift Ripper tilt

30-227 0

ASSEMBLY

OF HYDRAULIC CYLINDER ASSEMBLY

(BLADE LIFT, BLADE TILT, RIPPER LIFT, RIPPER TILT CYLINDER) *

Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. Be careful not to damage the packings, dust seals, and O-rings when assembling.

1. Head assembly 1) Assemble head as follows. i) Press fit bushing (34). ii) Assemble dust seal (33), and secure with snap ring (32). iii) Assemble packing (31). iv) Assemble backup ring (30) and O-ring (29). * Do not try to force the backup ring into piston. Warm it in warm water (50 - 60°C) before fitting it. v) Assemble O-ring (28). (blade lift cylinder only) 2) Assemble head assembly (8) or (10) to piston rod.

Blade tilt Ripper lift Ripper tilt

Blade lift

Blade tilt Ripper lift Ripper tilt

17MF02741

2. Piston assembly Blade lift cylinder l 1) Assemble the piston as follows. i) Assemble valve (21) and seat (20). ii) Using tool Q,, expand piston ring (19). j, Set the piston ring on tool Qs and turn the handle 8 - 10 times to expand the ring. iii) Remove piston ring (19) from tool 4, then install it to piston. iv) Using tool Q,, compress piston ring (19). v) Assemble wear ring (18).

J18

30-228 0

17MF02743

17MF02744

2:2FO5487

I 97F3779

2) Install retainer (17). 3) Install O-ring (16) and backup rings (15). * Do not try to force the backup ring into the piston. Warm it in warm water (50 - 60°C) before fitting it. * Coat the O-ring and the backup rings with grease, then secure the backup rings so that they do not open. 4) Install piston assembly (14). 5) Assemble valve (13) to spacer (12), then fit spacer and tighten with mounting bolts. /‘r\w

Mounting bolt: Thread tightener

17MF02739

(LT-2)

Mounting bolt: 11.25 Z!I 1.25 kgm

@Y c3

Blade tilt, ripper lift, ripper tilt cylinder

1) Using tool Q, in the same way as for Step

2’7

2-l) -ii) - iv), assemble piston ring (27), then assemble wear ring (26).

I95FO5364

2) In the same way as for Step 2-3) - 4), assemble O-ring (25), backup ring (24), and piston assembly (23). 3) Fix spacer (22) in position, then tighten with mounting bolts. &,

Mounting bolt: Thread tightener

Mounting bolt: 11.25 k 1.25 kgm

(LT-2)

17MF02740

3. Piston rod assembly Blade lift cylinder l 1) Set cylinder (35) in tool 0,. 2) Assemble piston rod assembly (9) to cylinder. Z-EL

Seal portion:

Grease (G2-LI)

Push the piston rod in the end of its stroke. 3) Using tool Q,, tighten head assembly (8). *

Head assembly:

105 _+ 10.5 kgm ,

1 :dFO2737

30-229 0

Blade tilt, ripper lift, ripper tilt cylinder piston rod assembly (11) cylinder (36).

;, Assemble H-E>=

Seal portion:

Grease (G2-LI)

Push the piston rod in to the end of its stroke. 2) Tighten head assembly (10) with mounting bolts. m

Mounting bolt: 17MF02745

Quick drop valve (blade lift cylinder only) Assemble collar (6), valves (5) and (4), spacer (3), and spring (2), then fit O-ring and install block (1). Tube Fit O-ring and install tube.

30-230 0

l98FO2792

REMOVAL OF WORK EQUIPMENT ASSEMBLY

Stop the machine on a firm, level place, and lower the work equipment to the ground. securely under the Then put blocks 0 straight frame on the left and right.

1. Remove cap (1).

m j, Check the number and thickness shims (2), and keep in a safe place.

of the

2. Sling blade lift cylinder (3), start engine and retract piston rod fully, then fit cylinder lock plate to secure to guard. A Tie the rod with wire to prevent it from coming out. * Repeat Steps 1 to 2 to disconnect the cylinder on the other side from the blade.

175FO2577

Stop the engine and operate the control lever several times to release the pressure in the hydraulic remaining piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

2 17MF02746

17MF02747

3. Remove right cover (4). 4. Disconnect hose (5). A Make match marks before disconnecting the hose. * Fit a blind plug to prevent dirt or dust from entering the piping. 5. Remove left and right trunnion caps (6).

6. Remove work equipment assembly (7). IfEt21 A Start engine and drive machine slowly in blade assembly reverse to disconnect from trunnion on track frame.

I98FO2808

30-231 0

INSTALLATION

Carry out installation removal.

OF WORK EQUIPMENT ASSEMBLY

in the reverse order to

Adjust so that play C of the spherical portion in the axial direction is within 0.5 mm, but can still rotate smoothly. Standard shim thickness: 4 mm

Adjust with a block @ so that the height and width of the left and right straight frames are dimensions A and B as shown below. Dimensions A: Approx. 2876 mm Dimensions B: Approx. 559 mm

198F1423

30-232 0

DISASSEMBLY

OF WORK EQUIPMENT ASSEMBLY

Insert 5 blocks 0 under the left and right A straioht frames, the bottom of the blade, and the left and right arm mounts to set the dozer assembly securely in the position. 1. Sling tilt brace (I), and remove lock plate, then pull out pin (2). * If the pin is stiff, rotate brace (1) with lever (3) to adjust. 2. Remove lock plate, then remove tilt brace (1). &

Tilt brace:

pull out pin (4) and

150 kg

17MF02749

3. Raise right center brace (5) and left center brace (6), remove pins (7) and (8) and connection with straight frame, then remove. m

A *

8 z lz

Always prevent

put block @ under arm (9) from falling.

the arm to

There are shims at the spherical connection at the straight frame end, so check the number and thickness of the shims, and keep in a safe place. &

Center brace:

130 kg

4. Sling straight frame (IO), then connecting pin (11) and lift off. & *

Straight

frame:

17MF02749

4 remove

900 kg

Check the condition of the block and be careful to prevent the blade from falling over during the operation.

._ 10

17MF02750

\11 17MF02751

30-233 0

5. Raise blade (12) and tip blade over. 6. Raise right arm (13), remove connection of blade (12) and left arm (14), then remove. Raise left arm (14). then remove from blade (12). PI kg

Blade: 3550 kg

6 kg

Arm:

175 kg

A There are shims at both ends and at the center spherical connection, so check the number and thickness of the shims, and keep in a safe place.

17MF02752

17MF02753

8 z z

30-234 0

ASSEMBLY OF WORK EQUIPMENT ASSEMBLY

* There

* .

are shims at all connections, so assemble the same number and thickness of shims as was disassembled, and adjust all dimensions. Coat the connecting pins with grease when installing. Carry out assembly in the reverse order to disassembly.

* Adjust * *

the shim at the spherical joint so that play of the spherical portion in the axial direction is within 1 mm, but can still rotate smoothly. Standard shim thickness: 4 mm If the arm does not match when connecting, shake the straight frame on the left or right to align.

1121 . Adjusting dimension C * Adjust so that the play of the spherical

portion in the axial direction is within 1 mm, but can still rotate smoothly. Standard shim thickness: 4 mm

C F15A01185

30-235 0

DISASSEMBLY

OF RIPPER ASSEMBLY

1. Set block 0, raise machine, and lower blade assembly to ground.

A Lock brake pedal securely. 2. Sling shank (1) temporarily, operate pin-puller cylinder and pull out pin. (For giant ripper) 3. Start engine, raise ripper fully, then shank (1) gradually, and remove. & kg

Shank:

lower

350 kg

4. Set block 0 under arm and beam to support ripper assembly. 5. Sling lift cylinder assembly (2) temporarily, remove pin (3). * Start engine, retract piston rod fully, and lower to arm. 6. Sling tilt cylinder assembly (4) temporarily, remove pin (3). * Start engine, retract piston rod fully, and lower to arm. *

Operate the control levers several times to release the remaining pressure in the hydraulic piping.

7. Sling beam (6), then using forcing screws 0, remove left and right pins (7) and remove beam (6). Beam:

1750 kg

8. Disconnect hoses (8) and (9). 9. Sling tilt cylinder assembly remove pin (10) and lift off.

el kg

Tilt cylinder assembly:

IO. Sling lift cylinder assembly remove pin (11) and lift off. & kg

Lift cylinder assembly:

(4) temporarily, 190 kg (2) temporarily, 205 kg

11. Sling arm, then using forcing screws Q, remove left and right pins (12), and remove arm (13). & kg

30-236 0

Arm:

700 kg

2755

ASSEMBLY OF RIPPER ASSEMBLY

1. Insert block under the arm, and set arm (13) in mounting position, install left and right pins (12) and lock with lock plate.

assembly (2) in mounting 2. Set lift cylinder position, then install pin (11) and lock with lock plate. 3. Set tilt cylinder assembly (4) in mounting position, then install pin (10) and lock with lock plate. 4. Connect

hoses (9) and (8).

5. Insert block 0 under the beam, and set beam (6) in mounting position, install left and right pins (7) and lock with lock plate. assembly (4) temporarily, 6. Sling tilt cylinder start engine, extend piston rod and align pin hole, then install pin (5) and lock with lock plate.

8 Is z

7. Sling lift cylinder assembly (2) temporarily, start engine, extend piston rod and align pin hole, then install pin (3) and lock with lock plate. 8. Set block 0, raise machine, assemly to ground.

and lower

‘/

17MF02759

blade

A Lock brake pedal securely.

9. Start engine, raise ripper assembly, and insert wire in hole of shank holder hook, then raise shank (1) gradually, align pin hole and install. 10. Raise blade, lower

machine

11. Bleed the air from hydraulic

from block 0. cylinder.

Bleeding air Bleed the air from cylinder. For details, see TESTING AND DADJUSTING. * Refill each connect pin with grease.

30-237 0

REMOVAL OF ROPS GUARD

1. Sling ROPS gvard (I), and remove mounting bolts, then remove ROPS guard. )#II &

ROPS guard:

INSTALLATION GUARD l

Carry out installation removal.

550 kg

OF ROPS

in the reverse order to

m m

30-238 0

Guard mounting bolt: 135 f

15 kgm

762

REMOVAL OF OPERATOR’S CAB ASSEMBLY

Disconnect the cable from the negative terminal of the battery.

(-)

1. Remove ROPS guard. For details, see REMOVAL OF ROPS GUARD. 2. Remove left and right covers (I), then remove rubber mat (2). 3. Remove left, right, and rear panel covers (3). 4. Disconnect central wiring connectors (4). * After disconnecting the connectors, fit caps to prevent dirt or dust from getting in. 5. Disconnect panel (6).

cable

(5), then

remove

heater

6. Disconnect 4 wiper hoses (vinyl hoses) (7). j, When disconnecting the hoses, mark them with tags to indicate the position where they are connected. m 7. Remove 14 cab mounting bolts, raise slowly, then remove operator’s cab assembly (8). m

el kg

Operator’s cab assembly:

500 kg

17MF02767

30-239 0

Carry out installation removal.

in the reverse order to

They vinyl hoses can be distinguished by their color, so connect the hose with the same color as the joint.

Install the cab assembly as follows. 1) Set mounting dimension a of adjusting joints installed at points A - G in the diagram to 10 - 12 mm. 2) Set cab assembly on floor frame, screw bolts 3 - 4 threads into points A - N in the diagram to check that the bolts can be tightened. 3) Tighten bolts H - N in the diagram. * When tightening the bolts, check that adjusting joints A - G in the diagram are not in contact with the surface of the floor frame. 4) Screw in adjusting joints A - G in the diagram until they contact the surface of the floor frame, then tighten the mounting bolts.

After installing the ROPS cab, check that the instruments and other equipment work normally.

30-240 0

17MFO2769

17MF02770

REMOVAL OF FLOOR FRAME ASSEMBLY

1. Remove operator’s cab assembly. For details, see REMOVAL OF OPERATOR’S CAB ASSEMBLY. 2. Remove covers (I), (2), and (3), floor plate (4) and step cover (5).

17MF02

3. Remove wiring clamp, and disconnect wiring connectors (6), (7), (8), (9), (IO), (11) and (12). * After disconnecting the connectors, fit caps to prevent water, dirt or dust from getting in. 4. Disconnect ground connection (13).

17MF02772

E ‘0

5. Remove cover (14). 6. Loosen top and bottom locknuts, rotate joint, and disconnect 4 transmission and steering control rods (15). 1111 7. Remove 2 mounting cable lock bracket.

bolts

(16)

of control

17MF02774

17MF02775

8. Disconnect heater hoses (17). * After disconnecting the hoses, fit caps to prevent dirt or dust from getting in. 9. Disconnect cooler hose (18). * When disconnecting the hoses, mark them with tags to indicate the position where they are connected. 10. Disconnect fuel control rod (19). m * After disconnecting the rod, tie it with wire to the floor to hold it in position.

30-241 0

11. Disconnect brake rod (20).

12. Disconnect control rod (21) of work equipment. m * After disconnecting the rod, tie it with wire to the floor to hold it in position.

17MF02777

13.

Remove 4 front and rear mounting bolts, then raise floor frame assembly (22) slowly and remove. j, Be careful not to damage the control cables, rods, and wiring when removing the assembly. PI kg

Floor frame assembly:

650 kg

17iFOi779

INSTALLATION OF FLOOR FRAME ASSEMBLY l

Carry out installation removal.

in the reverse order to

Locknut: 0.8 + 0.2 kgm

* After connecting

* Insert the stopper for the yoke connecting *

pin securely. After connecting the rod, adjust it correctly. For details, see TESTING AND ADJUSTING, Adjusting fuel control linkage.

m Bend the cotter securely.

30-242 0

After connecting the rod, adjust it correctly. For details, see TESTING AND ADJUSTING, Adjusting brake pedal linkage.

Insert the stopper for the yoke connecting pin securely. After connecting the rod, adjust it correctly. For details, see TESTING AND ADJUSTING, Adjusting ripper, blade control linkage.

the cables, adjust them

correctly. For details, see TESTING AND ADJUSTING, Adjusting speed lever linkage, and Adjusting steering clutch linkage.

Floor frame mounting bolt: 135 f

15 kgm

MAINTENANCE

STANDARD

Engine mount .......................... Power train mount ...................... Damper and universal joint .............. Torque converter ....................... Torque converter valve .................. Transmission ........................... Transmission control valve ............... Power train and lubricating pump ......... Transfer and bevel pinion ................ Bevel gear shaft, steering clutch and steering brake ..................... Steering control valve ................... Final drive ............................. Main frame ............................ Track frame ............................ Recoil spring ........................... Idler .................................. Track roller ............................ Carrier roller ........................... Track ................................. Suspension ............................ Hydraulic pump ........................ Blade lift control valve ................... ..... l Main relief valve and shuttle valve Blade tilt control and ripper low valve ..... Ripper high valve ....................... Hydraulic cylinder ...................... l Blade lift cylinder .................... l Blade tilt cylinder .................... ................... l Ripper lift cylinder l Ripper tilt cylinder ................... l Dual tilt cylinder ..................... l Pin puller cylinder .................... Quick drop valve ....................... Cylinder stay ........................... Semi U-dozer .......................... l Cutting edge and end bit .............. Ripper ................................. ......... l Variable multiple shank ripper l Variable giant ripper ..................

40- 2 40- 4 40- 6 40- 8 40-I 0 40-I 2 40-14 40-16 40-17 40-18 40-20 40-22 40-24 40-26 40-28 40-30 40-32 40-34 40-36 40-38 40-43 40-44 40-45 40-46 40-47 40-48 40-48 40-48 40-48 40-49 40-50 40-50 40-51 40-52 40-54 40-56 40-58 40-58 40-60

40-l 0

ENGINE MOUNT

94.5 + 10.5 kgm

94.5 f 10.5 kgm

B-B 17MF02101 A-A Unit: mm

No.

Check item

Criteria

Remedy

Tolerance I

Clearance

between

bracket and cushion

Standard size

40-2

Shaft

Hole

f0.018 -0.012

+0.046 0

Standard clearance

Clearance limit

-0.018 0.058

0.1

Standard size

Repair limit

108

106

Replace

Free height of mounting rubber

D275A-2

94.5/fl0.5 kgm

94.5f10.5 kgm

1 P

A-A 17MF02102

40-4

D275A-2

DAMPER AND UNIVERSAL JOINT

28.5 f 3 km

17MF02103 Unit: mm No.

Remedy

Criteria

Check item

Tolerance 1

Clearance between and cover

Clearance

flywheel housing

between flywheel and damper

Standard size

Standard clearance

Clearance limit

Shaft

Hole

647.7

-0.024 -0.105

+0.080 0

0.024 0.185

0.2

546

-0.022 -0.092

f0.110 0

0.022 0.202

0.25

I Standard 3

Outside diameter of coupling

Outside diameter of output shaft

Dimension

40-6

size

Repair limit

of oil seal contact surface

between

bearing and holder

0 ’ “-0.087

109.9

0 l lo-0.035

109.9

46 + 0.1

47.7

11.25fl.25kgm

11.25~1.25kgm

5.5f0.5kgm

6.75 f 0.75 kgm

11.25+

11.25+1.25kgm

6.75fl25kgm

1 .I5 f 0.15 kgm

1.25 kgm

6.75 f 0.75 kgm

-5

17MF02104

40-8

D275A-2

Unit: mm

2 3

Check item

Outside diameter of coupling

Remedy

Criteria Standard size

Tolerance

120

0 -0.100

inside diameter of retainer

of seal ring contact surface

+0.040 0

Inside diameter of sleeve

of seal ring contact surface

170

110 I

PTO drive gear and

Backlash between driven gear

PTO drive gear and

Wear of seal ring of stator shaft

119.8

170.5

+0.035 0

110.5 I

Clearance limit

0.250 -

0.420

0.204 -

0.516

Standard size

Repair limit

Width: Height:

4.45 6.00

5.0

Stator clutch

Overall thickness

15.0

Thickness of disc

5.0

Thickness of plate

5.0

Overall thickness

15.0

Stator clutch spring

D275A-2

4.5

Replace

13.8

4.5

13.9

Standard size

4.00 5.40

4.5

5.0 7

High chrome painting repair or replace

Standard clearance Backlash between driven gear

Repair limit

of oil seal contact surface

Repair limit

Free length

Installation length

Installation load

Free length

Installation load

8.7 kg

32.8

7.4 kg

40-9

TORQUE CONVERTER VALVE

6 __-__

17MF02105

40-10

D275A-2

Unit: mm

No.

Remedy

Criteria

Check item I

Tolerance Clearance between main relief valve and valve body

1 I

Standard size I

Standard clearance

Hole

Shaft

Clearance limit I

-0.035 -0.045

f0.016 0

0.035 0.061

0.08

Clearance between torque converter relief valve and valve body

-0.035 -0.045

f0.016 0

0.035 0.061

0.08

Clearance between stator clutch modulating valve and valve body

-0.035 -0.045

f0.013 0

0.035 0.058

0.08

Clearance between lock-up clutch modulating valve and valve body

-0.035 -0.045

f0.013 0

0.035 0.058

0.08

Clearance between lock-up selector valve and valve body

-0.035 -0.045

f0.016 0

0.035 0.061

0.08

Repair limit

Standard size

Main relief valve spring

Replace

Free length

Installation length

Installation load

Free length

Installation load

120.3

102.0

144.57 kg

116.7

137.3 kg

Torque converter relief valve spring

116.92

90.8

56.16 kg

I 13.41

53.35 kg

Stator clutch modulating valve spring

103.5

92.7

20.10 kg

100.4

19.10 kg

141.4

88.7

16.18 kg

137.16

15.37 kg

Lock-up clutch modulating valve spring

I (outer) 1o

Lock-up clutch modulating valve spring (inner)

80.5

78.09

Lock-up selector valve spring

I 10.07

100.0

3.0 kg

106.8

2.85 kg

40-11

TRANSMISSION

17MF02106

40-12

D275A-2

Unit: mm

No.

Criteria

Check item

No. I clutch spring

(12 PCS.)

No. 2 clutch spring

(12 PCS.)

No. 3 and 4 clutch spring

(I 2 PCS.)

No. 5 clutch spring

(5 PCS.)

Overall thickness of No. 1 clutch

60.3 1

91.0

22.3 kg

71.9

7.75

7.40

Standard

Remedy

16.6 kg

65.8

85.5

137.2 kg

size

19.0 kg

14.1 kg 116.6 kg

Tolerance

Repair limit

45.5

* 0.3

42.9

Overall thickness of No. 2 clutch

41.2

* 0.3

38.6

Overall thickness of No. 3 clutch

* 0.2

21.4

Overall thickness of No. 4 clutch

27.3

f 0.2

25.7

Overall thickness of No. 5 clutch

* 0.3

38.4

Thickness of discs of No. I -

4.8

* 0.1

4.3

Thickness of discs of No. 5 clutch

5.0

* 0.1

4.5

Thickness of plates of No. I -

4.3

+ 0.1

3.9

Thickness of plates of No. 5 clutch

Wear of seal ring of input shaft

4 clutches

Replace

4 clutches

4.0

f 0.1

Width:

3.0

Width:

Thickness:

3.1

Thickness:

Width:

4.5

Width:

Thickness:

5.8

Thickness:

Wear of seal ring of No. 5 clutch

Width:

5.0

Width:

Thickness:

6.0

Thickness:

-0.01 -0.03 * 0.15

Standard clearance 17

0.13 18

Backlash between and rina__ aear

19 20

No. 1 planetary

gear

Width:

2.7

Thickness:

2.9

Width:

4.1

Thickness:

5.6

Width:

4.5

Thickness:

5.8

Clearance

Backlash between No. I and 2 sun gears and planetary gears I

0.13 -

0.40

Backlash between No. 2,3 and 4 planetary gears and ring gear

0.14 -

0.40

Backlash between olanetarv aears

0.13 -

0.37

No. 3 and 4 sun gears and

limit

0.40

-0.01 -0.03 f 0.10 -0.01 -0.03 + 0:15

Wear of seal ring of output shaft

3.6

40-13

TRANSMISSION

CONTROL VALVE

17MF02107

D275A-2

Unit: mm

Clearance

between

modulating

Reducing valve spring

D275A-2

valve

68.0

55.5

26.7 kg

66.0

25.37 kg

40-15

POWER TRAIN AND LUBRICATING

PUMP

BAL100+140

11.5f

1.0 kgm_

11.5f

1.0 kgm

BALI 40

BALI00

I97F2008

Unit: mm No.

Check item

Criteria Model

Side clearance

Remedy

Standard Clearance

Clearance

BALl 00

0.04 -

0.10

0.13

BAL 140

0.07 -

0.12

0.15

0.060 -

0.145

0.20

limit

BAL 100 2

Clearance between inside diameter of plain bearing and outside diameter of gear shaft

Replace

BAL 140 Model 3

Pin insertion depth

Standard

size

Tolerance

Repair limit

0 -0.5

BAL 100 14 BAL 140

Rotation torque of spline shaft

0.6 kgm

@pm)

Pressure (kg/cm’)

Standard discharge (a/min)

Repair limit discharge (a/min)

BAL 100

2200

200

185

BAL 140

2200

280

258

Model

Revolution

Discharge Oil: Class-CD SAE 1OW Temperature:

40-16

45 -

50°C

D275A-2

TRANSFER AND BEVEL PINION

.25 f 3.25 kgm

f 0.75 kgm

/ m

18+2kgm

\ 18*2kgm

18f2kgm 17MF02108

Unit: No.

Check item

Criteria

I Standard

Backlash

of transfer

Standard Thickness of collar and bearing

Clearance

clearance

between

transfer

Standard

D275A-2

shim thickness

of bearing

Repair

size

gear

cage

Remedy

Adjustment or replace

0.75

0.61

limit Replace

14.6

limit

gears 0.22 -

2.0

Adjustment

40-17 @

BEVEL GEAR SHAFT, STEERING CLUTCH AND STEERING BRAKE

___-_---------___ ----

j--v /-t __ Ir-4d

1;.5+1

kgm

25+15kgm

V 18+2kgm 17MF02109

40-18

D275A-2

Unit: mm No

Check item

Criteria Standard

Remedy Repair limit

size

- Replace

Thickness of brake and clutch plate 2.9

2.6

Tolerance

Repair limit

within 0.3

0.4

Correct or replace

Strain of brake and clutch plate

Standard

size

Repair limit Replace

Thickness of brake and clutch disc 4.5

4.2

Tolerance

Repair limit

within 0.3

0.4

2 Correct or replace

Strain of brake and clutch disc

Standard

Overall thickness of brake plates and discs

Overall thickness of clutch plates and discs

Backlash between and brake hub

brake and clutch discs,

53.8

59.2

57.7

clearance

0.4 -

0.7

0.3 -

0.4 0.8

Backlash between bevel pinion

Clearance between seal ring groove of piston and seal ring

0.5 -

Clearance between seal ring groove of cage and seal ring

0.5 -0.8

Repair limit

56.3

Standard

bevel gear and

size

Clearance

Replace limit

1.0 Adjustment or replace

0.75

0.8 0.8

Tolerance 9

Inside diameter of seal ring contact surface of cage

Standard size 275

Shaft

Hole

Standard clearance

- 0.110 - 0.191

+ 0.081 0

0.110 0.272

Inside diameter of seal ring contact surface of brake piston

230

- 0.100 - 0.172

+ 0.072 0

0.100 0.244

Inside diameter of seal ring contact surface of clutch piston

220

- 0.100 - 0.172

+ 0.072 0

0.100 0.244

Standard 12

Brake belleville spring

Clutch belleville spring

Clearance limit

Replace

Repair limit

size

Free length

Installation length

Installation load

Free length

Installation load

16.5

10.4

3.530 kg

15.9

3.550 kg

16.5

10.6

3.500 kg

15.9

3.330 kg

Standard interference

Interference limit

Tolerance 14

Interference between reamer bolt

bevel gear and

Standard size 14

Shaft

Hole

+ 0.019 + 0.001

+ 0.027 0

0.026 0.019

0.02

Face runout of back of bevel gear

Repair limit: 0.05 (measure

Preload of tapered roller bearing of lever gear shaft

Standard rotating torque: 0.4 - 0.5 kgm (2.2 - 2.8 kg at tip of bevel gear teeth with bevel pinion and bevel gear not meshed)

Adjustment

Standard

2.0

Adjust shim

shim thickness of bearing cage

D275A-2

after installing to bevel gear shaft)

~~~~c&e

40-19

STEERING CONTROL VALVE

197F161

40-20 D275A-2

Unit: mm

Remedy

Criteria

Check item

Tolerance 1

Standard size

Clearance between brake and clutch valves, and valve body

_ Standard clearance

Clearance limit

Shaft

Hole

24.0

-0.020 -0.030

+0.013 0

0.020 0.043

0.06

clutch shaft and

24.0

-0.020 -0.030

+0.013 0

0.020 0.043

0.06

between

brake shaft and guide

22.0

-0.034 -0.043

+0.013 0

0.034 0.056

0.08

between

brake shaft and guide

20.5

-0.034 -0.043

f0.013 0

0.034 0.056

0.08

Clearance between and piston

brake and clutch valve,

9.0

-0.030 -0.040

f0.015 0

0.030 0.055

0.08

Clearance between valve body

check valve and

20.0

-0.020 -0.041

f0.052 0

0.020 0.093

0.11

Clearance between valve body

Clearance

Replace

I 7

Clutch modulating

spring

Standard

size

Free length

Installation length

76.0

49.0

Repair limit

Installation load

Free length

Installation load

14.7

72.0

14.0 kg

40.0

6.9 kg

Clutch valve return spring

41.9

32.0

7.3

Clutch shaft return spring

15.5

Brake modulating

spring

50.0

42.0

6.5

Brake valve return spring

50.2

37.0

18.0

Check valve spring

38.5

30.0

14.0

47.5

6.2 kg

47.5

17.1 kg

0.34 kg

34.5

0.3 kg

40-21

N 80flOkgm

w 28.5 f 3 kgm

135?15kgm

,_.l~YmYrjI bm

120?10kgm

56+6

kgm

cgx53

28.5 do3 kgm

15.5 * 2.5 kgm

17MF02110

40-22

D275A-2

Unit: mm

Standard Backlash between No. 1 gear

Remedy

Criteria

Check item clearance

No. 1 pinion and

Backlash between planetarv aear

sun gear and

Backlash between ring gear

planetary

Outside diameter of oil seal contact surface of No. 1 pinion

gear and

Clearance

1.5

0.28 -

0.93

0.22 -

0.81

1.5

0.25 -

0.90

1.5

Standard

limit

Repair limit

size

Replace 95.0

94.9

16.5

15.0

Height of cover and ball

Tolerance

Clearance carrier

between

Standard size

pinion shaft and

Shaft

Hole

-0.036 -0.058

-0.024 -0.059

Clearance in axial direction of No. 1 pinion bearing

Press-fitting force of rubber bushing

Max. 13.5 ton

Press-fitting force of sun gear

Max. 10 ton

0 -

0.1 (Standard

Standard clearance

Clearance limit

-0.023 0.034

0.1

shim thickness:

2) Adjustment

40-23

MAIN FRAME

A-A

D-D 17MF02111

40-24

D275A-2

Unit: mm No.

Remedy

Criteria

Check item

Tolerance Standard size

’ Clearance between radiator guard mounting pin and bushing

Standard clearance

Clearance limit

Shaft

Hole

-0.030 -0.076 -0.030

f0.479 f0.380 f0.329

0.410 0.555 0.343 -

-0.076

f0.313

0.405

1.5

Press-fitting force of ripper beam mount bushing

110

-0.036 -0.090

+0.164 +0.062

0.098 0.254

1.5

Clearance between ripper cylinder mounting pin and bushing

-0.036 -0.090

+0.170 f0.073

0.1090.260

1.5

Clearance mounting

between

radiator guard

pin and bushing

Press-fitting force of radiator guard mount bushing

6.2 -

14.1 ton

Press-fitting force of radiator guard mount bushing

10.2 -

23.2 ton

Clearance between pin and bushina

7.1 -

14.0 ton

5.9 -

11.7 ton

1.0 Replace

Adjustment ripper beam mounting I

Press-fitting force of ripper cylinder mount bushina

D275A-2

40-25

TRACK FRAME

_--.------

-%-

_--

15.5 f 2.5 kgm

A-A

-.-.-.--_.e B-B 17MF02112A

40-26 0

Unit: mm No.

Check item Standard

Clearance

between

Remedy

Criteria size

Repair limit Adjustment

idler yoke and guide 0 - 0.5

40-27

56f6kgm

135f15kgm

25 f 3.25 kgm

159.5 & 17.5 kgm B-B A-A F17MO2006

40-28

D275A-2

Unit: mm

No -

Remedy

Criteria

Check item

Recoil spring

Tolerance

Clearance between outside end and inside end of outside cylinder bushing

Clearance bushing

between

adjustment

cylinder and

Clearance between inside cylinder and adjustment cylinder

Standard size

Standard clearance

Clearance limit

f0.317 f0.060

0.115 0.545

0.8

-0.100 -0.350

f0.054 0

0.100 0.404

-0.15 -0.35

f0.1 0

0.15 0.45

Shaft

Hole

340

-0.055 -0.228

110

Item

2.0

Repair limit

7 (in length of 3000 mm)

Bend 5

Replace

Correct or replace

Deformation of track frame (outside cylinder) Torsion

3 (in length of 300 mm)

Dents (bent plate)

Press-fitting force of outside cylinder bushing

4.3 -

9.8 ton

Press-fitting force of inside cylinder bushing

4.5 -

23.3 ton

Dimension

between

front pilot and nut

Adjustment

4.0

40-29

IDLER

1 3 21 zt 5 kgm

9’

L- -

___._-I 17MF02114

40-30

D275A-2

Unit: mm No.

Criteria

Check item Standard Outside diameter section

of idler protrusion

Outside diameter

of idler tread face

Remedy Repair limit

size

872

830

805

Width of idler protrusion section

124

107

Width of idler tread face

79.5

Overall width of idler

266

Width of collar of shaft

242

Clearance

between

Rebuild or replace

Clearance limit

shaft and bushing 155

-0.350 -0.413

+0.220 -0.120

0.230 0.633

1.5

Standard interference

IInterference limit

Replace bushing

Tolerance

Interference

between

shaft and seal guard

Standard size

Shaft

Hole

+0.046 0

-0.150 -0.200

Standard

clearance

0.150 0.246

Replace

I 9

Clearance

limit

Free play of shaft in the axial direction 0.47 -

D275A-2

0.83

1.5

40-31

TRACK ROLLER

8,_

12 /

21 f5

kgm

17MF02115

40-32

D275A-2

Unit: mm

No.

Criteria

Check item Standard

Outside diameter

size

Remedy Repair limit

of flange (outside) -

291 2 1 Outside diameter

of flange (inside)

Outside diameter tread face

284

of track roller

255

219

1 Overall width of track roller

Width track roller tread face (single flange)

Width of track roller tread face (double flange)

Width of flange (single flange)

Width of flange (double flange outside)

Width of flange (double flange inside)

Width of collar of shaft

) 11

Clearance

Interference seal guard

between

327

27.5

I I

Standard size

18.5 14

276

Rebuild or replace

18.5

27.5

:ta::;;

Cly$ce

shaft and bushing

between

130

-0.350 -0.413

10.260 +0.010

0.360 0.673

1.5

Standard interference

Interference limit

0.150 0.246

Replace bushing

Tolerance shaft and

Standard size

Shaft

Hole

-0.150 -0.200

f0.046 0

Standard

clearance

Clearance

Replace

limit

Free play of shaft in the axial direction 0.49 -

0.86

1.5

40-33

CARRIER ROLLER

i-i

-li__li-

-1 I

-21

*5kgm

‘\“\

17MF02116

40-34

D275A-2

Unit: mm No

Check item

Criteria Standard

Outside diameter

size

of flange 242 of carrier roller

Remedy

Repair limit

Outside diameter tread face

Width of carrier roller tread face

Width of flange

210

Rebuild or replace

185

Tolerance 5

Clearance

between

shaft and support

Standard size

Interference seal guard

between

shaft and

Standard size

Hole

0 -0.2

f0.350 0

+0.245 +0.185

Standard

clearance

Free play of roller in the axial direction 0.01 -

D275A-2

Standard clearance

0.22

Clearance limit

Replace bushing

0.550

~~.::tar:de

Shaft

lnteyferynce

f0.035 0

I I

0.150 0.245 Clearance 0.3

Replace

limit

I I

40-35

TRACK (LUBRICATED TRACK LINK)

1st tightening: 80 * 8 kgm 2nd tightening: 120’ f IO”

1st tightening: 50 5 5 kgm 2nd tightening: 180” f IO”

197F169

40-36 0

D275A-2

Unit: NC

Criteria

Check item Standard

I Repair limit

size

Remedy

Turn or replace

Link pitch 260.6

Height of grouser

Lug weld, repair by build-up welding, or replace

Link height

161

143

Repair by build-up welding or replace

Outside diameter

84 (Normal loading) 86.5 (Hard loading)

92.5

of bushing

Interference

between

link and bushing

Turn or replace

Standard size

92 6

Interference

between

link and pin

+0.30 +0.20

-0.21 -0.28

0.41 0.58

0.25

Clearance

D275A-2

between

links

Replace

40-37 0

SUSPENSION Serial No.:

(l/3)

10001 -10127

_..e

[Pivot shaft L.H. side]

___.._----------

,2---\

“1

[Pivot shaft R.H. side]

17MF02117

40-38 @

D275A-2

c-c SBDO1524

Unit: mm

No.

1 1

Interference and seal

Standard size

between thrust washer

Interference and seal

between thrust washer

Interference and seal

between

Interference and seal

between side pin bushing

Interference and seal

between

Interference between side pin boss and bushing

Clearance between

pivot shaft and bushing

Clearance between

pivot shaft and bushing

Clearance between

center shaft and

Clearance between

bolster bushing and

pivot shaft

210 140

-to.1 40 +0.100

100

Hole

Interference limit

0.130-

-0.180 -0.226

f0.096 +0.035 0

-0.061 -0.124 -0.115 -0.187

+0.050

Standard interference

f0213 f0.098

194

Remedy

Tolerance

Shaft

Criteria

Check item

-0.104 -0.171

side pin boss

Replace

0.229 0.386

1 .o

32.4 - 225.6

kN I3.3 - 23 ton}

Press-fitting force of equalizer bar bushing

Press-fitting force of bolster bushing

19.6 - 127.5 kN I2 - 13 ton1

Press-fitting force of side pin bushing

68.6 - 133.4 kN I7 - 13.6 ton}

Standard shim thickness between plate and side pin

Adjustment

D275A-2

lock

40-39 0

Serial No. : 10128 and up

:: .--Tim__;@I_

-..

’ __

[Pivot shaft L.H. side]

[Pivot shaft R.H. side]

17MF02117

40-39- 1 0

D275A-2

13 0-B

SBDOI 524

Unit: mm

No. -

Interference and seal

between

thrust washer

2 3 4

5 6

Clearance between

pivot shaft and bushing

8 9 10

11 12

19.6 - 127.5

kN {2 - 13 ton)

13 -

D275A-2

40-39-2 a

SUSPENSION

(Z/3)

E-E

F-F

17MF02119

Unit: mm C

No.

Remedy

Criteria

Check item

Tolerance

Interference

between

rod and rod bushing

Standard size 90

Shaft

Hole

0 -0.015

-0.024 -0.059

Standard interference

IInterferencf limit

0.009 0.059

Standard clearance

Clearance limit

Tolerance Standard size

Clearance between rod pin and bolster hole and crossbar hole

Shaft

Hole

-0.030 -0.060

+0.146 +0.100

0.130 0.206

0.5

-0.030 -0.060

+0.046 0

0.030 0.106

0.5

0.08 0.15

0.5

Clearance

between

rod and rod bushing

Clearance

at spherical face of rod pin

Press-fitting force of rod bushing

p30

I -I-

6.9 - 43.2 kN IO.7 - 4.4 ton}

40-40 0

D275A-2

SUSPENSION

(313)

Small cushion Small cushion

Large cushion /

Large cushion \

17MF02120

---_ t3-l

I I

Z-Z

B’

Under cover

(When chassis is contacting ground)

z-z

(When chassis is floating)

17MF02121 Unit: mm

Criteria

Check item Standard value

Remedy Repair limit

Total of stepped difference at bottom face of equalizer bar and bottom face of under-bar

Replace cushion 2.0 f 2.0

8.0

Procedure for measurement Measure the stepped difference at two places (e and f) in front of and behind the center (portion P) of the equalizer bar center pin. When the chassis is floating, operate the blade tilt to make the equalizer bar horizontal. With the chassis in contact with the ground, raise the blade and ripper, and measure stepped difference A at the bottom face of the equalizer bar and the bottom face of the under-bar. (At points e and f) With the chassis floating (the chassis lifted off the ground by using the blade and ripper), measure stepped difference 6 or B’ at the bottom face of the equalizer bar and the bottom face of the under-bar. (At points e and f) * For machines not equipped with blade and ripper, jack up the chassis at the front and rear. Calculate the movement of the equalizer bar as follows: l With the chassis floating, when the bottom face of the equalizer bar is in the +direction from the bottom face of the under-bar:A -6 l With the chassis floating, when the bottom face of the equalizer bar is in the -direction from the bottom face of the under-bar:A +B * If the movement of the equalizer bar is more than 8.0 mm, check for damage to the cushion (large), (small), and replace the cushion. (The same applies if the value is more than 8.0 mm at either point e or point f.)

D275A-2

40-41

HYDRAULIC PUMP SAR (3) 100 + SAR (2) 50

/ m

28.5 f 3.5 kgm

I= SAR (3) 100

SAR (2) 50 17MF02122

Unit: mm No

Check item

Criteria Model

Side clearance

limit

Clearance

0.13 -

0.18

SAR (2) 50

0.10 -

0.15

SAR (3) 100

0.06 -

0.149

0.20

SAR (2) 50

0.06 -

0.149

0.20

0.22

0.19

Pin insertion depth

Standard 14

SAR (3) 100

0 - 0.5

2.4 kgm

(rpm)

Pressure (kg/cmz)

Standard discharge (n/min)

Repair limit discharge (n/mm)

SAR (3) 100

2500

210

231

214

SAR (2) 50

2500

210

112

102

Model

Revolution

0 - 0.5 1.4 -

Replace

Repair limit

Tolerance

Rotation torque of spline shaft

Oil: Class-CD SAE 1OW 45 - 55°C Temperature:

size

Remedy

Clearance between inside diameter of plain bearing and outside diameter of gear shaft

SAR (2) 50 4

clearance

Standard

SAR (3) 100

Model 3

40-43 Q

BLADE LIFT CONTROL VALVE

kgm

19fl B-B

A-A

3.5 _+0.5 kgm

D-D

E-E

F-F

197FO2120

40-44

D275A-2

MAIN

RELIEF VALVE AND SHUTTLE VALVE

k 1 .O kgm

7.0 f

197Fl74

/ m

7.0 f 1 .O kgm Unit:

Check item

Criteria Standard

Spool return spring

size

Remedy Repair limit

Free size

Installation length

Installation load

Free length

Installation load

55.6

38.0

6.0

52.1

4.8

Detent spring

20.5

17.0

3.7

19.8

2.96 kg

Check valve spring

75.7

43.5

1.0

69.3

0.8

Check valve spring

32.7

24.5

4.5

31 .o

3.6

Suction valve spring

75.9

38.5

1.16 kg

69.4

0.93 kg

Demand spool spring

121.4

99.0

36.0

114.7

28.8

Main relief valve spring

41 .I

32.6

26.4

39.4

21.1

Shuttle valve spring

42.7

22.0

0.83 kg

38.6

0.66 kg

Height of main relief pressure adjustment screw

Replace

8 (one turn of the screw will charge the pressure by: 24.9 kg/cm’)

‘.

D275A-2

40-45

BLADE TILT CONTROL AND RIPPER LOW VALVE

3.5 f 0.5 kgm

197F175

0.5 kgm Unit: mm

No.

Criteria

Check item

Remedy

Standard size

Spool return spring

40-46

D275A-2

RIPPER HIGH VALVE 135

1 3.5 + 0.5

52.5 * 2.5 kgm

197FI

Unit: : mm

No.

Criteria

Check item

Remedy

Standard size Spool return spring

Replace

BLADE LIFT CYLINDER

\ w

11.25+1.25kgm 17MF02123

BLADE TILT CYLINDER

50;5kgm

11.;5f

1.25 kgm 17MF02124

RIPPER LIFT CYLINDER

11.25kl.25

kgm

17MF02125

40-48

D275A-2

17MF02126

Unit: mm No

Clearance between piston rod and bushing

f0.200 0

1.o

Ripper lift

+0.207 +0.120

1 .o

Ripper tilt

+0.207 f0.120

1 .o

Blade lift

Blade tilt

+0.174 +0.100

2.0

Ripper lift

+0.207 f0.120

1 .o

Blade tilt

Clearance between piston rod connecting pin and bushing

Clearance between trunnion bushing and cylinder stay

Clearance between cylinder bottom connecting pin and bushing

Ripper tilt

Remedy

Criteria

Check item

Standard shim thickness between too of oiston rod and cao

Blade lift

-0.170 -0.250

1 .o

90 I

f0.207 f0.120 4.0

1 .o I

I I

Adjustment

DUAL TILT CYLINDER

50+-5kgm

11.25f1.25

kgm

17MF02127

PIN PULLER CYLINDER

45 f 4.5 kgm \

17MF02128

Unit: mm

No.

Check item

Clearance between and bushing

piston rod

Criteria

Dual tilt Pin puller

Clearance between piston rod connecting pin and bushing

Clearance between pin and spherical face of piston rod

Clearance between cylinder bottom connecting pin and bushing

Clearance between cylinder bottom support shaft and boss

40-50

D275A-2

QUICK DROP VALVE

17MF02129

Unit: mm

Remedy

Criteria

Check item

Tolerance 1

Clearance between valve body

plunger and

Standard size

38.0

Shaft

Hole

-0.011 -0.016

+0.010 0

Standard

Valve spring

D275A-2

Standard clearance

Clearance limit

0.011 0.026 Replace Repair limit

size

Free length

Installation length

Installation load

Free length

Installation load

75.2

55.9

13.9 kg

67.7

12.5 kg

40-5 1

CYLINDER STAY

17MF02130

Unit: mm Remedy

Criteria

Check item

No.

Tolerance

Clearance between and bushing

cylinder yoke

Standard size

Clearance limit

f0.063 0

0.085 0.211

0.5

-0.072 -0.126

+0.054 0

0.072 0.180

0.5

-0.120 -0.207

+0.035 0

0.120 0.242

0.5

Hole

140

-0.085 -0.148

Clearance between and bushing

cylinder yoke

105

Clearance between and bushing

lift cylinder trunnion

40-52

Standard clearance

Shaft

Replace

D275A-2

SEMI

U-DOZER

li'

B-B

‘7

c-c

A-A

14 \

F-F

E-E

G-G

J-J H-H

40-54

K-K 17MF02131

D275A-2

17MF02132

Unit: mm

ce between

D275A-2

joint and bracket

40-55

CUlTING

EDGE AND END BIT

152.5 + 16.5 kgm

_-------------------------------

197Fl8l-I

Unit: mm No.

Check item

Criteria Standard

size

Remedy Repair limit

Height of end bit outside 415

300 Replace

Width of end bit

662

500

Height of end bit inside

330

260

Height of cutting edge

330

260 (215 after turned)

Replace or turn

D275A-2

VARIABLE MULTIPLE SHANK RIPPER

---

40-58 0

A-A

B-B

C-C

D-D

Unit: mm No.

Remedy

Criteria

Check item

Tolerance

Clearance between and bushing

Standard size

bracket and arm pin,

Clearance between and bushing

beam and arm pin,

Clearance between pin and bushing

cylinder connecting

Clearance limit

Shaft

Hole

1 I”

-0.036 -0.090

+0456 f0.369

0.405 0.546

~c “=

110

-0.036 -0.090

+0.456 +0.369

0.405 0.546

1.5

-0.036 -0.090

f0.207 f0.120

0.156 0.207

1.5

..n

Standard clearance

Replace Standard 4

Dimension

of shank mounting

Tolerance

size

pin 80

* 0.3

Standard 5

Wear of point

Wear of protector

D275A-2

Repair limit

131

Repair limit

size

106

VARIABLE

GIANT RIPPER

-..-

” -.-

A-A

B-B

P-

tL_l

c-c

D-D

-..-

40-60 0

Detail P

Unit: mm

No.

Remedy

Criteria

Check item

Tolerance Clearance between and bushing

Standard size

bracket and arm pin,

Clearance between and bushing

beam and arm pin,

Clearance between pin and bushing

cylinder connecting

Standard clearance

Clearance limit

+ 0456 + 0.369

0.405 0.546

1.5

- 0.036 - 0.090

+ 0.456 + 0.369

0.405 0.546

1.5

- 0.036 - 0.090

+ 0.207 + 0.120

0.156 0.207

1.5

Shaft

Hole

110

0.036 - 0.090

110 90

I 4

Standard

Dimension

of shank mounting

I 5

f 0.3

1 Wear

Reolace Repair limit

Tolerance

size

Standard

size

I I

Repair limit

of point

Wear of protector

131

106

40-61 0

Komatsu America international Company 440 North Fairwav Drive I Vernon Hills, IL 66061-8112 U.S.A. Attn: Technical Publications Fax No. (847) 970-4186

PROPOSAL

FOR MANUAL

REVlslON

FOR INTERNAL USE ONLY -- No. PMR 2

NAME OF COMPANY:

PHONE NO:

: S

DEPARTMENT:

E R

NAME:

MANUAL NAME: MANUAL NO: MACHINE MODEL: S/N IF APPLICABLE: PAGE NO:

PROBLEM:

Attach photo or sketch. If more space is needed, use another sheet.

1 FOR INTERNAL USE ONLY CORRECTIVE ACTION:

PFMRl 081696

LOCATION:

DATE: